System Diagnosis - Generator-Delphi CS 144 (KG9)

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

To diagnose the CS 144 generator, use the following procedure:
1. Ignition switch "OFF." Turn all electrical accessory loads "OFF"
2. Turn load in carbon pile load tester all the way "OFF" Connect load test across battery terminals.

Important
^ Refer to wiring diagram in ELECTRICAL DIAGNOSIS to be sure the ammeter clip is placed for entire generator output to pass through clip. If circuits are split so that any of the current can pass through other parallel circuits, the generator output reading on the inductive ammeter will not be accurate unless all such circuits pass through the clip.

3. Install inductive ammeter around output wire(s) of generator.
4. Perform universal tester self-test procedure per manufacturer's instructions to verify proper operation of tester.
5. Connect red alligator clip of tester to generator output terminal. Connect black clip to metal generator housing. Green "POWER" lamp on tester should light. If it does, go to step 8. If not, go to step 6.
6. Use digital multimeter (DMM) to check voltage between generator output terminal and battery negative terminal. If reading is B+ voltage, go to step 7. If not, check for open fusible link or other open condition in 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 if the green "POWER" lamp still does not light, go to step 7.
7. With tester still connected as described in step 5, connect a jumper wire between the generator metal housing and the battery negative terminal. Green "POWER" lamp on tester should light. If it does, check ground path from generator housing to battery negative terminal for 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 procedure, including the universal tester self-test procedure.
8. 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 it does, go to step 10. If it does not, go to step 9.
9. Disconnect 4-way tester connector from generator. With ignition key in "RUN" (engine stopped), use a fused jumper lead (with 5 ampere fuse) and Metri-Pack 150 terminal probe adapter to ground the "U" terminal (cavity B) in vehicle harness 4-way connector. If fuse does not blow, replace the generator. If fuse blows diagnose and repair "L" terminal circuit (225) for direct short to B+ or miswired/no resistance condition, then replace generator. Fix wiring BEFORE replacing generator.
10. Turn "OFF" all electrical accessories and close doors, etc. to be sure all loads are off. With tester connected as described in step 8, start engine and let it 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 lighted. If it is still lighted, replace the generator. If it is not lighted, go to step 11.
11. Increase engine speed to 2500 RPM. The "DIAGNOSTIC" lamp on the tester should not light. If it lights, replace the generator. If it is not lighted, go to step 12.
12. With 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 listed in the Generator Usage Chart under "Specifications".
- If the red "DIAGNOSTIC" lamp on the J 41450-B tester does not light and the load test value is attained, the generator is GOOD - DO NOT replace the generator. Go to step 13.
- If the red lamp on the tester lights with the generator operating at or below the load test output value, replace the generator.
- If the load test value can not be reached but the red tester lamp does not come on, check carbon pile tester for low ampere capacity.
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 vehicle charge indicator in the instrument cluster still does not operate as required, refer to INSTRUMENT PANEL, GAUGES AND WARNING INDICATORS to diagnose and repair the generator control circuit.
- If the customer has commented about erratic or high voltage or an overcharged battery from a generator that uses an S terminal connection, be sure to check the S terminal circuit for intermittent or high resistance connections.
- If the customer has commented about a battery that loses charge over a period of time check for abnormal parasitic loads. Battery