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Test A: Charging System Test

  1. If diagnostic system check was not performed, perform ENGINE ELECTRICAL DIAGNOSTIC SYSTEM CHECK  . If diagnostic system check was performed, go to next step.
  2. Start engine and observe charge indicator on Instrument Panel Cluster (IPC) or message on Driver's Information Center (DIC). If charge indicator illuminates or DIC displays a charging system message, go to next step. If charge indicator does not illuminate or DIC does not display a charging system message, problem is intermittent. Check wiring and connections.
    3. NOTE: Green POWER light of tester should remain illuminated while tester is being used.
  3. Turn ignition switch to OFF position. Using CS Generator Tester (J-41450-B), connect Red lead to generator output terminal and Black lead to metal generator housing. If Green POWER light does not illuminate, go to next step. If Green POWER light illuminates, go to step  6 .
  4. Using a DVOM, measure voltage between output terminal of generator and generator metal housing. If battery voltage exists, go to step  14 . If battery voltage does not exist, go to next step.
  5. Using a DVOM, measure voltage between output terminal of generator and battery negative terminal. If battery voltage exists, go to step  12 . If battery voltage does not exist, go to step  11 .
    6. CAUTION: Ensure load is completely turned off before connecting or disconnecting carbon pile load tester to battery.
  6. Connect carbon pile tester to battery. Connect inductive ammeter to output circuit of generator. Disconnect generator harness connector. Locate matching harness connector on CS Generator Tester (J-41450-B) and connect it to generator. If Red DIAGNOSTIC light illuminates, go to next step. If Red DIAGNOSTIC light does not illuminate, go to step  13 .
  7. Start engine and allow to idle for 30 seconds. Increase engine speed to 2500 RPM. If Red DIAGNOSTIC light does not illuminate, go to next step. If Red DIAGNOSTIC light illuminates, go to step  15 .
    8. NOTE: If generator is not capable of producing load test amps, operate generator at possible maximum output.
  8. Maintain engine speed at 2500 RPM. Turn on load of carbon pile tester and increase load until load is equal to test value of generator to 70 amps. If Red DIAGNOSTIC light does not illuminate, go to next step. If Red DIAGNOSTIC light illuminates, go to step  15 .
  9. 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 and positive battery terminal. If voltage drop is 0.5 volt or less, go to next step. If voltage drop is greater than 0.5 volt, go to step  11 .
  10. 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 0.5 volt or less, go to step  16 . If voltage drop is greater than 0.5 volt, go to step  12 .
  11. Repair high resistance or open in generator output circuit. See WIRING DIAGRAMS  . After repair, go to step  16 .
  12. Repair high resistance or open in ground circuit of generator. See WIRING DIAGRAMS  . After repair, go to step  16 .
  13. Disconnect J-41450-B tester harness connector from generator, but leave alligator clips connected so Green POWER light remains illuminated. Connect a jumper wire with an in-line 100-ohm resister between CS Generator Tester harness connector terminal "B" and a good ground. If Red DIAGNOSTIC light illuminates, go to step  15 . If Red DIAGNOSTIC light does not illuminate, go to next step.
  14. If a problem exists with CS Electronic Generator Tester (J-41450-B). Refer to manufacturer's instructions, how to test J-41450-B for proper operation. If tester has been repaired or replaced, go to step  3 .
  15. Replace generator. See GENERATOR  . After repair, go to next step.
  16. Operate system to verify repair. If system is not operating correctly, repeat test beginning at step  2 .
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