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Test A: Charging System Test

  1. If diagnostic system check was not performed, perform ENGINE ELECTRICAL DIAGNOSTIC SYSTEM CHECK  under ON-VEHICLE TESTING. If diagnostic system check was performed, go to next step.
  2. Start engine and observe charge indicator on Instrument Panel Cluster (IPC), or message in the Driver's Information Center (DIC). If charge indicator light illuminates, or DIC displays a charging system message, go to next step. If charge indicator light does not illuminate, or no message appears, problem is intermittent. Check wiring and connections.
    3. NOTE: GREEN POWER light on tester should remain illuminated while CS Generator Tester (J-41450-B) 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 illuminates, go to step  6 . If GREEN POWER light does not illuminate, go to next step.
  4. Measure voltage between output terminal of generator and generator housing. If battery voltage exists, go to step  14 . If battery voltage does not exist, go to next step.
  5. Measure voltage from generator output terminal to negative battery 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 to generator. If RED DIAGNOSTIC light on tester 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 to maximum possible output.
  8. Maintain engine speed at 2500 RPM. Turn on load of carbon pile tester and increase load until generator output is greater than or equal to 75 amps. If RED DIAGNOSTIC light illuminates, go to step  15 . If RED DIAGNOSTIC light does not illuminate, go to next step.
  9. Maintain engine speed at 2500 RPM and continue to operate generator at test load value. Measure voltage drop between generator output terminal and positive battery terminal. If voltage drop is greater than 0.5 volt, go to step  11 . If voltage drop is 0.5 volt or less, go to next step.
  10. Maintain engine speed at 2500 RPM and continue to operate generator at test load value. Measure voltage drop between generator metal housing and negative battery terminal. If voltage drop is greater than 0.5 volt, go to step  12 . If voltage drop is 0.5 volt or less, go to step  16 .
  11. Repair high resistance or open in Red wire (Black wire on 5.7L engine) between generator output terminal and positive battery terminal. 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 CS Generator Tester (J-41450-B) harness connector from generator, leave alligator clips connected to GREEN POWER light remains on. Connect a jumper wire with an in-line 100-ohm resister between CS Generator Tester (J-41450-B) 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. A problem exists within CS Generator Tester (J-41450-B). Refer to manufacturers 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  under REMOVAL & INSTALLATION. After repair, go to next step.
  16. Operate vehicle to verify repair. If system is not operating correctly, repeat test beginning at step  2 .
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