Troubleshooting Guide 9 Or 15 Amp Regulated Battery Charging System - Kohler Courage SV470 Service Manual

Troubleshooting Guide 9 or 15 amp Regulated Battery Charging System

NOTE: Zero ohmmeters on each scale to ensure accurate readings. Voltage tests should be made with engine
running at full throttle - no load. The battery must be fully charged.
Problem
1. Trace B+ lead from rectifier-regulator to
key switch, or other accessible connection.
Disconnect it from switch or connection.
Connect an ammeter from loose end of B+
lead to positive terminal of battery. Connect
DC voltmeter from loose end of B+ lead to
negative terminal of battery. See Figure 7-11.
With engine running in the fast position, read
voltage on voltmeter.
If voltage is 13.8 volts or more, place a
minimum load of 5 amps* on battery to
reduce voltage. Observe ammeter.
*NOTE: Turn on lights, if 60 watts or more.
2. Remove connector from rectifier-regulator.
No
With engine running in the fast position,
Charge
measure AC voltage across stator leads using
To
an AC voltmeter.
Battery
3a. With engine stopped, measure the resistance
across stator leads using an ohmmeter.
3b. With the engine stopped, measure the
resistance from each stator lead to ground
using an ohmmeter.
1. Perform same test as step 1 above.
Battery
Continuously
Charges At
High Rate
Test
Or place a 2.5 ohm, 100 watt resistor
across battery terminals.
Electrical System and Components
Conclusion
1. If voltage is 13.8-14.7 and charge rate increases
when load is applied, the charging system is
OK and battery was fully charged.
If voltage is less than 13.8 or charge rate does
not increase when load is applied, test stator
(Tests 2 and 3).
2. If voltage is 28 volts or more, stator is OK.
Rectifier-regulator is probably faulty. Verify
with Rectifier-regulator tester KO3221.
If voltage is less than 28 volts, stator is probably
faulty and should be replaced. Test stator
further using an ohmmeter (Test 3).
3a. If resistance is 0.1/0.2 ohms, the stator is OK.
If the resistance is infinity ohms, stator is open.
Replace stator.
3b. If the resistance is infinity ohms (no continuity),
the stator is OK (not shorted to ground).
If resistance (or continuity) is measured, the
stator is shorted to ground. Replace stator.
1. If the voltage is 14.7 volts or less the charging
system is OK. The battery is unable to hold a
charge. Service battery or replace as necessary.
If voltage is more than 14.7 volts, the
rectifier-regulator is faulty. Replace
rectifier-regulator.
Section 7
7
7.13