Stu:
I've had the same problems.
Are you disconnecting the leads at terminals A1 and A at the
control box and joining them before taking the readings?
If you are and still have problems then instead of following
that proceedure, leave the connections alone on the box.
Test between the dynamo D terminal and ground. Set the
regulator so you get about 14.4 volts between the D terminal
and ground. If that setting is still too high, you may be
able to go as low as 14.2 volts and maybe even lower. The
lower the setting, the less the dynamo output. So if you're
using lots of light, you may not have enough output to keep
the battery up at night.
Other than that, you may need to adopt the old Ford Model A
proceedure of running with a few lights on. The Ford only
had a cut out. Voltage was set by a third brush on the
generator which had to be a compromise between road and city
driving.
Blake
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