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Test A: Charging System Test

NOTE: Ensure battery is in good condition before proceeding with charging system tests. See BATTERY TESTING & INSPECTION  under ON-VEHICLE TESTING.
  1. If engine electrical diagnostic system check was performed, go to next step. If engine electrical diagnostic system check was not performed, go to ENGINE ELECTRICAL DIAGNOSTIC SYSTEM CHECK  under ON-VEHICLE TESTING.
  2. Turn all electrical loads off. Start engine. Using scan tool, observe IGNITION 1 parameter in PCM data list. If scan tool indicates voltage is between 11 and 15.5 volts, go to next step. If scan tool does not indicate voltage as specified, check for intermittent or poor connections in wiring systems and repair as needed. See PRELIMINARY INSPECTION  under TROUBLE SHOOTING.
  3. Turn ignition switch to OFF position. Connect a charging system tester to battery. Follow manufacturers instructions. Operate engine at 2500 RPM. Adjust carbon pile as necessary to obtain maximum current output (73-amps for K68 or 87-amps for KG7). If generator is not within 10-amps of specified output, go to next step. If generator output is within 10-amps of specified value, go to step  9 .
  4. Maintain engine speed at 2500 RPM and continue to operate generator at load test value. Using a DVOM, measure voltage drop between generator output terminal (Red wire) and battery positive terminal. See WIRING DIAGRAMS  . If voltage drop is less than 0.5 volts, go to next step. If voltage drop is 0.5 volts or more, go to step  6 .
  5. Maintain engine speed at 2500 RPM and continue to operate generator at load test value. Using a DVOM, measure voltage drop between generator metal housing and negative battery terminal. If voltage drop is less than 0.5 volt, go to step  8 . If voltage drop is 0.5 volt or more, go to step  7 .
  6. Check battery positive circuit between generator output terminal (Red wire) and battery positive terminal for high resistance. See WIRING DIAGRAMS  . If no problem exists, go to next step. If problem exists, repair 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 was found and corrected, system is okay. If condition was not found, go to step  3 .
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