Output Current Test

Output Current Test:

The purpose of this test is to determine whether the generator outputs normal current.
1. Before carrying out the current output test, always be sure to check the following:
- Generator installation.
- Battery condition Testing and Inspection

NOTE: The battery to be used for the current output test should be slightly discharged. The load in a fully-charged battery will be insufficient and the test may not be able to be carried out correctly.
- Generator drive belt tension
- Fusible link condition
- Abnormal noise from the generator while the engine is running.

2. Turn the ignition switch to the OFF position.
3. Disconnect the negative battery cable.
4. Disconnect the generator output wire from the generator "B" terminal and 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, and then connect the (-) lead of the ammeter to the disconnected output wire.)

CAUTION: Because high current will be flowing, all bolts and nuts of the connectors should be securely tightened. Using clips to make the connections should be absolutely avoided.

NOTE: A clamp-type ammeter which enables measurements to be taken without disconnecting the generator output wire should ideally be used.

5. Connect a voltmeter with a range of 0-2O V 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.)
6. Connect a tachometer.
7. Connect the negative battery cable.
8. Leave the hood open.
9. Check to be sure that the reading on the voltmeter is equal to the battery voltage.

NOTE: If the voltage is O V, the cause is probably an open circuit in the wire or fusible link between the generator "B" terminal and the battery (+) terminal.

10. After turning the light switch on and turning on the headlights, start the engine.
11. immediately after setting the headlights to high beam and turning the heater blower switch to the high position, increase the engine speed to 2500 rpm and take a reading of the maximum current output value displayed on the ammeter.
Limit value: 70% of nominal current output

NOTE:
- Because the current from the battery will soon drop after the engine is started, the above step should be carried out as quickly as possible in order to obtain the maximum current output value.
- The current output value will change in accordance with the electrical load and the temperature of the generator body.
- If the electrical load is small while the test is being carried out, the required level of current may not be output even though the generator is normal. In cases such as this, increase the electrical load by leaving the headlights turned on for some time to deplete the battery or by using the lighting system in another vehicle, and then carry out a repeat test.
- The required level of current also may not be output if the temperature of the generator body or the ambient temperature is too high. In such cases as this, cool the generator and then carry out a repeat test.

12. 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 normal, remove the generator from the engine and check the generator.
13. After testing is completed, run the engine at idle.
14 Turn the ignition switch to the OFF position.
15. Disconnect the negative battery cable.
16. Disconnect the test ammeter, voltmeter and tachometer.
17. Connect the generator output wire to the generator "B" terminal.
18. Connect the negative battery cable.