23HP Kawasaki Charging Problems

Discussion in 'Mechanic and Repair' started by Mack77, May 6, 2009.

  1. Mack77

    Mack77 LawnSite Member
    from NJ
    Posts: 208

    Hi All,

    I have a Bobcat ZTR, 23HP/61" with a charging issue. The machine will not charge the battery under normal operation.

    Serial #94222304518
    Model #942234

    Is there a troubleshoot somewhere online for the charging system? Some areas to check first, a possible schematic of the wiring system to narrow down the problem? Or some folks that have had this problem and are willing to share their own experiences with their Kawasaki Equipment not charging the battery...

    Thanks!
     
  2. MowerMedic77

    MowerMedic77 LawnSite Bronze Member
    Posts: 1,164

  3. Mack77

    Mack77 LawnSite Member
    from NJ
    Posts: 208

    Thanks!

    I've heard the regulators are more common to fail on these engines than the stator...how can I check the regulator to see if it is working properly? Any signs that are a dead giveaway?
     
  4. MowerMedic77

    MowerMedic77 LawnSite Bronze Member
    Posts: 1,164

    If the out put of the stator is within spec then the next thing to check is the regulator. The regulator(you can see it in the pic)has three posts the two that the stator plugs into and the third is the charge wire out, if that third post is not pushing 12volts(should be putting out more then 12volts) @ 3600 rpms then it has failed.
     
  5. Mack77

    Mack77 LawnSite Member
    from NJ
    Posts: 208

    Ok...just tested my mower with the directions in this thread:

    [​IMG]

    I am getting NO voltage read out from the stator, NOTHING. I have another bobcat Z, and when I tested this clip on that mower, i got a voltage read-out. (that other one works great, no problems at all). This mower i'm having trouble with is just not charging the battery during normal operation.

    I can charge up the battery the night before, and during my first lawn with the blades engaged, they will just stop after a while. I guess the electric PTO clutch draws from the battery, and if it's not charging, then it shuts down.

    So what does this mean? A zero rating from the above instructions? Will i need a new stator? If so, is this an easy job to do by one's self?

    Thanks!
     
  6. Mack77

    Mack77 LawnSite Member
    from NJ
    Posts: 208

    Ok...

    I just exposed the stator and attached some pictures of what I found. Underneath the flywheel, there was a heavy buildup of dust/debris. Could this cause the stator to keep from charging the battery and working properly? Before I go spend the money for a new one, i'd like to try to see if all it needs was a good clean-out.

    Any thoughts? Pics attached......

    p_00001.jpg

    p_00003.jpg

    p_00006.jpg
     
  7. MowerMedic77

    MowerMedic77 LawnSite Bronze Member
    Posts: 1,164

    Ok you need to run 2 more tests on the wires from the stator.

    1. You need to connect you ohmmeter between the two wires and test resistance and it should be 0.01 to 0.1 Ohms.

    2. You also need to check for continuity between each stator pin and ground.
    There should be no continuity or (infinite ohms)

    If the stator fails either of these tests then you will need to replace the stator.
     
  8. Mack77

    Mack77 LawnSite Member
    from NJ
    Posts: 208

    Thanks!

    I'll check that out later tonight and report back...

    If I find that my machine fails one of these tests, can the stator be repaired or fixed, or would I need a whole new assembly?
     
  9. MowerMedic77

    MowerMedic77 LawnSite Bronze Member
    Posts: 1,164

    I have never attempted to fix one or have one fixed, but that is mostly for the reason that I am usually charging someone to put that item in and If a repaired one fails then I would be stuck eating the R/R of a new one and then have a very unhappy customer for the extra down time. I only like fixing things once....
     
  10. Mack77

    Mack77 LawnSite Member
    from NJ
    Posts: 208

    MowerMedic...thanks you've been a great help! :)

    A noob question, how do I use my tester and test this?

    Last night I used the battery ground as a ground, and touched the positive lead of the tester to each "tip" of the stator. Is this what I should be doing? The tester had a few resistance testing choices to choose from, so i'm not really sure which one to use. The test showed .04 on all pins or "tips". Is that correct?

    Also which wire are you referring to? "You need to connect you ohmmeter between the two wires and test resistance and it should be 0.01 to 0.1 Ohms."
     

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