Pinpoint Test F: The Charging System Warning Indicator Flickers Or Is Intermittent

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: 6.0L diesel generator is shown, all others are similar.

F1 CHECK FOR LOOSE CONNECTIONS
- Check all generator, battery, and power distribution connections for looseness, corrosion, loose or bent terminals, or loose eyelets.
- Are all connections clean and tight?
- Yes : GO to F2.
- No : REPAIR as necessary. TEST the system for normal operation.
F2 CHECK THE FUSE CONNECTIONS
- Key in START position.
  With the engine running, check the central junction box (CJB) fuse 14 (5A) in I circuit 904 (LG/RD) for looseness by wiggling the fuse and noting the charging system warning indicator operation.
- Does the charging system warning indicator flicker?
- Yes : REPAIR the loose fuse connection(s) as necessary. TEST the system for normal operation.
- No : GO to F3.
F3 CHECK THE A CIRCUIT 35 (OG/LB) CONNECTIONS
- Key in OFF position.
- Connect a fused (15A) jumper wire between the generator C102a-3, circuit 35 (OG/LB) (back-probed), harness side and the positive battery terminal.
  
  Fig 1: Connecting Fused (15A) Jumper Wire Between Generator And Positive Battery Terminal
  Courtesy of FORD MOTOR CO.
- Key in START position.
  With the engine running, note the charging system warning indicator operation.
- Does the charging system warning indicator flicker?
- Yes : If the generator has an external stator circuit 4 (WH/BK), GO to F4. If the generator has an internal stator circuit, GO to F5.
- No : REPAIR the loose connection(s) in circuit 35 (OG/LB). TEST the system for normal operation.
F4 INSPECT THE S TERMINAL
- Key in OFF position.
- Check the generator S terminal C102b to make sure it is correctly mated to the generator and making good contact with the S terminal on the generator.
- Is the S terminal in satisfactory condition?
- Yes : GO to F5.
- No : REPAIR as necessary. TEST the system for normal operation.
F5 CHECK THE GENERATOR BRUSHES
- Remove the generator. Refer to GENERATOR AND REGULATOR .
- Measure the resistance between the A and F terminals on the voltage regulator.
  
  Fig 2: Measuring Resistance Between A And F Terminals On Voltage Regulator
  Courtesy of FORD MOTOR CO.
- Is the resistance less than 5 ohms?
- Yes : INSTALL a new generator. Refer to GENERATOR AND REGULATOR . TEST the system for normal operation.
- No : GO to F6.
F6 CHECK FOR A GROUNDED SLIP RING
- Remove the voltage regulator. Refer to GENERATOR AND REGULATOR .
- Measure the resistance between the generator slip rings.
  
  Fig 3: Checking For Grounded Slip Ring
  Courtesy of FORD MOTOR CO.
- Is the resistance greater than 10,000 ohms?
- Yes : INSTALL a new generator. REFER to GENERATOR AND REGULATOR . TEST the system for normal operation.
- No : If the generator has an external stator circuit 4 (WH/BK), INSTALL a new regulator. REFER to GENERATOR AND REGULATOR . If the generator has an internal stator circuit, INSTALL a new generator. REFER to GENERATOR AND REGULATOR . TEST the system for normal operation.