Generator/Regulator Output Test
- Test system using a generator tester with integral carbon pile (to apply electrical load to system). Hook up tester according to manufacturer's instructions. Turn tester selector to STARTING position. Start engine and bring to operating temperature. Increase engine speed to 2000 RPM and hold. Observe voltmeter. If voltage is more than 15.1 volts, replace voltage regulator.
- If voltage is 15.1 volts or less, return engine to idle. Ensure all accessories are off. Turn tester selector to CHARGING position. Remove inductive pick-up and zero ammeter. Connect inductive pick-up over generator battery terminal wire (ensure arrow points away from generator). See Fig 1.
- Increase engine speed to 2000 RPM and hold. Observe voltmeter. If voltage is 13.9 volts or more, go to next step. If voltage is less than 13.9 volts, test battery condition. Recharge or replace battery as necessary.
- While observing ammeter, apply load with generator tester carbon pile until battery voltage drops to 12-13.5 volts. If less than 60 amps are present, go to next step. If 60 amps or more are present, charging system is functioning properly.CAUTION: Voltage will increase rapidly during full field test. DO NOT allow voltage to exceed 18 volts. Damage to electrical system may result.
- With engine speed still at 2000 RPM, full field generator. Attach probe to generator tester full field test lead. Insert probe into full field access hole located on back of generator. See Fig 1. Switch field selector to "A" (ground) position briefly and observe amperage reading. If 60 amps or more are present, go to next step. If less than 60 amps are present, test and repair generator components. See BENCH TESTING .
- Return engine to idle and turn ignition off. Disconnect generator 4-pin harness connector. Turn ignition on. Measure voltage between ground and generator 4-pin harness connector terminal "IG" (Black/Yellow wire). See Figure. If battery voltage is present, replace voltage regulator. If battery voltage is not present, repair open in Black/Yellow wire.