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608KEB

520H overcharging and not turning over

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One repair leads to more problems. My 520h is overcharging on the meter. I cleaned a area on the regulator. I ran a jumper wire from reg. to - battery terminal. Nothing changed still overcharging. I also checked the battery voltage. Not running it was at 12.4. Running it was at 14.8 I fixed the tachometer. I bypassed the 9 pin connector. So after that it turns over at random. All the lights and dummy gauges work when it finally did start after turning the key 30 times. How do I jump start the 520H/ What possible problems are going on with it starting at random? Is the regulator bad? I've cleaned the connections on the 9 pin connector. and basically looked at all the connections. What do I look at to fix these 2 problems? I do have the wiring diagram for the 520H too.

Edited by 608KEB

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There are 3 relays below the battery.  Use your wiring diagram wire colors to determine which are in the starting circuit.  To test, you can just swap connectors as they are all the same.  Yes, they are next to impossible to access.

 

It might be the ignition switch.  Check for 12 volts on the S terminal when turned to start.

 

Report back.

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dumb question are you sure you got all the wires paired up right, at the 9 pin connector and at the fuse block. is the battery fully charged because if not it will charge high and don't worry if the gauge shows over charge check the charge at the battery with a meter with the engine running. sounds like you have some wires crossed some place, so i would go back and double check everything maybe have somebody else check it with you, sometimes you can't see the forest for the trees if you know what i mean. i've look at the same problem over and over before i see the problem right in front of me. good luck

 

 

 

 

eric j

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I have the the 9 pin connector right, because it can only plug in one way. I cleaned the relays and plug ins. I rotated them one spot. Gonna try it in a little bit. I mentioned before that the reading off the battery with 520H running was 14.8 volts on my mutimeter

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How do I test the ignition switch?

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I tried starting it. No luck. I can hear the relay switch closing when I turn the key.

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Edited by 608KEB

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See that light blue wire on the starter photo?  Pull it off and you should get 12v between it and ground when you turn ign. switch to start.  If not, test the S terminal on the switch when turned to start.

 

To rule out the starter, jump from the + battery terminal (or the big wire on the srarter) to where you pulled out that light blue wire.  The starter should engage.

 

I have had poor connections in the fuse block cause a no start but still show some voltage at the light blue wire when it is disconnected.  If you make up a jumper, at light blue wire connection, you can connect to it and check voltage with the wires connected and under load.

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O.k. I'll try it tomorrow. Is the S terminal at the switch the red wire? So I take the tester and touch the S terminal and the + on the battery? I Also have a battery tender on it. So battery is fully charged. I'm starting to think it's the ignition switch. I had the key held in the start position for a while. It would then turn over at random.

Edited by 608KEB

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Connect tester to ground and the S terminal.  Should read when switch is turned to start.  The S terminal is the one that is located not in line with the others.

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O.k so I tested the voltage between the starter blue wire connector and ground. I had zero voltage. I jumped a wire between + on battery and the blue wire connection on starter and it turned over.

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When I hook up tester to S on ignition switch where does other wire to tester go? To the - battery post??

Edited by 608KEB

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I found problem!!! Its the PTO safety switch!!! Where can I pick one up?

Edited by 608KEB

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I cleaned up the safety switch. I will order one, It works for now. Next I placed the tester (In AC mode) on both B+ terminals of the regulator. The readings were -16.75 to -17.75 at 3/4 throttle. The voltage meter was reading normal for a while at 14.6. Then it started moving up to 17-18 volts and stayed there. Is the regulator shot?

Edited by 608KEB

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The regulator is probably shot.  Make sure that it is grounded properly before tossing it.

 

I got the numbers off my safety switches and bought them at industrial supply houses for a fraction of the dealer prices.

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I took the voltage regulator off and cleaned the connections and where it attaches to the engine. It still reads 16.75 to 17.75 at 3/4 throttle. I ordered one from EBay. Thanks for the input!

Edited by 608KEB

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  :confusion-scratchheadblue: In a related question...as I joined recently and have been reading up here, to help diagnose my own 520H electrical problems..

 

Is there a Diode on any of the 520H's circuits? :confusion-scratchheadblue:

Thanks

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The diodes are built into the voltage regulator.

  • Like 1

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The diodes are built into the voltage regulator.

That's the likely failure in the Voltage regulator than...me thinks. Can they be taken apart? Diode's are a dime a dozen. As long as it has the value on it. 

Edited by chex313

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I replaced the voltage regulator. Nothing has changed. Battery is reading 14.6 volts. VR is reading -16.75-17.50. So what do I check out next?

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Battery voltage appears fine.

 

You are probably making the AC reading incorrectly.

To measure AC stator voltage, multimeter should be set on the AC function and one lead placed on one AC terminal of the reg and the other meter lead placed on the second AC terminal of the reg. You appear to be using the 12v ground as reference ground forthe AC measurements.

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I'm placing the multimeter leads on each AC lead on the Voltage Regulator. The volt meter on the tractor is reading 17ish. This winter when I was clearing snow the battery went dead twice. I put a full charged battery in each time and the volt meter read correct at 14.6 for a long time. I read the multimeter manual some and I think I found the right setting for the multimeter. I tested it on a outlet and it read 120ac. Let me know if this setting is wrong.

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Edited by 608KEB

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The AC reading from the stator should be made with the selector switch pointing toward 200 V~

 

ironically, 180 degrees opposite of where it is in the image above.

 

You may also want to paint the scribe line on the selector switch to make it more obvious the function the selector is pointing toward.

 

With the selector in the V~ (AC) position. meter should show greater than 32 Volts AC at full engine throttle.

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Edited by Save Old Iron
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Thank you, I just printed the page 2 from the manual.

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from your image

 

the position for volts AC and DC

 

 


Thank you, I just printed the page 2 from the manual.

that manual leaves much to be desired if you are new to multimeter use.

 

there are many good "how to use a multimeter" videos on youtube

 

good luck

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