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THE ENGINE IS PUTTING OUT 29 VOLTS AC WHILE RUNNING AND MELTING THE BATTERY POSTS AND TERMINALS. WE CHECKED THE RECTIFIER AND IT CHECKS OK AND CANNOT FIGURE WHAT IS WRONG
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connect a multi meter across the battery terminals and set on volts dc there should be 14.5 volts across the posts when the charger is on check for the dc notice on the dial as if the rectifiers in the charger have failed , you will get an ac voltage and that will not charge a battery
have the voltage regulator checked
also have the rectifier pack checked in the alternator by using a multimeter that reads ac as well as dc volts
if it is ac volts , replace the alternator
if the voltage regulator is faulty there will not be enough volts to charge a battery
At this point I doubt if it is a short in a circuit but a problem in the charging system
have the battery checked out with a carbon pile discharge tester , this will test the battery under load , then test the alternator to see if is charging ok, make sure the battery terminals and posts are shiny clean, check the back up light fuse and switch, and check air con fuse . if the battery is below 10 volts the engine may crank but it wont start.
Ok.. The rectifier only changes AC voltage to DC voltage.. the voltage to charge the battery comes from the generator.
With the engine running at half throttle+, and IN NEUTRAL, check the voltage at the battery terminals it should be 13 volts +. If you are not getting at least that much.. make sure all connections are tight.. if its less than 13V..... more checking is indicated. (Shop time)..sorry...
check that the charge rate from the alternator is no ac current. A multi meter will show a charge rate of 13.5 to 14.5 volts but that could be unrectified current because of a failed diode in the rectifier in the alternator. Set the meter to read for ac voltage and if you have ac reading then have the alternator overhauled. Have a load test done to check the batteries for a problem cell under load.
Might have 12.67 volts, but not enough amps to crank engine or light the lights properly. Try putting a charger on the battery, bring it to a full charge. Next, put a load tester on the battery to see if battery is weak or dead cell. If battery checks good, check the charging system. With engine running at idle, put volt meter on battery-read volts, then rev engine to high idle. Volts should climb higher than idle reading.
Proper battery charging will show ~13.5 to 14.5 volts at the battery terminals. Check for continuity through the alternator windings, check each diode in the rectifier stack and look for a voltage regulator which may be defective.
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