B. Install the Voltage Regulator
Detail Steps/Work Items  Key Items/References 
(1)  Put the voltage regulator in position on the mounting bracket. 
(2)  Install the 4 washers and nuts which attach the regulator to the mounting bracket. 
(3)  Connect the electrical connections at the in-line connector. 
(4)  Connect the battery. Make sure that you connect the positive lead first.  Refer to Section 24-31. 
(5)  Install the engine cowlings.  Refer to Section 71-10. 
(6)  Do a function test of the alternator.  Refer to Paragraph 6. 

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6.
Test the Alternator

7.
Adjust/Test the Voltage Regulator

DA 40 Series

Detail Steps/Work Items  Key Items/References 
(1)  Set the ALT/BAT switch to ON.  The alternator warning light (ALT or ALTERNATOR) must come on. The amperage and voltage graphic displays in the integrated engine indicator must flash. 
(2)  Start the engine.  Refer to the DA 40 Airplane Flight Manual. 
(3)  Set the engine speed to 1720 RPM. Until the battery has charged and the load meter has stabilized.  Monitor the integrated engine indicator. The voltage must be 28 volts ± 2.5 % 
(4)  Set all the electrical loads to ON.  The voltage must remain at 28 volts ± 2.5 % and the load meter should indicate an increase in load. 
(5)  Operate intermittent loads throughout this part of the test, for example, flaps, Pitot heat.  The voltage must remain at 28 volts ± 2.5 %. The load meter should indicate the related loads. 
(6)  Shut-down the engine.  Refer to the DA 40 Airplane Flight Manual. The alternator warning light (ALT or ALTERNATOR) must come on. 
(7)  Set the ALT/BAT switch to OFF. 

The voltage regulator can be adjusted in service. Refer to the equipment manufacturers manuals for data on adjusting the voltage of the voltage regulator.
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Section 24-31 % Battery System - Lycoming Engine
1. General
%  This Section tells you about the battery system for airplanes with the Lycoming engine installed. See Sections 24-00 and 24-30 for the description and operation of the battery in the electrical generation system.
The battery is located in the engine bay on the front of the fire-wall, on the right. When the alternator voltage is greater than the battery voltage, the alternator charges the battery.
When the alternator is operating, the voltmeter shows the alternator voltage. When the alternator is off-line, the voltmeter shows the battery voltage.
The battery supplies current to the main bus or, if installed, to the essential bus through the battery relay. The battery relay is in the relay box which is located on the firewall, inboard of the battery. A 70 amps circuit-breaker protects the battery system.
Regular maintenance of the battery system is necessary. Do not wait until a starting problem occurs.
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Figure 1: Battery Installation
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AMM

Trouble-Shooting
1. General
The table below lists the defects you could have with the battery system. If you have the trouble detailed in the Trouble column read across to the Possible Cause column. Then do the repair given in the Repair column.
Trouble  Possible Cause  Repair 
Battery voltage low.  Battery electrolyte level low. Battery capacity low. Alternator output low.  Fill to correct level. Do a capacity test. If necessary, replace the battery. Trouble-Shoot the alternator, refer to Section 24-30. 
　
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