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Test A: System Does Not Charge

  1. Turn ignition switch to OFF position. Measure ground circuit voltage drop by touching negative voltmeter probe to battery negative terminal, and voltmeter positive probe to generator case. If voltmeter reads less than .25 volt, go to next step. If voltmeter reads .25 volt or greater, clean or repair ground connections or generator mounting surfaces. Retest system operation.
  2. Measure voltage between battery terminal B+ (Black wire) and ground. If battery voltage is present, go to next step. If battery voltage is not present, inspect mega fuse (175-amp). If mega fuse (175-amp) is blown, replace fuse. If mega fuse (175-amp) is okay, repair open in Black wire between generator and battery. See WIRING DIAGRAMS  .
  3. Measure voltage between generator terminal "A" and ground. See Fig 1 . If battery voltage is present, go to next step. If battery voltage is not present, repair circuit between battery and generator. See WIRING DIAGRAMS  . Retest system operation.
  4. Measure voltage drop by connecting voltmeter positive probe to generator terminal "A", and voltmeter negative probe to battery positive terminal. See Fig 1 . If voltmeter reads less than .25 volt, go to next step. If voltmeter reads .25 volt or less, repair high resistance in circuit between battery and generator. See WIRING DIAGRAMS  . Retest system operation.
  5. Turn ignition switch to RUN position. Measure voltage between generator test terminal "F" and ground. See Fig 1 . If battery voltage is present, go to next step. If battery voltage is not present, replace generator. See GENERATOR  under REMOVAL & INSTALLATION.
  6. Measure voltage between generator connector terminal (Green/Black wire) and ground by backprobing connector. Connector must not be disconnected for measurement. If voltage is greater than one volt, go to next step. If voltage is one volt or less, repair circuit between generator and instrument cluster. See WIRING DIAGRAMS  . Retest system operation.
  7. Start engine. Measure voltage between generator terminal "F" and ground. If voltage is less than 2 volts, go to next step. If voltage is 2 volts or greater, replace generator. See GENERATOR  under REMOVAL & INSTALLATION.
  8. Turn headlights on and place blower in high position. With engine running at 2000 RPM, measure voltage drop in B+ circuit by connecting voltmeter positive probe to generator terminal B+ (Black wire), and voltmeter negative probe to battery positive terminal. If voltmeter reads less than .5 volt, go to next step. If voltmeter reads .5 volt or more, repair open in Black wire between battery and generator. See WIRING DIAGRAMS  . Retest system operation.
  9. With all accessories off, run engine at 1500 RPM and record battery voltage. Connect jumper wire between generator terminal "F" and battery negative terminal. Run engine at 1500 RPM and compare voltmeter reading with recorded voltage. If voltage is at least .5 volt greater than recorded voltage, replace voltage regulator. See VOLTAGE REGULATOR  under REMOVAL & INSTALLATION. If voltage is within .5 volt of recorded voltage, replace generator. See GENERATOR  under REMOVAL & INSTALLATION. Retest system operation.
    Fig 1: Identifying Generator Terminals (Typical)
    G94H32141Courtesy of FORD MOTOR CO.
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