Initial Inspection and Diagnostic Overview

WARNING:
- BATTERIES CONTAIN SULFURIC ACID. AVOID CONTACT WITH SKIN, EYES, OR CLOTHING. ALSO, SHIELD YOUR EYES WHEN WORKING NEAR BATTERIES TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID SOLUTION. IN CASE OF ACID CONTACT WITH SKIN OR EYES, FLUSH IMMEDIATELY WITH WATER FOR A MINIMUM OF 15 MINUTES AND GET PROMPT MEDICAL ATTENTION. IF ACID IS SWALLOWED, CALL A PHYSICIAN IMMEDIATELY.
- BATTERIES NORMALLY PRODUCE EXPLOSIVE GASES WHICH CAN CAUSE PERSONAL INJURY. THEREFORE, DO NOT ALLOW FLAMES, SPARKS OR LIGHTED SUBSTANCES TO COME NEAR THE BATTERY. WHEN CHARGING OR WORKING NEAR A BATTERY, ALWAYS SHIELD YOUR FACE AND PROTECT YOUR EYES. ALWAYS PROVIDE VENTILATION.
- WHEN LIFTING A PLASTIC-CASED BATTERY, EXCESSIVE PRESSURE ON THE END WALLS COULD CAUSE ACID TO SPEW THROUGH THE VENT CAPS RESULTING IN PERSONAL INJURY, DAMAGE TO THE VEHICLE OR TO THE BATTERY. LIFT WITH A BATTERY CARRIER OR WITH YOUR HANDS ON OPPOSITE CORNERS.

1. Verify the customer concern by operating the engine to duplicate the concern.
2. Inspect the charging system (battery, generator cable, harness connectors, connections) to determine if any obvious mechanical or electrical concerns exist. If found, repair as necessary and test the system for normal operation. Refer to the Visual Inspection Chart:


VISUAL INSPECTION CHART

Mechanical
- Battery case, posts, hold-down clamp, cables and connections for damage
- Generator drive (serpentine) belt for condition and tension to make sure there is no slip between the belt and the pulley. Repair as necessary.
- Generator pulley loose or bent

Electrical
- Battery junction box Fuse ALT (20 A)
- Central junction box Fuse 5 (15 A)
- Harness electrical connectors and connections (loose or corroded)
- Inline mini-fuse
- Battery charge warning indicator
- Other electrical system concerns (missing grounds, failed fuses, damaged cables)
- Fuse link A and B

3. Check the operation of the charging system warning indicator lamp (instrument panel). Normal operation is as follows:
- With the ignition switch OFF, the charging system warning indicator should be OFF.
- With the ignition switch in RUN and the engine OFF, the charging system warning indicator light should be ON.
- With the engine running, the charging system warning indicator light should be OFF.







4. Verify the battery is being charged. Carry out the Battery Load Test. [1][2]Battery Load Test
5. If the customer concern is verified after the initial inspection, refer to the Symptom Chart to determine which tests to carry out and for the appropriate engine and generator configuration. Symptom Related Diagnostic Procedures