1J-4 Charging System:
Diagnostic Information and Procedures
Battery Inspection
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Common Causes of Failure
A battery is not designed to last indefinitely; however, with proper care, it will provide many years of service. If the
battery performs satisfactorily during test but fails to operate properly for no apparent reason, the following are some
factors that may point to the cause of trouble:
• Accessories left on overnight or for an extended period without the generator operating.
• Slow average driving speeds for short periods.
• Electrical load exceeding generator output particularly with addition of aftermarket equipment.
• Defects in charging system such as high resistance, slipping drive belt, loose generator output terminal, faulty
generator or voltage regulator, Refer to “Generator Symptom Diagnosis”.
• Battery abuse, including failure to keep battery cable terminals clean and tight or loose battery hold down.
• Mechanical problems in electrical system such as shorted or pinched wires.
Visual Inspection
Check for obvious damage, such as cracked or broken case or cover, that could permit loss of electrolyte. If obvious
damage is noted, replace battery. Determine cause of damage and correct as needed.
Generator Symptom Diagnosis
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CAUTION
!
• Do not mistake polarities of “IG” terminal and “L” terminal.
• Do not create short circuit between “IG” and “L” terminals. Always connect these terminals through
a lamp.
• Do not connect any load between “L” and “E” terminals.
• When connecting charger or booster battery to vehicle battery, refer to “Jump Starting in Case of
Emergency”.
Trouble in charging system will show up as one or more of the following conditions:
1) Faulty indicator lamp operation.
2) An undercharged battery as evidenced by slow cranking or indicator dark.
3) An overcharged battery as evidenced by excessive spewing of electrolyte from vents.
Condition Possible cause Correction / Reference Item
Noisy generator Loose drive belt Adjust or replace drive belt.
Loose drive belt pulley Tighten by specified torque.
Loose mounting bolts Tighten by specified torque.
Worn or dirty bearings Replace.
Defective diode or stator Replace.
Charge light does not
light with ignition ON and
engine off
Fuse blown Replace fuse and check for shorted circuit.
Indicator lamp (LED) faulty Replace combination meter.
Wiring connection loose Tighten loose connection.
IC regulator or field coil faulty Replace.
Poor contact between brush and slip
ring
Repair or replace.
Charge light does not go
out with engine running
(battery requires frequent
recharging)
Drive belt loose or worn Adjust or replace drive belt.
IC regulator or generator faulty Replace.
Wiring faulty Repair wiring.
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