Bench Check - Generator - Delphi CS 144 (KG9)

TOOL REQUIRED:
J 41450-B Universal Electronic CS Generator Tester

The following bench check may be used to verify the operation of a CS-144 generator that has been repaired. Use only a test - stand with known calibrated generator speed and ampere load indicators. This check simulates the operation of the generator on a vehicle.
1. Mount generator in suitable test stand according to test stand manufacturer's instructions. Test stand must be capable of driving generator at 6500 RPM.
2. Assure that test stand battery is a fully charged, 12-volt automotive battery.
3. Turn "OFF" internal or external test load, depending on type of stand used. Connect across battery terminals.
4. Assure that internal or external ammeter is connected in series with the test stand leads. DMM must be capable of reading up to 100 amperes.
5. Connect positive test stand lead to generator output "BAT" terminal. Connect negative test stand lead to metal housing of generator.
6. Perform J 41450-B self-test procedure per manufacturer's instructions to verify proper operation of tester.
7. Connect red alligator clip of J 41450-B to generator output terminal and black alligator clip to metal generator housing. Green "POWER" lamp on tester should light. If lamp lights, go to next step. If not, recheck wiring for correct connections (lamp will not light if polarity or tester connections are reversed).
8. Connect matching 4-way connector on J 41450-B tester to generator. Red "DIAGNOSTIC" lamp should light. If lamp lights, go to next step. If it does not light, repair generator for improper assembly or faulty regulator.
9. With both red and green lamps lighted on J 41450-B tester, start test stand and slowly increase speed. The red "DIAGNOSTIC" lamp on tester should become dark before speed reaches 2500 RPM. Increase speed to 6500 RPM. Red lamp on tester should remain dark. If lamp on tester becomes dark at lower speed, go to next step. If red lamp either remains lighted or lights again at the higher speed, repair the generator for either a no-output or an uncontrolled voltage condition.
10. With test stand driving generator at 6500 RPM, turn on test load and adjust to load test value shown in "Specifications". Red lamp on J 41450-B tester should remain dark. If the lamp remains dark, the generator is GOOD and should be returned to service. If the red lamp lights with the test load at or below the specified value, repair the generator for a low output condition. If the load test amperes cannot be reached and the red lamp does not come on, check the test stand load bank for low ampere capacity.
11. Turn the test load "OFF," then stop the test stand. Disconnect ground load from generator housing before disconnecting test lead from generator output "BAT" terminal.