Installation and Troubleshooting Guide
NOTE: This installation is to be completed by an Authorized Dealer or Professional Service
Technician. For questions regarding installation or warranty, call CDI Tech Support
at 866-423-4832.
Do not return to the Dealer or Distributor where the part was purchased.
Contact CDI Electronics Directly for Return Material Authorization
.
CDI Electronics, LLC
353 James Record Road SW
Huntsville, AL 35824 USA
Web Support: www.
cdielectronics.com
Tech Support: 1-866-423-4832
Order Parts: 1-800-467-3371
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Rev J
8/9/2019 Page - 2 of 2 QF-358
TROUBLESHOOTING
BATTERY NOT CHARGING:
1.
Check the 25-30 Amp fuse between the Regulator/Rectifier and the battery (if present). Replace and retest if blown.
2.
Verify that
Both
Red wires are connected to 12 VDC from the battery. Both wires must be connected to 12 VDC from
the battery for the Regulator/Rectifier to work.
3.
Remove the flywheel and inspect the heavy battery charge windings for discoloration. If the windings are a dark
color, replace the stator.
NO TACHOMETER SIGNAL:
1. At 800-1000 RPM, check DVA output on the Grey wire from the Regulator/Rectifier, you should have at least 8 DVA.
A low reading usually indicates a bad regulator if the system is charging the battery.
2. Check the resistance between the Grey wire from the Regulator/Rectifier and engine ground. You should read about
10K Ω. Grey to Red, and Grey to the Yellow wires should be a high reading, usually in the M range.
MAXIMUN OUTPUT TEST
1. Install an ammeter capable of reading at least 30 Amps between the Red wire (Y jumper) and the starter solenoid
battery post.
2. Connect a load bank to the battery.
3. In the water or on a Dynamometer, start the engine and bring the RPM up to approximately 4500 in gear.
4. Turn on the load bank switches to increase the battery load to equal 30 Amps.
5. Check the ammeter.
6. If the amperage is low,
A) Check the load bank for battery amperage draw.
B) Reconnect the ammeter between the Red wire (Y jumper) going to the terminal strip. Retest. You should
show about 15 - 20 Amps from the regulator/rectifier.
C) If the output is still low, check and clean all connections between the battery and the regulator/rectifier plate.
7. If the amperage is correct, but the battery voltage remains low, replace the battery.
OVERCHARGING
1. Clean all battery terminals, cables and mounting bosses.
2. Check the voltage on the battery with a digital voltmeter and compare it to the dash meter.
3. Compare the voltage at the regulator/rectifier with the voltage at the battery. If the voltage is ok at the
regulator/rectifier and not good at the battery, you have a bad connection somewhere. Clean the battery posts and
terminals.
4. Replace the battery with a known good marine battery and retest. If the battery voltage remains ok, install a new
battery.
BENCH TEST
METER TESTING:
Test the Regulator/Rectifier as follows:.
Red Meter Lead
Black Meter Lead
Ohms
Yellow Stator Leads (each)
Red Regulator Y Jumper
30K – 50K Ω (a)
Yellow Stator Leads (each)
Case
Open, M Ω or OL(Out of Limit)
Red Regulator (w/Barrel Terminal) Red Regulator Y Jumper
Open, M Ω or OL(Out of Limit)
Case
Yellow Stator Lead (each)
Open, M Ω or OL(Out of Limit)
Case
Red Regulator Y Jumper
Open, M Ω or OL(Out of Limit)
Case
Grey Terminal
10K Ω
(a) If one of the Yellow wires shows a low reading of about 10K Ω, leave the meter connected for a minute. It
should change to the 30K – 50K Ω range.
