Diagnosis Procedure

The terminal "L" circuit controls the charge warning lamp. The charge warning lamp turns ON when the ignition switch is set to ON or START. When the generator is providing sufficient voltage with the engine running, the charge warning lamp turns OFF. If the charge warning lamp illuminates with the engine running, a malfunction is indicated.

1. CHECK TERMINAL "L" CONNECTION 
   1. Turn ignition switch OFF.
   2. Check if terminal L is clean and tight.

   Is the inspection result normal?

   YES

   GO TO 2.

   NO

   Repair terminal "L" connection. Confirm repair by performing system test using DSS-5000P NI. Refer to applicable Instruction Manual for proper testing procedures.

2. CHECK TERMINAL "L" CIRCUIT (OPEN) 
   1. Disconnect the generator connector.
   2. Apply ground to generator harness connector.
   3. Check condition of the charge warning lamp with the ignition switch in the ON position.

      Generator		Ground	Condition
      Connector	Terminal		Ignition switch position	Charge warning lamp
      F205 (with Cummins 5.0L) F242 (with VK56VD)	2		ON	Illuminate

   Does it illuminate?

   YES

   Terminal "L" circuit is normal. Refer to Work Flow (With DSS-5000P NI) (with Cummins 5.0L) , Work Flow (With DSS-5000P NI) (with VK56VD) , Work Flow (Without DSS-5000P NI) (with Cummins 5.0L) , or Work Flow (Without DSS-5000P NI) (with VK56VD) .

   NO

   GO TO 3.

3. CHECK HARNESS CONTINUITY (OPEN CIRCUIT) 
   1. Disconnect the battery cable from the negative terminal.
   2. Disconnect the combination meter connector.
   3. Check continuity between generator harness connector and combination meter harness connector.
      With Cummins 5.0L
      
      

      Generator		Combination meter		Continuity
      Connector	Terminal	Connector	Terminal
      F205	2	M25	11	Yes

      With VK56VD (with type A combination meter)
      
      

      Generator		Combination meter		Continuity
      Connector	Terminal	Connector	Terminal
      F242	2	M25	11	Yes

      With VK56VD (with type B combination meter)
      
      

      Generator		Combination meter		Continuity
      Connector	Terminal	Connector	Terminal
      F242	2	M163	11	Yes

   Is the inspection result normal?

   YES

   GO TO 4.

   NO

   Repair or replace the harness or connectors.

4. CHECK HARNESS CONTINUITY (OPEN CIRCUIT) 

   Check continuity between combination meter harness connector and fuse block (J/B).

   With Cummins 5.0L
   
   

   Combination meter		Fuse box (J/B)		Continuity
   Connector	Terminal	Connector	Terminal
   M24	42	M4	13P	Yes

   With VK56VD (with type A combination meter)
   
   

   Combination meter		Fuse box (J/B)		Continuity
   Connector	Terminal	Connector	Terminal
   M24	42	M4	13P	Yes

   With VK56VD (with type B combination meter)
   
   

   Combination meter		Fuse box (J/B)		Continuity
   Connector	Terminal	Connector	Terminal
   M163	6	M4	13P	Yes

   Is the inspection result normal?

   YES

   GO TO 5.

   NO

   Repair or replace the harness or connectors.

5. CHECK POWER SUPPLY CIRCUIT 
   1. Connect the battery cable to the negative terminal.
   2. Check voltage between combination meter harness connector and ground.
      With Cummins 5.0L
      
      

      (+)		(-)	Condition	Voltage (Approx.)
      Combination meter
      Connector	Terminal
      M24	42	Ground	When the ignition switch is in ON position	Battery voltage

      With VK56VD (with type A combination meter)
      
      

      (+)		(-)	Condition	Voltage (Approx.)
      Combination meter
      Connector	Terminal
      M24	42	Ground	When the ignition switch is in ON position	Battery voltage

      With VK56VD (with type B combination meter)
      
      

      (+)		(-)	Condition	Voltage (Approx.)
      Combination meter
      Connector	Terminal
      M163	6	Ground	When the ignition switch is in ON position	Battery voltage

   Is the inspection result normal?

   YES

   Replace the combination meter. Refer to Removal and Installation .

   NO

   Repair or replace the harness or connectors.