Be sure to check the following before testing:
Generator installation and wiring connections
Generator drive belt tension
Fusible link
Abnormal noises from the generator while the engine is running.
Turn the ignition switch to the OFF position.
Disconnect the negative battery cable.
Disconnect the generator output wire from the generator "B" terminal. Connect a DC test ammeter with a range of 0-100A in series between the "B" terminal and the disconnected output wire. (Connect the (+) lead of the ammeter to the "B" terminal. Connect the (-) lead of the ammeter to the disconnectedoutput wire.)
An inductive-type ammeter which enables measurements to be taken without disconnecting the generator output wire is recommended. Using this equipment will lessen the possibility of a voltage drop causedby a loose "B" terminal connection.
Connect a digital-type voltmeter between the generator "B" terminal and the battery (+) terminal. (Connect the (+) lead of the voltmeter to the "B" terminal. Connect the (-) lead of the voltmeter to the battery (+) cable.)
Reconnect the negative battery cable.
Connect a tachometer or the scan tool.
Start the engine.
With the engine running at approx. 2500 rpm, turn the headlights and other lights on and off to adjust the generator load on the ammeter slightlyabove 30A.
When the generator output is high and the value displayed on the ammeter does not decrease to 30A, set the value to 40A. Read the value displayed on the voltmeter. In this case the limit becomesmax. 0.4V.
If the value displayed on the voltmeter is still above the limit, a fault in the generator output wire may exist. Check the wiring between the generator "B" terminal and the battery (+) terminal (including fusible link). If a terminal is not sufficiently tight or if the harness has become discoloreddue to overheating, repair, then test again.
After the test, run the engine at idle.
Turn off all lights and turn the ignition switch to the OFF position.
Disconnect the tachometer or the scan tool.
Disconnect the negative battery cable.
Disconnect the ammeter and voltmeter.
Connect the generator output wire to the generator "B" terminal.
Connect the negative battery cable.
Before testing, be sure to check the following :
Generator installation and wiring connections
Battery
Generator drive belt tension
Fusible link
Abnormal noise from the generator while the engine is running
The battery used should be slightly discharged. The load needed by a fully-charged battery is insufficient for an accuratetest.
Turn the ignition switch to the OFF position.
Disconnect the negative battery cable.
Disconnect the generator output wire from the generator "B" terminal. Connect a DC test ammeter with a range of 0-100 A in series between the "B" terminal and the disconnected output wire. (Connect the (+) lead of the ammeter to the "B" terminal. Connect the (-) lead of the ammeter to the disconnectedoutput wire.)
Never use clips. Use bolts and nuts to connect the line. Otherwise, loose connections (e.g. using clips) may lead to a seriousaccident because of high current.
An inductive-type ammeter which enables measurements to be taken without disconnecting the generator output wire is recommended.
Connect a voltmeter with a range of 0-20V between the generator "B" terminal and the ground. (Connect the (+) lead of the voltmeter to the "B" terminal, and then connect the (-) lead of the voltmeter to the ground.)
Connect the negative battery cable.
Connect a tachometer or the scan tool.
Leave the hood open.
Check that the reading on the voltmeter is equal to battery voltage.
If the voltage is 0 V, the cause is probably an open circuit in the wire or fusible link between the generator "B" terminaland the battery (+) terminal.
Start the engine, and turn the headlights on.
Switch the headlights to high beam, turn the heater blower switch to high, increase the engine speed to approx. 2,500 rpm, and read the maximumcurrent output displayed on the ammeter.
For the nominal current output, refer to the Generator Specifications page EE-2.
Because the current from the battery will drop soon after the engine is started, steps 10 and 11 should be carried out as quickly as possiblein order to obtain the maximum current output value.
The current output value will depend on the electrical load and the temperature of the generator body.
If insufficient electrical load is used while testing, the specified level of current may not be output, even though the generator is normal. In such a case, increase the electrical load by leaving the headlights on withthe engine off to discharge the battery before testing.
The specified level of current may not be output if the temperature of the generator body and/or ambient temperature is too high. In such a case,allow the generator to cool before testing.
The reading on the ammeter should be above the limit value. If the reading is below the limit value and the generator output wire is OK, removethe generator from the engine and check the generator.
Run the engine at idle speed after the test.
Turn the ignition switch to the OFF position.
Disconnect the tachometer or the scan tool.
Disconnect the negative battery cable.
Disconnect the ammeter and voltmeter.
Connect the generator output wire to the generator "B" terminal.
Connect the negative battery cable.
Be sure to check the following:
Generator installation and wiring connections
Battery fully charged
Generator drive belt tension
Fusible link
Abnormal noise from the generator while the engine is running
Turn the ignition switch to the OFF position.
Disconnect the negative battery cable.
Connect a digital-type voltmeter between the generator "S" terminal and the ground. (Connect he (+) lead of the voltmeter to the "S" terminal. Connect the (-) lead of the voltmeter to a secure ground or to the battery(-) terminal.)
Disconnect the generator output wire from the generator "B" terminal.
Connect a DC test ammeter with a range of 0-100A in series between the "B" terminal and the disconnected output wire.
(Connect the (+) lead of the ammeter to the "B" terminal. Connect the (-) lead of the ammeter to the disconnected output wire.)
Reconnect the negative battery cable.
Connect a tachometer or the scan tool. Check that the reading on the voltmeter is equal to the battery voltage.
If the voltage is 0 V, the cause is probably an open circuit in the wire or fusible link between the generator "S" terminaland the battery (+) terminal.
Make sure all lights and accessories are off.
Start the engine.
Increase the engine speed to approx. 2,500 rpm.
Read the voltmeter when the current output of the generator becomes 10 A or less.
If the voltage reading conforms to the value in the voltage regulation table, the voltage regulator is operating normally. If the voltage is not within the standard value, a malfunction of the voltage regulator or of thegenerator exists.
