When the charging system is operating normally, the charge
indicator lamp will turn on when the ignition switch is turned on and will
turn off when the engine starts. If the lamp operates abnormally, refer to
Instrument Cluster Diagnostic Information
in Instrument Panel, Gauges and Console. If an undercharged or overcharged
battery condition occurs, refer to
Battery Is Undercharged or Overcharged
. 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 the 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. |
• | Use only approved Metri-pack terminal probe adapters to connect
the meter leads and the jumper wires to the connector terminals. Using improper
adapters will damage the concrete terminals and cause charging system or test
harness failure. |
• | Before connecting a charger or a booster battery to the vehicle
battery, refer to
Battery Charging
. |
Before testing the generator inspect the following :
• | Battery. Make sure that the vehicle battery is in good condition
and fully charged. Refer to
Battery Load Test
. |
• | Built-in hydrometer in the battery. The green eye must be showing
in the hydrometer. |
• | The voltage across the battery terminals with all loads OFF should
be above 12 volts. |
• | Make sure that the battery connections are clean and tight. |
• | 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. |
Generator
Tools Required
J 41450-B Universal
Electronic CS Generator Tester
To diagnose a CS generator use the following procedure:
- Turn the ignition switch OFF. Turn all the electrical accessory
loads OFF.
- Turn the load in the carbon pile load tester all the way OFF.
Connect a 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
Starting and Charging 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 the
generator.
- Perform the universal tester self-test procedure per the manufacturer's
instructions to verify proper operation of the tester.
- Connect the red alligator clip of the tester to the generator
output terminal. Connect the black clip to the metal generator housing. The
green POWER lamp on the tester should light. If the green POWER lamp lights,
go to step 8. If the POWER lamp does not light, go to step 6.
- Use a digital multimeter to check the voltage between the generator
output terminal and the battery negative terminal. If the reading is B+ voltage,
go to step 7. If not, check for an open fusible link or 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 the green POWER
lamp does light, check the ground path from the generator housing to the
battery negative terminal for an open condition and repair as necessary.
If the tester's green POWER lamp now lights, go to step 8. If the lamp does
not light, 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 DIAGNOSTIC lamp does light, go to step 10. If the 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
Starting and Charging 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 red 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. Refer to
Generator Usage
. 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, ammeter, and 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. |