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Tube Ref No.
2-4-C with PTFE
95
4.
If specific gravity drops below 1.240, check battery for reason and recharge. When gravity reaches 1.260, discontinue
charging. To check specific gravity, use a hydrometer, which can be purchased locally.
5.
Repeat preceding charging procedure every 30–45 days, as long as the battery is in storage, for best possible
maintenance during inactive periods to ensure a good serviceable battery in spring. When ready to place the battery back
in service, remove excess grease from the terminals (a small amount is desirable on terminals at all times), recharge
again, as necessary, and reinstall the battery.
Battery Charging System
Battery Charging System Description
The battery charging system components are the flywheel, stator, regulator/rectifier, and the battery. Alternating current (A.C.)
is generated in the stator assembly and flows to the regulator/rectifier which changes the A.C. to a regulated direct current
(D.C.) for charging the battery.
Troubleshooting Battery Charging System
IMPORTANT: The charging system may be damaged by:
•
Reversed battery cables
•
Running the engine with the battery cables disconnected and stator leads connected to the rectifier
•
An open circuit, such as a broken wire or loose connection
A fault in the battery charging system usually will cause the battery to become undercharged. Check the battery electrolyte
level and charge battery.
If the battery will not accept a satisfactory charge, replace the battery.
If the battery accepts a satisfactory charge, determine the cause of the charging system problem as follows.
•
Check for correct battery polarity: red cable to positive (+) battery terminal. If the polarity was incorrect, check for a
damaged rectifier and/or main fuse. Refer to Regulator/Rectifier Diode Test.
•
Check for loose or corroded battery connections.
•
Visually inspect the wiring between the stator and the battery for cuts, chafing, loose, corroded, or disconnected
connection.
•
Excessive electrical load from too many accessories will cause battery to run down.
Voltage Regulator/Rectifier Description
The voltage regulator is an electronic device that regulates alternator output according to the accessory loads and state of the
battery. The voltage regulator manages the alternator output according to operating conditions. The voltage regulator must
balance the needs of a fully charged battery, long battery life, and accessory loads.
The voltage regulator has a voltage sensing lead that is connected to a direct battery voltage source. The sensing lead allows
the voltage regulator to monitor and regulate the amount of input voltage and amperage needed to maintain the battery state of
charge.
Symptoms of a faulty voltage regulator may include a discharged battery, short battery life, poor accessory and lighting
operation, frequent bulb replacement, lower than normal voltmeter readings, or frequent topping off of the battery's electrolyte.
Voltage Regulator/Rectifier Removal and Installation
Voltage Regulator/Rectifier Removal
Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or
death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the
battery before maintaining, servicing, installing, or removing engine or drive components.
1.
Cut the cable tie securing the voltage regulator/rectifier stator connector to the engine harness. Disconnect the voltage
regulator/rectifier harness connector.
90-8M0105568 eng MARCH 2016
Description
!
Where Used
Battery terminal bolts
WARNING
© 2016 Mercury Marine
Charging and Starting System
Part No.
92-802859A 1
Page 2B-15
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