jrotten13 18 #1 Posted April 21, 2020 I have a 91 or 92, 416-8 wheel horse that isn't charging the battery. During my troubleshooting I cleaned all grounds and connections. Including 9 pin connector, which all looked corrosion free. I tested the rectifier as shown on other forum topics and I get battery charge on B+. However when checking for ACV i get 0.5 on the rectifier. From what i have seen, it is very rare for a coil winding to go bad. Any ideas on what it can before I go through the process of taking the flywheel off? Share this post Link to post Share on other sites
Achto 29,252 #2 Posted April 21, 2020 (edited) 1 hour ago, jrotten13 said: Any ideas on what it can before I go through the process of taking the flywheel off? There should be 2 wires coming out from behind the fly wheel to the regulator rectifier.Unplug the regulator/rectifier, check for cracks or breaks in these wires, Use a multi meter to check the AC voltage produced between these 2 wires with the engine running 3/4 throttle or more, you should have 30+ volts AC. If this is good and all of your connections, including case ground on your regulator/rectifier and DC power to the 3rd term on the reg/req with the switch on. Then I would change your regulator/rectifier. Edited April 21, 2020 by Achto 1 Share this post Link to post Share on other sites
jrotten13 18 #3 Posted April 21, 2020 11 hours ago, Achto said: 11 hours ago, Achto said: There should be 2 wires coming out from behind the fly wheel to the regulator/rectifier So I checked again and decided to take the wire nut off of one of the wires... there are 3 wires total. 2 white that are connected and one grey. When they are wired up the way I got it, the gray was on the left and the two whites were on the right of the rectifier. Acv between grey and white while running more than 3/4 throttle was 0 to 0.5. The acv between the 2 whites is 60... Share this post Link to post Share on other sites
Achto 29,252 #4 Posted April 21, 2020 10 minutes ago, jrotten13 said: The acv between the 2 whites is 60... Not sure what the gray wire is for. The two whites are what are normally hooked to the reg./rec. Find a manual for your tractor with a wire diagram from the manuals section to confirm proper wiring. But I do not believe that the gray wire should be connected to the reg./rec. at all. Share this post Link to post Share on other sites
jrotten13 18 #5 Posted April 21, 2020 2 minutes ago, Achto said: Not sure what the gray wire is for. The two whites are what are normally hooked to the reg./rec. Find a manual for your tractor with a wire diagram from the manuals section to confirm proper wiring. But I do not believe that the gray wire should be connected to the reg./rec. at all. Hmm looks like the grey wire goes to the 9 pin connector. Looking at the diagram, the colors are different but I dont see where that grey wire comes into play. It almost looks like a ground... the wiring was replaced from the original owner so difficult to tell where that grey wire goes. So to be clear, connect the 2 white wires to the rectifier ac + ac - and for now leave the grey unplugged? Lol Share this post Link to post Share on other sites
WHX?? 51,415 #6 Posted April 21, 2020 (edited) The two wires in the sleeve should be connected to the outside terminals on the regulator. The gray wire maybe connected to either one of the white wires or may not be needed at all if you don't have a tach. Center term charges the batt through the nine pin and a fuse. Your regulator is probably shot as they are known to do. Very common on the jungle site and cheap. Read the service manual attached it will give you all the info you need. 492-4006 Onan P216 P218 P220 P224 SM.pdf Edited April 21, 2020 by WHX24 1 Share this post Link to post Share on other sites
Achto 29,252 #7 Posted April 21, 2020 1 minute ago, jrotten13 said: connect the 2 white wires to the rectifier ac + ac - and for now leave the grey unplugged? This is what I would do. Cap off the gray wire & run it. 1 Share this post Link to post Share on other sites
WHX?? 51,415 #8 Posted April 21, 2020 Grey wire is tach signal and only used on 520's Share this post Link to post Share on other sites
WHX?? 51,415 #9 Posted April 21, 2020 Dan you need to read the manual too... page 8-5 #6... Share this post Link to post Share on other sites
jrotten13 18 #10 Posted April 21, 2020 Well then that worked. Now reading 14.5 on the voltmeter. Thanks for the help everyone. 1 2 Share this post Link to post Share on other sites
WHX?? 51,415 #11 Posted April 21, 2020 Your keep an eye on the voltmeter on the tractor if you have one. These regulators are more known more for overcharging and can cook a battery. 2 Share this post Link to post Share on other sites
jrotten13 18 #12 Posted April 21, 2020 32 minutes ago, WHX24 said: Your keep an eye on the voltmeter on the tractor if you have one. These regulators are more known more for overcharging and can cook a battery. Thanks. Yes I plan on it. While the voltmeter shows I'm charging at 14.5 I have yet to see someone say 60 acv is the amount to look for form the coil pack. The highest I've seen is 42 but everyone says to check for 30+... not 60 lol Share this post Link to post Share on other sites
kasey54 305 #13 Posted May 17, 2020 I'm curious about that range my self. I have a bad reg. ,and read 30 volts ac full throttle at the two wires from under the fly wheel.I expected more, Is 30 ok? Share this post Link to post Share on other sites
jrotten13 18 #14 Posted May 17, 2020 2 minutes ago, kasey54 said: I'm curious about that range my self. I have a bad reg. ,and read 30 volts ac full throttle at the two wires from under the fly wheel.I expected more, Is 30 ok? From what ive read 30 is okay. Ever since I fixed my charging issue I have had no issues. 30volts. Although I was getting 25 volts before I went through and cleaned the contacts. Still plenty from what I understand. Share this post Link to post Share on other sites
kasey54 305 #15 Posted May 17, 2020 Thanks for that. Do you know if a printed ckt. board has become available for these old girls? Share this post Link to post Share on other sites
kasey54 305 #16 Posted May 19, 2020 Found a bad fuse holder and solved my charging problem. Is putting out about 14 volts dc. Share this post Link to post Share on other sites
