Initial Inspection and Diagnostic Overview

WARNING:
^ BATTERIES CONTAIN SULFURIC ACID. AVOID CONTACT WITH SKIN, EYES, OR CLOTHING. ALSO, SHIELD YOUR EYES WHEN WORKING NEAR BATTERIES TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID SOLUTION. IN CASE OF ACID CONTACT WITH SKIN OR EYES, FLUSH IMMEDIATELY WITH WATER FOR A MINIMUM OF 15 MINUTES AND GET PROMPT MEDICAL ATTENTION. IF ACID IS SWALLOWED, CALL A PHYSICIAN IMMEDIATELY.
^ BATTERIES NORMALLY PRODUCE EXPLOSIVE GASES WHICH CAN CAUSE PERSONAL INJURY. THEREFORE, DO NOT ALLOW FLAMES, SPARKS OR LIGHTED SUBSTANCES TO COME NEAR THE BATTERY. WHEN CHARGING OR WORKING NEAR A BATTERY, ALWAYS SHIELD YOUR FACE AND PROTECT YOUR EYES. ALWAYS PROVIDE VENTILATION.
^ WHEN LIFTING A PLASTIC-CASED BATTERY, EXCESSIVE PRESSURE ON THE END WALLS COULD CAUSE ACID TO SPEW THROUGH THE VENT CAPS RESULTING IN PERSONAL INJURY, DAMAGE TO THE VEHICLE OR TO THE BATTERY. LIFT WITH A BATTERY CARRIER OR WITH YOUR HANDS ON OPPOSITE CORNERS.

NOTE: Test the charging system with a fully charged, correctly operating battery. Check the testing equipment and instructions. If the testing equipment is malfunctioning or the instructions for use are incorrect, use the equipment on a vehicle known to be operating correctly.

Perform a visual inspection using the following procedure:
1. Check the battery posts and battery cable terminals for clean and tight connections. Remove the battery cables (if corroded); clean and install them securely.
2. Check for clean and tight wiring connections at the generator and engine.
3. Check the drive belt tension; refer to Drive Belts, Mounts, Brackets and Accessories.
4. Check the battery state of charge; refer to Component Tests. Component Tests and General Diagnostics

Isolating the Concern
Isolate the battery, the charging system and the electrical circuits to correctly identify the area where the difficulty lies. Check the battery before performing any electrical system diagnosis.

Open circuits or other wiring concerns can prevent the generator from operating normally.

Battery Check
Check the battery to see if it can accept and hold a charge; refer to Component Tests. If the battery is good, then the charging system should be checked to see that it can keep the battery charged. Component Tests and General Diagnostics

The battery test will determine the ability of a battery to accept and hold a charge. If the battery cannot meet specification, replace it with a new fully charged battery before further diagnosis.

Drain Testing
Refer to Component Tests. Component Tests and General Diagnostics
Following are some of the most common current drain concerns:
^ The interior lamp stays on continuously.
^ An electronic component malfunctions.

Generator Check
Check the generator to see if it is producing the correct output current and voltage. Refer to the Component Tests. If the generator does not meet specification, use the Symptom Chart to determine the correct test procedure for the charging system concern. Component Tests and General Diagnostics Symptom Related Diagnostic Procedures

1. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart:

2. If an obvious cause for an observed or reported concern is found correct the cause (if possible) before proceeding to the next step.
3. If the concern is not visually evident, verify the symptom and refer to the Symptom Chart. Symptom Related Diagnostic Procedures