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Test A: Charging System Test

  1. Check generator mounting. Check wiring harness electrical connections at generator. Check battery cables. Check drive belt tension. Ensure battery is fully charged. Reviewing the description and operation information will help determine the correct symptom diagnostic procedure when a malfunction exists and will also help determine if the condition described by the customer is normal operation. See DESCRIPTION & OPERATION  . If review was performed, go to next step.
  2. Turn off all electrical loads. Connect scan tool to Data Link Connector (DLC). Start engine. Using scan tool, observe BATTERY VOLTAGE parameter in Powertrain Control Module (PCM) data list. If scan tool indicates voltage is 11-15.5 volts, go to next step. If scan tool indicates voltage is not 11-15.5 volts, problem may be intermittent. Check wiring and connections, see PRELIMINARY INSPECTION  under TROUBLE SHOOTING.
  3. Turn ignition switch to OFF position. Connect charging system tester to battery. Follow manufacturers instructions. Operate engine at 2500 RPM. Adjust carbon pile as necessary in order to obtain maximum current output. If generator output is not 79-99 amps, go to next step. If generator output is 79-99 amps, go to step  9 .
  4. Maintain engine speed at 2500 RPM and continue to operate generator at load test value. See GENERATOR SPECIFICATIONS  . Using DVOM measure voltage drop between generator output terminal (Black/Green wire) and battery positive terminal. See WIRING DIAGRAMS  . If voltage drop is less than .5 volt, go to next step. If voltage drop is greater than .5 volt, go to step  6 .
  5. Maintain engine speed at 2500 RPM and continue to operate generator at load test value. See GENERATOR SPECIFICATIONS  . Measure voltage drop between battery negative terminal and generator metal housing. See WIRING DIAGRAMS  . If voltage drop is greater than .5 volt, go to step  7 . If voltage drop is less than .5 volt, go to step  8 .
  6. Test battery positive circuit between generator output terminal and battery positive terminal for high resistance. See WIRING DIAGRAMS  . If high resistance was not found, go to next step. If problem exists, repair circuit as necessary and go to step  9 .
  7. Repair high resistance in ground circuit between generator housing and battery negative terminal. See WIRING DIAGRAMS  . After repairs are made, go to step  9 .
  8. Replace generator. See GENERATOR  under REMOVAL & INSTALLATION. After repairs are made, go to next step.
  9. Operate system to verify repair. If condition is corrected, system is okay. If condition was not found and corrected, go to step  2 .
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