Charging System: Testing and Inspection

ON-VEHICLE INSPECTION

NOTE: If the battery is weak or the engine is difficult to start, recharge the battery and perform inspections again before returning the vehicle to the customer.

1. CHECK BATTERY CONDITION
a. Check the battery for damage and deformation. If severe damage, deformation or leakage is found, replace the battery.
b. Check the electrolyte quantity of each cell.
For maintenance-free batteries:
If the electrolyte quantity is the recommended amount, replace the battery.
For non-maintenance-free batteries:
If the electrolyte quantity is the recommended amount, add distilled water.

2. INSPECT DRIVE BELT




a. Check the belt for wear, cracks and other signs of damage.
If any defect is found, replace the drive belt.

HINT: Replace the drive belt if any of the following defects are found:
- The belt is worn out and the wire is exposed.
- If the cracks reach the wire in more than one place.
- If the belt has chunks missing from the ribs.




b. Check that the belt is fitted properly in the ribbed grooves.

HINT: With your hand, confirm that the belt has not slipped out of the groove on the bottom of the pulley.

3. CHECK BATTERY TERMINALS AND FUSES
a. Check that the battery terminals are not loose or corroded.
If the terminals are corroded, clean the terminals.
b. Check the H-fuses and fuses for resistance.

Standard: 1 Ohm

If the H-fuse or fuse is not as specified, replace as necessary.

4. VISUALLY CHECK GENERATOR WIRING
a. Check that the wiring is in good condition.

5. LISTEN FOR ABNORMAL NOISES FROM GENERATOR
a. Check that the wiring is in good condition.
b. Check that no abnormal noise is emitted from the generator while the engine is running.

6. INSPECT CHARGE WARNING LAMP CIRCUIT
a. Turn the ignition switch ON. Check that the charge warning lamp turns on.
b. Start the engine and check that the lamp turns off.
If the lamp does not operate as specified, troubleshoot the charge warning lamp circuit.




7. INSPECT CHARGING CIRCUIT WITHOUT LOAD
a. If a battery/generator tester is available, connect the tester to the charging circuit according to the manufacturer's instructions.
b. If a tester is not available, connect a voltmeter and ammeter to the charging circuit as follows.
1. Disconnect the wire from terminal B of the generator and connect it to the ammeter's negative (-) lead.
2. Connect the ammeter's positive (+) lead to terminal B of the generator
3. Connect the voltmeter's positive (+) lead to terminal B of the generator.
4. Ground the voltmeter's negative (-) lead.

c. Check the charging circuit.
1. Keep the engine speed at 2,000 rpm. Check the reading on the ammeter and voltmeter.

Standard amperage: 10 A or less
Standard voltage: 13.2 to 14.8 V

If the result is not as specified, replace the generator.

8. INSPECT CHARGING CIRCUIT WITH LOAD
a. With the engine running at 2,000 rpm, turn the high beam headlamps on and turn the heater blower switch to the HI position.
b. Check the reading on the ammeter.

Standard amperage: 30 A or more

If the ammeter reading is less than the standard amperage, repair the generator.

HINT: If the battery is fully charged, the indication will sometimes be less than the standard amperage.