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Yeah, I agree. I really think that the original rectifier not being grounded has something to do with the problem. Way too much to do having it rewound. I think just manually charge the battery like you said. Thanks again for all the help. I really appreciate it.

Speddmon, do you agree?

Well curiosity got the better of me so I went to the garage. Meter has 200,2000 20k,200k,and 2000k (ohms). Anyway,I hooked it all up and gave it a try. Immediately after turning power on, ammeter shows 15 amp discharge as before. I started it anyway figuring it might go to charging position,but...

Yes, all readings were from red to AC. The meter does have other selections (ohm's) , but the meter is at the garage and can get them selections for you tomorrow. I have it all hooked up except for the one AC to stator. Will do that tomorrow,fire it up, and give you the results. Thank you Speddmon

Thank you very much for your reply. I understand everything you are saying. If it works , great,if it doesn't, it doesn't but we gave it our best. Thats all that can be expected. I would just like to clarify one item. Connect unused "AC" from rec. to ground. Would this not short out rectifier. I...

Hi Speddmon, I got the new regulator today but am kinda skiddish in doing anything with it. Have you had a chance to look at the .PDF files I posted? If you get a chance,could you let me know what you think on the wiring? Thank you much...Len

This one says something about upgrade from 3 wire to 2 that I do not understand. It may be helpful in determining red wire location. If I have uploaded too much,please delete accordingly if taking up too much space. I don't mean for that to happen.

I hope I'm not getting carried away with this,but just trying to give as much info as possible. This is what the Kohler charging system looks like. If any of the .jpg's are too small, just right click on them and "save image" to desktop or somewhere and then you can make them bigger.

This is one showing reg & rec and photo of what I bought and am trying to change to.

Ok trying. If it works please refer to pages 71 & 105...Thank you very much...Len

Glad you wrote back..thought you were mad at me. New part will be here on Thursday. The red wire does go to the stator, then it goes into original regulator on one side and other side of regulator goes to same place that rectifier connects to ammeter/battery. I don't know if I can post the...

Speddmon,where'd ya go? Did I say something wrong?

No, I never did run it with the regulator un-grounded. I have not removed the regulator from the mount. It has a plug that fits together and wires are color coded. After trying the new Kohler rec/reg and it not working, I did unplug the regulator and tried it. Was still no go. The 39.5v AC ...

Thank you so much Speddmon for all your help. I know I have been pretty vague on my descriptions and such,but I hope this is better.The Rectifier/Regulator is described as follows : Regulator Rectifier Assy. 12 Volt, Series Type, 14.4 Vset ..For 15 amp permanent magnet charging systems...

Speddmon; Thank you very much for your reply. I have replaced the rectifier with a Kohler Rectifier/regulator PN:41-403-05. It is a 12v system.This is what is happening. With the stator leads connected to rectifier and engine running, I am getting 19v AC from "B" connection according to the...

Hello all; I am new here and if this is the wrong place to ask,please let me know and I apologize. Anyway, I have had this G204 Hobart welder for about ten years or so. It runs and works great. I usually don't use it much but run it at least 2 times a year to keep it lubed up. I asked my son...