When the charging system is operating normally, the charge
indicator lamp will come on when the ignition switch is turned on and will
go out when the engine starts. If the lamp operates abnormally, or if
an undercharged or overcharged battery condition occurs, diagnose and
repair the charging system. Remember that an undercharged battery is
often caused by accessories being left on overnight, or by a rear compartment
or instrument panel compartment lamp that stays on.
Noise from a generator may be caused by:
• | Improper routing of hoses, wiring or shielding against the generator
housing. |
• | Brush/slip ring friction |
Important: To avoid damage to the electrical equipment, observe the following precautions:
• | Do not reverse connections to the generator. |
• | Do not short across, or ground any of the terminals in the charging
circuit, except as directed by the instructions. |
• | Do not attempt to hot wire the generator by connecting B+ voltage
to any of the generator 4-way connector terminals. Use only an approved
test harness as described in these instructions. |
• | Never disconnect the output terminal while the generator is operating. |
• | Before connecting a charger or a booster battery to the vehicle
battery, refer to
Battery Charging
. |
Inspect the following before testing the generator:
• | The battery. Make sure that the vehicle battery is in good condition
and fully charged. Refer to
Battery Load Test
. |
• | The built-in hydrometer in the battery. The green eye must be
showing in the hydrometer. |
• | The voltage across the battery terminals with all the loads OFF
should be above 12 V. Refer to
Battery Load Test
. |
• | Make sure that the battery connections are clean and tight. |
• | The wiring harness at the generator. Make sure that the harness
connector is tight and latched. Make sure that the output terminal of the
generator is connected to the vehicle battery (positive) generator lead. |
• | All the charging system related fuses and electrical connections
for damage or looseness. Refer to the starter and charging system schematics. |
Generator
Tools Required
J 41450-B CS Electronic
Generator Tester
To diagnose a CS generator use the following procedure:
- Turn the ignition switch OFF. Turn all electrical accessory loads
OFF.
- Turn the load in the carbon pile load tester all the way OFF.
Connect load test across the battery terminals. Make sure the ammeter clip
is placed for the entire generator output to pass through the clip.
Refer to the starter and charging system schematics. If the circuits
are split so that any of the current can pass through parallel circuits,
all such circuits must pass through the clip or the generator output
reading on the inductive ammeter will not be accurate.
- Install the inductive ammeter around the output wire(s) of generator.
- Perform the universal tester self-test procedure per the manufacturer's
instructions to verify proper operation of tester.
- Connect the red alligator clip of tester to generator output terminal.
Connect black clip to metal generator housing. The green POWER lamp on the
tester should light. If it does, go to step 8. If the POWER lamp does
not light, go to step 6.
- Use a digital multimeter to check voltage between the generator
output terminal and the battery negative terminal. If reading is B+ voltage,
go to step 7. If not, check for an open condition in the generator
output wiring and repair as necessary. If the tester's green POWER
lamp now lights when connected per step 5, go to step 8. If no open
condition was found or the green POWER lamp still does not light, go
to step 7.
- With the tester still connected as described in step 5, connect
a jumper wire between the generator metal housing and the battery negative
terminal. The green POWER lamp on the tester should light. If it does,
check the ground path from the generator housing to the battery negative
terminal for an open conditions and repair as necessary. If the tester's
green POWER lamp now lights, go to step 8. If not, return to step
1 and repeat the procedure, including the tester self-test procedure.
- With tester still connected as described in step 5, disconnect
the 4-way generator connector from the generator and connect the matching
connector on the tester to the generator. The red DIAGNOSTIC lamp
on the tester should light. If the red DIAGNOSTIC does light, go to
step 10. If the red DIAGNOSTIC lamp does not light, go to step 9.
- Disconnect the 4-way tester connector from the generator. With
the ignition key in RUN (engine stopped), use a fused jumper lead (with a
5 A fuse) and Metri-Pack 150 terminal probe adapter to ground
the L terminal (cavity B) in the vehicle harness 4-way connector.
If the fuse does not blow, replace the generator. If the fuse blows,
refer to the starter and charging system schematics to diagnose
and repair the L terminal circuit (225) for direct short to B+
or mis-wired/no resistance condition, then replace the generator.
Fix the wiring before replacing the generator.
- Turn OFF all the electrical accessories and close the doors to
be sure all the loads are off. With the tester connected as described in step
8, start the engine and let the engine idle briefly. (Note that
the vehicle's generator control circuits are bypassed during this
test, and the charge indicator in the instrument cluster will not
operate normally.) After the engine starts, the red DIAGNOSTIC
lamp on the tester should not be lit. If the red DIAGNOSTIC lamp
is still lit, replace the generator. If the red DIAGNOSTIC lamp is
not lit, go to step 11.
- Increase the engine speed to 2500 RPM. The red DIAGNOSTIC lamp
on the tester should not light. If the red DIAGNOSTIC lamp lights, replace
the generator. If the DIAGNOSTIC lamp is not lit, go to step 12.
- With the engine speed still at 2500 RPM, turn the load on the
carbon pile load tester to ON and adjust until the generator output is at
the Load Test value.If the red DIAGNOSTIC lamp on the tester lights
with the generator operating at or below the load test output value,
replace the generator. If the red light does not light and the
load test value is attained, the generator is good. DO NOT replace
the generator. Go to step 13.
- Turn the carbon pile load tester load to OFF and stop the engine.
Remove the generator tester, the ammeter, and the load tester from the vehicle.
Reconnect the 4-way harness connector to the generator. Be sure
the connector is fully seated and latched.
• | If the customer has commented about erratic or high voltage from
a generator that uses an S terminal connection, be sure to check the S terminal
circuit (cavity D in the harness connector) for intermittent or
high resistance connections. |