On a flight, I suspect after a good landing bump training a student the generator light comes on. Voltage goes from 13.5 to 12.5 and we drained the battery during that flight to about 11.7 by the end of flight with heating gear etc. Obviously the generator was not charging (generator warning light on).
Double checked the accuracy of the voltage reading on the battery with a Fluke voltage calibration (used the Fluke throughout troubleshooting). First step was to replace the voltage regulator with one that worked. No fix. Double checked voltage regulators on other aircraft and they worked fine.
Checked the positive continuity from the generator plug to the battery, good with master on, 30 amp fuse ok. Checked all the positive connections at the voltage regulator plug for continuity per Heavy Maintenance manual 74-00-00 figure 74-12. Checked the generator circuit at the regulator plug both wires-no continuity to ground, generator resistance- low but within specks at the regulator plug .25 ohms while not running, checked the generator output AC voltage while running and about what Rotax Owner video charging trouble shooting observed.
Put conductive paste (not dielectric bulb stuff) on the regulator plug to assure a good connection.
Just replaced the capacitor with a new one. No fix.
Everything works but it is not charging. Battery reads 12.5 and can not get it to charge. Somehow I am not getting from the voltage regulator to the battery. I am out of things I know how to troubleshoot. Any ideas? What could I possibly be missing?
