414-00-1 Charging System — General Information 414-00-1

DIAGNOSIS AND TESTING

Charging System — Dual Generators Connector C1251a End View
Refer to Wiring Diagrams Cell 12, Charging System
for schematic and connector information.
Special Tool(s)
73III Automotive Meter
105-R0057 or equivalent

SABRE Premium Electrical

System Tester
010-00736 or equivalent Functionality
With the ignition switch in the ON position (dual
generator system), voltage is supplied by the
powertrain control module (PCM)-controlled I
circuit 1183 (WH/YE) to I circuit 904 (LG/RD) to
Worldwide Diagnostic System the upper generator and through the I circuit 1185
(WDS) (YE) from the PCM to the lower generator. If the
418-F224, glow plug system is not cycling, the PCM will
New Generation STAR (NGS) maintain power to the lower generator. If the glow
Tester plug system is cycling, the PCM will supply power
418-F052, or equivalent
diagnostic tool with appropriate to the lower generator momentarily to verify there is
adapter cable a volt drop, then the PCM shuts off the power on
Micro 490 Digital Battery the lower generator I circuit 1185 (YE). Once the
Analyzer glow plug system stops cycling, the PCM will
162-00004 supply power on the lower generator I circuit 1185
(YE), which turns the regulator on allowing current
to flow from the battery sense A circuit to the
generator field coil; at which time it begins to
function normally. The PCM maintains power on
the upper generator I circuit 1183 (WH/YE) / 904
Principles of Operation (LG/RD), which turns on the regulator, allowing
Connector C102a End View current to flow from the battery sense A circuit to
the generator field coil.
Once the generator begins generating current, a
voltage signal is taken from the generator stator and
fed back to the regulator internally. This voltage
feedback signal (typically half the battery voltage) is
used by the PCM to turn off the warning indicator.
With the system functioning normally, the generator
output current is determined by the voltage of the A
circuit 35 (OG/LB). The A circuit 35 (OG/LB)
voltage is compared to a set voltage internal to the
regulator, and the regulator controls the generator
field current to maintain the correct generator
output.

Copyright  2003, Ford Motor Company

Last updated: 9/19/2005 2004 Excursion, F-Super Duty 250-550, 12/2004
414-00-2 Charging System — General Information 414-00-2
DIAGNOSIS AND TESTING (Continued)
The set voltage will vary with temperature and is WARNING: When lifting a plastic-cased
typically higher in cold temperatures and lower in battery, excessive pressure on the end walls could
warm temperatures. This allows for more efficient cause acid to spew through the vent caps
battery recharge in the winter and reduces the resulting in personal injury, damage to the
chance of overcharging in the summer. vehicle or to the battery. Lift with a battery
carrier or with your hands on opposite corners.
Battery Positive Output Circuit 36 (B+)
(YE/WH) Failure to follow these instructions may result in
personal injury.
The generator output is supplied through the battery
positive output (B+) terminal on the rear of the 1. Verify the customer concern by operating the
generator to the battery and the electrical system. engine to duplicate the concern.
2. Inspect to determine if one of the following
I Circuit — Dual Generator mechanical or electrical concerns apply.
The I (ignition) circuit is used to turn on the voltage
regulator(s). This circuit is powered up when the Visual Inspection Chart
ignition switch is in the ON position. When the Mechanical Electrical
PCM detects ignition ON, the PCM will provide • Battery case, posts, • Central junction box
power to the upper generator I circuit 1183 hold-down clamp, (CJB) fuse 45 (10A)
(WH/YE) and also to the lower generator I circuit cables and connections • Charging system
1185 (YE). The power to the lower generator will for damage warning indicator
only be momentary unless the glow plug system is • Generator drive • Circuitry
(serpentine) belt for • Cables
not cycling. Once the glow plugs stop cycling, the condition and tension to
PCM will provide constant power on the lower make sure there is no
generator I circuit 1185 (YE). slip between the belt
and the pulley. For
A Circuit additional information,
The A circuit or battery sense circuit is used to refer to Section 303-05.
• Battery condition
sense battery voltage. This voltage is used by the • Generator pulley
regulator to determine generator output.
Inspection and Verification 3. If the inspection reveals obvious concern(s) that
can be readily identified, service as necessary.
WARNING: Batteries contain sulfuric acid.
Avoid contact with skin, eyes, or clothing. Also, 4. Verify the battery condition. Refer to Section
shield your eyes when working near batteries to 414-01.
protect against possible splashing of the acid 5. Observe the charging system warning indicator
solution. In case of acid contact with skin or status under the following conditions:
eyes, flush immediately with water for a
• The charging system warning indicator will
minimum of 15 minutes and get prompt medical
illuminate with the ignition switch ON and
attention. If acid is swallowed, call a physician
the engine OFF.
immediately. Failure to follow these instructions
may result in personal injury. • The charging system warning indicator will
be OFF with the engine running.
WARNING: Batteries normally produce
• The charging system warning indicator will
explosive gases which can cause personal injury.
be OFF with the ignition switch OFF.
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. Failure to follow these
instructions may result in personal injury.

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414-00-3 Charging System — General Information 414-00-3
DIAGNOSIS AND TESTING (Continued)
6. NOTE: The powertrain control module (PCM)
requires three key cycles so the PCM can
re-learn the configuration.
NOTE: On California vehicles the malfunction
indicator lamp (MIL) will illuminate if the
lower generator circuit has 12 volts (which the
PCM has commanded off) for two consecutive
drive cycles.
Check the battery voltage before and after
starting the engine to determine if the battery
voltage increases. Refer to the Normal Charging
System Voltages chart.
Normal Charging System Voltages
NOTE: When testing the I circuit with the engine running, make certain to load the charging
system by turning the blower motor to the HIGH position and the headlamps on high beam.
Charging
System
Ignition Generator Engine to Warning
Switch A Circuit 35 I Circuit 904 B+ Circuit Battery Indicator
Position (OG/LB) (LG/RD) 36 (YE/WH) Battery Ground Operation
Key OFF 12V 0V 12V 12V 0V Off
Key ON - 12V 1-3V (glow 12V 12V 0V Illuminated
engine off plugs off)
Engine 13- 15V 8- 9V 13- 15V 13- 15V 0V Off
running

7. If the concern remains after the inspection, • No response/not equipped for powertrain
connect the diagnostic tool to the data link control module (PCM), refer to Powertrain
connector (DLC) located beneath the instrument Control/Emissions Diagnosis (PC/ED)
panel and select the vehicle to be tested from manual.
the diagnostic tool menu. If the vehicle • System passed, retrieve and record the
selection cannot be entered: continuous diagnostic trouble codes (DTCs),
• Check that the program card is correctly erase the continuous DTCs and carry out the
installed. self-test diagnostics for the PCM.
• Check the connections to the vehicle. 10. If the DTCs retrieved are related to the concern,
• Check the ignition switch position. go to the Powertrain Control Module (PCM)
Diagnostic Trouble Code (DTC) Index or the
8. If the diagnostic tool still does communicate Instrument Cluster Diagnostic Trouble Code
with the vehicle, refer to the diagnostic tool (DTC) Index.
operating manual.
11. If no DTCs related to the concern are retrieved,
9. Carry out the diagnostic tool data link test. If go to the Symptom Chart to continue
the diagnostic tool responds with: diagnostics.
• SCP or ISO circuits fault; all electronic
control units no response/not equipped, refer
to Section 418-00.

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414-00-4 Charging System — General Information 414-00-4
DIAGNOSIS AND TESTING (Continued)
Powertrain Control Module (PCM) Diagnostic Trouble Code (DTC) Index
DTC Description Action
P0620 Dual generator upper fault detected GO to Pinpoint Test T.
P1148 Dual generator lower fault detected GO to Pinpoint Test U.
P1149 Dual generator lower circuit fault GO to Pinpoint Test V.
detected
P0623 Dual generator battery lamp circuit REFER to Section 413-01.
fault detected
P1397 System voltage out of self-test range GO to Pinpoint Test Q.

Instrument Cluster Diagnostic Trouble Code (DTC) Index

DTC Description Action
B1317 Battery voltage high GO to Pinpoint Test Q.
B1318 Battery voltage low GO to Pinpoint Test Q.

Symptom Chart

Symptom Chart
Condition Possible Sources Action
• The charging system warning • I circuit 1183 or 1185. • GO to Pinpoint Test I.
indicator is ON with the • B+ circuit fuse links.
engine running (the charging • B+ circuit 36.
system voltage does not • Upper generator.
increase) • Lower generator.
• Powertrain control module
(PCM).
• The charging system warning • Upper generator connector • GO to Pinpoint Test J.
indicator is OFF with the C102a unplugged.
ignition switch in the RUN • Lower generator connector
position and the engine OFF C1251 unplugged.
• I circuit 1183 or 1185.
• Lamp circuit 904.
• Upper generator.
• Lower generator.
• Instrument cluster.
• Powertrain control module
(PCM).
• The charging system warning • Lamp circuit 904. • GO to Pinpoint Test K.
indicator is ON with the • Instrument cluster.
engine running and the • A circuit 35.
battery increases voltage • I circuit 1183 or 1185.
• Upper generator.
• Lower generator.
• Powertrain control module
(PCM).
• The charging system warning • B+ circuit fuse links. • GO to Pinpoint Test L.
indicator operates correctly • B+ circuit 36.
but the battery voltage does • Upper generator.
not increase • Lower generator.
• Loose or damaged harness
connectors.

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414-00-5 Charging System — General Information 414-00-5
DIAGNOSIS AND TESTING (Continued)
Symptom Chart (Continued)
Condition Possible Sources Action
• The battery is discharged or • High key-off loads. • GO to Pinpoint Test M.
battery voltage is low • Upper generator connector
C102a unplugged.
• Lower generator connector
C1251a unplugged.
• B+ circuit fuse links.
• B+ circuit 36.
• A circuit 35.
• I circuit 1183 or 1185.
• Upper generator.
• Lower generator.
• The charging system warning • Upper generator connector • GO to Pinpoint Test N.
indicator flickers or is C102a unplugged.
intermittent • Lower generator connector
C1251a unplugged.
• I circuit 1183 or 1185.
• Lamp circuit 904.
• Upper generator.
• Lower generator.
• Instrument cluster.
• Powertrain control module
(PCM).
• The charging system • A circuit fuse. • GO to Pinpoint Test O.
overcharges (battery voltage • A circuit 35.
is greater than 15.5 volts) • Upper generator.
• Lower generator.
• Battery leakage or damage • Battery. • GO to Pinpoint Test P.
• Battery breakdown.
• A circuit 35.
• Upper generator.
• Lower generator.
• The voltage gauge reads high • Upper generator. • GO to Pinpoint Test Q.
or low • Lower generator.
• Instrument cluster.
• The generator(s) is noisy • Loose bolts/brackets. • GO to Pinpoint Test R.
• Drive belt.
• Upper generator.
• Lower generator.
• Radio interference • Upper generator. • GO to Pinpoint Test S.
• Lower generator.
• Wiring/routing.
• In-vehicle entertainment
system.
• Dual generator upper fault • Upper generator connector • GO to Pinpoint Test T.
detected (P0620) C102a unplugged.
• B+ circuit fuse links.
• B+ circuit 36.
• A circuit 35.
• I circuit 1183.
• Upper generator.

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414-00-6 Charging System — General Information 414-00-6
DIAGNOSIS AND TESTING (Continued)
Symptom Chart (Continued)
Condition Possible Sources Action
• Dual generator lower fault • Lower generator connector • GO to Pinpoint Test U.
detected (P1148) C1251a unplugged.
• B+ circuit fuse links.
• B+ circuit 36.
• A circuit 35.
• I circuit 1185.
• Lower generator.
• Dual generator lower circuit • I circuit 1185. • GO to Pinpoint Test V.
fault detected (P1149) • Lower generator.
• Dual generator battery lamp • Lamp circuit 904. • REFER to Section 413-01.
circuit fault detected (P0623) • Instrument cluster.

Pinpoint Tests NOTE: Dual generator I circuit/bulb circuit 4-way

connector MUST be connected before disconnecting
CAUTION: Do not make jumper
or connecting the battery. The PCM relearns its
connections except as directed. Incorrect
parameters every time it is disconnected and
connections may damage the voltage regulator
connected to power. Failure to follow this procedure
test terminals.
will mislead the PCM into misinterpreting the
CAUTION: Do not allow any metal object charging system as a single generator system,
to come in contact with the generator housing causing loss of DTC capability and control.
and internal diode cooling fins. NOTE: All voltage measurements are referenced to
NOTE: While carrying out any pinpoint test, the negative (-) battery post unless otherwise
disregard any DTCs set while following any specific specified.
pinpoint test. After the completion of any test, be
sure to clear all codes in the PCM.
PINPOINT TEST I: THE CHARGING SYSTEM WARNING INDICATOR IS ON WITH THE ENGINE RUNNING
(THE CHARGING SYSTEM VOLTAGE DOES NOT INCREASE)
Test Step Result / Action to Take
I1 CHECK THE FAULT CODES IN THE PCM
• Connect the diagnostic tool. Yes
• Key in ON position. GO to the appropriate pinpoint test listed
With the key ON, engine OFF, check the PCM for fault codes in the Symptom Chart.
with the diagnostic tool. No
• Do generator fault codes exist? GO to I2.
I2 CHECK I CIRCUIT 904 (LG/RD)
• Key in OFF position.
• Disconnect the diagnostic tool.
• Disconnect: Upper Generator C102a.
• Key in ON position.
(Continued)

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414-00-7 Charging System — General Information 414-00-7
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST I: THE CHARGING SYSTEM WARNING INDICATOR IS ON WITH THE ENGINE RUNNING
(THE CHARGING SYSTEM VOLTAGE DOES NOT INCREASE) (Continued)
Test Step Result / Action to Take
I2 CHECK I CIRCUIT 904 (LG/RD) (Continued)
• With the key ON, engine OFF, measure the voltage at the upper
generator C102a, pin 1, I circuit 904 (LG/RD), harness side and
ground.

Yes
GO to I4.
No
• Is the voltage greater than 10 volts? GO to I3.
I3 CHECK I CIRCUIT 1183 (WH/YE) / 904 (LG/RD) FOR AN OPEN
• Key in OFF position.
• Disconnect: PCM C1381c.
• Measure the resistance of I circuit 1183 (WH/YE) / 904 (LG/RD)
between the PCM C1381c pin 1, harness side and the upper
generator C102a pin 1, I circuit 904 (LG/RD), harness side.

Yes
GO to I8.
No
REPAIR I circuit 1183 (WH/YE) / 904
(LG/RD). TEST the system for normal
• Is the resistance less than 5 ohms? operation.
I4 CHECK THE VOLTAGE TO THE LOWER GENERATOR
• Key in OFF position.
• Disconnect: Lower Generator C1251a.
• Key in ON position.
(Continued)

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414-00-8 Charging System — General Information 414-00-8
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST I: THE CHARGING SYSTEM WARNING INDICATOR IS ON WITH THE ENGINE RUNNING
(THE CHARGING SYSTEM VOLTAGE DOES NOT INCREASE) (Continued)
Test Step Result / Action to Take
I4 CHECK THE VOLTAGE TO THE LOWER GENERATOR
(Continued)
• Measure the voltage between the lower generator C1251a pin 1,
circuit 1185 (YE), harness side and ground.

Yes
GO to I6.
No
• Is the voltage greater than 10 volts? GO to I5.
I5 CHECK LOWER GENERATOR I CIRCUIT 1185 (YE) FOR AN
OPEN
• Key in OFF position.
• Connect: Upper Generator C102a.
• Disconnect: Lower Generator C1251a.
• Disconnect: PCM C1381c.
• Measure the resistance between the I circuit 1185 (YE) from the
PCM C1381c pin 4, harness side, to the lower generator
C1251a pin 1, I circuit 1185 (YE), harness side.

Yes
GO to I8.
No
REPAIR I circuit 1185 (YE). TEST the
• Is the resistance less than 5 ohms? system for normal operation.
I6 CHECK THE UPPER GENERATOR OUTPUT
• Connect: PCM C1381c. Yes
• Key in START position. GO to I7.
• Carry out the generator load test on the upper generator. Refer No
to Component Tests, Generator On-Vehicle Tests in this section. INSTALL a new upper generator. REFER
• Is the upper generator OK? to Section 414-02. TEST the system for
normal operation.
I7 CHECK THE LOWER GENERATOR OUTPUT
• Key in OFF position.
• Connect: Lower Generator C1251a. Yes
• Disconnect: Upper Generator C102a. GO to I8.
• Key in START position. No
• Carry out the generator load test on the lower generator. Refer INSTALL a new lower generator. REFER
to Component Tests, Generator On-Vehicle Tests in this section. to Section 414-02. TEST the system for
• Is the lower generator OK? normal operation.
(Continued)

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414-00-9 Charging System — General Information 414-00-9
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST I: THE CHARGING SYSTEM WARNING INDICATOR IS ON WITH THE ENGINE RUNNING
(THE CHARGING SYSTEM VOLTAGE DOES NOT INCREASE) (Continued)
Test Step Result / Action to Take
I8 CHECK FOR CORRECT PCM OPERATION
• Disconnect all PCM connectors. Yes
• Check for: INSTALL a new PCM. REFER to Section
• corrosion 303-14B. REPEAT the PCM self-test.
• pushed-out pins TEST the system for normal operation.
• Connect all PCM connectors and make sure they seat correctly. No
• Operate the system and verify the concern is still present. The system is operating correctly at this
• Is the concern still present? time. The concern may have been caused
by a loose or corroded connector. CLEAR
the DTCs. REPEAT the self-test. TEST
the system for normal operation.

PINPOINT TEST J: THE CHARGING SYSTEM WARNING INDICATOR IS OFF WITH THE IGNITION
SWITCH IN THE RUN POSITION AND THE ENGINE OFF
Test Step Result / Action to Take
J1 CHECK THE FAULT CODES IN THE PCM
• Connect the diagnostic tool. Yes
• Key in ON position. GO to the appropriate pinpoint test listed
• With the key ON, engine OFF, check the PCM for fault codes in the Symptom Chart.
with the diagnostic tool. No
• Do generator fault codes exist? GO to J2.
J2 CHECK THE CHARGING SYSTEM WARNING INDICATOR
OPERATION
• Key in OFF position.
• Disconnect the diagnostic tool.
• Disconnect: PCM C1381a.
• Key in ON position.
• With the key ON, engine OFF, connect a fused (15A) jumper
wire between the PCM C1381a pin 30, circuit 3090 (VT),
harness side and ground.

Yes
GO to J3.
No
• Does the charging system warning indicator illuminate? REFER to Section 413-01.
J3 CHECK FOR CORRECT PCM OPERATION
• Disconnect all PCM connectors. Yes
• Check for: INSTALL a new PCM. REFER to Section
• corrosion 303-14B. CLEAR the DTCs. REPEAT the
• pushed-out pins PCM self-test.
• Connect all PCM connectors and make sure they seat correctly. No
• Operate the system and verify the concern is still present. The system is operating correctly at this
• Is the concern still present? time. Concern may have been caused by
a loose or corroded connector. CLEAR the
DTCs. REPEAT the self-test.

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414-00-10 Charging System — General Information 414-00-10
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST K: THE CHARGING SYSTEM WARNING INDICATOR IS ON WITH THE ENGINE
RUNNING AND THE BATTERY INCREASES VOLTAGE
Test Step Result / Action to Take
K1 CHECK FAULT CODES IN PCM
• Connect the diagnostic tool. Yes
• Key in ON position. GO to the appropriate pinpoint test listed
With the key ON, engine OFF, check the PCM for fault codes in the Symptom Chart.
with the diagnostic tool. No
• Are generator fault codes present? GO to K2.
K2 CHECK THE SYSTEM FOR OVERCHARGING
• Key in OFF position.
• Disconnect the diagnostic tool.
• Key in START position.
• With the engine running and all accessories off, measure the
voltage at the primary (passenger side) battery terminals while
varying the engine rpm.

Yes
GO to Pinpoint Test O.
No
• Is the voltage greater than 15.5 volts? GO to K3.
K3 CHECK THE CHARGING SYSTEM WARNING INDICATOR
OPERATION
• Key in OFF position.
• Connect: Lower Generator C1251a.
• Disconnect: PCM C1381a.
• Key in ON position. Yes
With the key ON, engine OFF, monitor the charging system GO to K4.
warning indicator. No
• Is the indicator illuminated? GO to K5.
K4 CHECK THE WARNING INDICATOR CIRCUIT
• Key in OFF position.
• Disconnect: Instrument Cluster C220b.
• Measure the resistance between the PCM C1381a pin 30, circuit
3090 (VT) harness side and ground.

Yes
Section 413-01.
No
REPAIR the circuit. TEST the system for
• Is the resistance greater than 10,000 ohms? normal operation.
K5 CHECK THE LOWER GENERATOR A CIRCUIT
• Key in OFF position.
(Continued)

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414-00-11 Charging System — General Information 414-00-11
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST K: THE CHARGING SYSTEM WARNING INDICATOR IS ON WITH THE ENGINE
RUNNING AND THE BATTERY INCREASES VOLTAGE (Continued)
Test Step Result / Action to Take
K5 CHECK THE LOWER GENERATOR A CIRCUIT (Continued)
• Connect: Upper Generator C102a.
• Disconnect: Lower Generator C1251a.
• With the key ON, engine OFF, measure the voltage at the lower
generator connector C1251a pin 3, A circuit 35 (OG/LB),
harness side and ground.

Yes
GO to K6.
No
CHECK lower generator A circuit 35
(OG/LB). REPAIR as necessary. TEST the
• Is the voltage equal to battery voltage? system for normal operation.
K6 CHECK FOR CORRECT PCM OPERATION
• Disconnect all PCM connectors. Yes
• Check for: INSTALL a new PCM. REFER to Section
• corrosion 303-14B. CLEAR the DTCs. REPEAT the
• pushed-out pins PCM self-test.
• Connect all PCM connectors and make sure they seat correctly. No
• Operate the system and verify the concern is still present. The system is operating correctly at this
• Is the concern still present? time. Concern may have been caused by
a loose or corroded connector. CLEAR the
DTCs. REPEAT the self-test.

PINPOINT TEST L: THE CHARGING SYSTEM WARNING INDICATOR OPERATES CORRECTLY BUT THE
BATTERY VOLTAGE DOES NOT INCREASE
Test Step Result / Action to Take
L1 CHECK FAULT CODES IN THE PCM
• Connect the diagnostic tool. Yes
• Key in ON position. GO to the appropriate pinpoint test listed
With the key ON, engine OFF, check the PCM for fault codes in the Symptom Chart.
with the diagnostic tool. No
• Do generator fault codes exist? GO to L2.
L2 CHECK THE UPPER AND LOWER GENERATOR CONNECTIONS
• Key in OFF position. Yes
• Disconnect the diagnostic tool. GO to L3.
• Check the battery terminals and all generator connectors for No
corrosion, damage and correct connection. REPAIR the connections as necessary.
• Are all connections clean and tight? TEST the system for normal operation.
(Continued)

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414-00-12 Charging System — General Information 414-00-12
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST L: THE CHARGING SYSTEM WARNING INDICATOR OPERATES CORRECTLY BUT THE
BATTERY VOLTAGE DOES NOT INCREASE (Continued)
Test Step Result / Action to Take
L3 CHECK THE OUTPUT (B+) CIRCUIT 36 (YE/WH) OF THE UPPER
GENERATOR
• Check the voltage at the upper generator B+ terminal, circuit 36
(YE/WH), harness side and ground.

Yes
GO to L4.
No
REPAIR upper generator output (B+)
circuit 36 (YE/WH) (including the fuse
links) as necessary. TEST the system for
• Is the voltage equal to battery voltage? normal operation.
L4 CHECK THE OUTPUT (B+) CIRCUIT 36 (YE/WH) OF THE
LOWER GENERATOR
• Check the voltage at the lower generator B+ terminal, circuit 36
(YE/WH), harness side and ground.

Yes
GO to L5.
No
REPAIR lower generator output (B+)
circuit 36 (YE/WH) (including the fuse
links) as necessary. TEST the system for
• Is the voltage equal to battery voltage? normal operation.
L5 CHECK THE BATTERY CONDITION
• Carry out the Battery — Condition Test to determine if the Yes
battery can hold a charge and is OK for use. Refer to Section GO to L6.
414-01. No
• Are the batteries OK? INSTALL a new applicable battery. TEST
the system for normal operation.
L6 CHECK THE UPPER GENERATOR OUTPUT
• Disconnect: Lower Generator C1251a. Yes
• Check the upper generator output. Refer to Component Tests, GO to L7.
Generator On-Vehicle Tests in this section. No
• Is the upper generator OK? INSTALL a new generator. REFER to
Section 414-02. CLEAR the DTCs. TEST
the system for normal operation.
(Continued)

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414-00-13 Charging System — General Information 414-00-13
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST L: THE CHARGING SYSTEM WARNING INDICATOR OPERATES CORRECTLY BUT THE
BATTERY VOLTAGE DOES NOT INCREASE (Continued)
Test Step Result / Action to Take
L7 CHECK THE LOWER GENERATOR OUTPUT
• Key in OFF position. Yes
• Connect: Lower Generator C1251a. System is OK. VERIFY the symptoms
• Disconnect: Upper Generator C102a. from the Symptom Chart and TEST the
• Check the lower generator output. Refer to Component Tests, system for normal operation. COMPARE
Generator On-Vehicle Tests in this section. to a similar vehicle.
• Is the lower generator OK? No
INSTALL a new lower generator. REFER
to Section 414-02. CLEAR the DTCs.
TEST the system for normal operation.

PINPOINT TEST M: THE BATTERY IS DISCHARGED OR BATTERY VOLTAGE IS LOW

Test Step Result / Action to Take
M1 CHECK THE FAULT CODES IN THE PCM
• Connect the diagnostic tool. Yes
• Key in ON position. GO to the appropriate pinpoint test listed
• With the key ON, engine OFF, check the PCM for fault codes in the Symptom Chart.
with the diagnostic tool. No
• Are generator fault codes present? GO to M2.
M2 CHECK THE BATTERY CONDITION
• Key in OFF position.
• Disconnect the diagnostic tool. Yes
• Carry out the Battery — Condition Test to determine if the GO to M3.
battery can hold a charge and is OK for use. Refer to Section No
414-01. INSTALL a new battery(s). TEST the
• Is the battery(s) OK? system for normal operation.
M3 CHECK THE BATTERY DRAIN
• Make sure all interior lights and switches are off and all doors Yes
are closed. Carry out the battery drain test. Refer to Component REPAIR the battery drain as necessary.
Tests, Battery — Drain Testing in this section. TEST the system for normal operation.
• Is the drain greater than .05 amp? No
GO to M4.
M4 CHECK THE UPPER GENERATOR OUTPUT
• Disconnect: Lower Generator C1251a. Yes
• Key in START position. GO to M5.
• With the key ON, engine running, check the upper generator No
output. Refer to Component Tests, Generator On-Vehicle Tests INSTALL a new upper generator. REFER
in this section. to Section 414-02. CLEAR the DTCs.
• Is the upper generator OK? TEST the system for normal operation.
M5 CHECK THE LOWER GENERATOR OUTPUT
• Key in OFF position.
• Connect: Lower Generator C1251a.
• Disconnect: Upper Generator C102a. Yes
• Key in START position. GO to M6.
• With the key ON, engine running, check the lower generator No
output. Refer to Component Tests, Generator On-Vehicle Tests INSTALL a new lower generator. REFER
in this section. to Section 414-02. CLEAR the DTCs.
• Is the lower generator OK? TEST the system for normal operation.
M6 CHECK THE OTHER SYSTEMS FOR DRAINS
• Check for drains from the electronic modules. Refer to Yes
Component Tests, Battery — Electronic Drains Which Shut Off RECHARGE the batteries. TEST the
When the Battery Cable is Disconnected in this section. system for normal operation.
• Are the electronic modules OK? No
REPAIR as necessary. TEST the system
for normal operation.

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414-00-14 Charging System — General Information 414-00-14
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST N: THE CHARGING SYSTEM WARNING INDICATOR FLICKERS OR IS INTERMITTENT
Test Step Result / Action to Take
N1 CHECK THE FAULT CODES IN THE PCM
• Connect the diagnostic tool. Yes
• Key in ON position. GO to the appropriate pinpoint test listed
With the key ON, engine OFF, check the PCM for fault codes in the Symptom Chart.
with the diagnostic tool. No
• Do generator fault codes exist? GO to N2.
N2 CHECK THE BATTERY VOLTAGE
• Key in START position.
• With the key ON, engine running, and all accessories turned off,
measure the voltage at the battery while varying the engine rpm.

Yes
GO to Pinpoint Test O.
No
• Is the voltage greater than 15.5 volts? GO to N3.
N3 CHECK THE CHARGING SYSTEM INDICATOR OPERATION
• Key in OFF position.
• Key in ON position.
• With the key ON, engine OFF, enter the following diagnostic
mode on the diagnostic tool: Active Commands. Active Yes
command the charging system warning indicator to the ON GO to N4.
position. No
• Does the charging system warning indicator illuminate? REFER to Section 413-01.
N4 CHECK THE PCM OPERATION
• Key in OFF position. Yes
• Disconnect the diagnostic tool. PCM is operating correctly. RECHECK
• Key in ON position. generator circuits (including generators) for
With the key ON, engine OFF, monitor the charging system intermittent shorts or opens. TEST the
warning indicator. system for normal operation.
• Is the light illuminated? No
GO to N5.
N5 CHECK FOR CORRECT PCM OPERATION
• Disconnect all PCM connectors. Yes
• Check for: INSTALL a new PCM. REFER to Section
• corrosion 303-14B. CLEAR the DTCs. REPEAT the
• pushed-out pins PCM self-test.
• Connect all PCM connectors and make sure they seat correctly. No
• Operate the system and verify the concern is still present. The system is operating correctly at this
• Is the concern still present? time. Concern may have been caused by
a loose or corroded connector. CLEAR the
DTCs. REPEAT the self-test.

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414-00-15 Charging System — General Information 414-00-15
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST O: THE CHARGING SYSTEM OVERCHARGES (BATTERY VOLTAGE IS GREATER THAN
15.5 VOLTS)
Test Step Result / Action to Take
O1 CHECK THE FAULT CODES IN THE PCM
• Connect the diagnostic tool. Yes
• Key in ON position. GO to the appropriate pinpoint test listed
• With the key ON, engine OFF, check the PCM for fault codes in the Symptom Chart.
with the diagnostic tool. No
• Are generator fault codes present? GO to O2.
O2 CHECK THE BATTERY VOLTAGE
• Key in OFF position.
• Disconnect the diagnostic tool.
• Key in START position.
• With the key ON, engine running and all accessories turned off,
measure the voltage at either battery while varying the engine
rpm.

Yes
GO to O3.
No
• Is the voltage greater than 15.5 volts? GO to O7.
O3 CHECK THE UPPER GENERATOR OUTPUT
• Key in OFF position.
• Disconnect: Lower Generator C1251a.
• Key in START position.
• Note: After starting the engine, wait at least two minutes for the
glow plugs to turn off. With the key ON, engine running and all
accessories turned off, measure the voltage at the battery while
varying the engine rpm.

Yes
GO to O4.
No
• Is the voltage greater than 15.5 volts? GO to O5.
O4 CHECK THE UPPER GENERATOR A CIRCUIT
• Key in OFF position.
• Connect: Lower Generator C1251a.
• Disconnect: Upper Generator C102a.
• Key in ON position.
(Continued)

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414-00-16 Charging System — General Information 414-00-16
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST O: THE CHARGING SYSTEM OVERCHARGES (BATTERY VOLTAGE IS GREATER THAN
15.5 VOLTS) (Continued)
Test Step Result / Action to Take
O4 CHECK THE UPPER GENERATOR A CIRCUIT (Continued)
• With the key ON, engine OFF, measure the voltage drop
between the upper generator C102a pin 3, A circuit 35 (OG/LB)
harness side and the battery positive terminal.

Yes
INSTALL a new upper generator. REFER
to Section 414-02. CLEAR the DTCs.
TEST the system for normal operation.
No
REPAIR the upper generator A circuit 35
(OG/LB) for high resistance. CLEAR the
DTCs. TEST the system for normal
• Is the voltage drop less than 0.5 volt? operation.
O5 CHECK THE LOWER GENERATOR OUTPUT
• Key in OFF position.
• Disconnect: Upper Generator C102a.
• Connect: Lower Generator C1251a.
• Key in START position.
• Note: After starting the engine, wait at least two minutes for glow
plugs to turn off. With the key on, engine running and all
accessories turned off, measure the voltage at the battery while
varying the engine rpm.

Yes
GO to O6.
No
• Is the voltage greater than 15.5 volts? GO to O7.
O6 CHECK THE LOWER GENERATOR A CIRCUIT
• Key in OFF position.
• Connect: Upper Generator C102a.
• Disconnect: Lower Generator C1251a.
• Key in ON position.
(Continued)

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414-00-17 Charging System — General Information 414-00-17
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST O: THE CHARGING SYSTEM OVERCHARGES (BATTERY VOLTAGE IS GREATER THAN
15.5 VOLTS) (Continued)
Test Step Result / Action to Take
O6 CHECK THE LOWER GENERATOR A CIRCUIT (Continued)
• With the key ON, engine OFF, measure the voltage drop
between the lower generator C1251a pin 3, A circuit 35 (OG/LB)
harness side and the positive battery terminal.

Yes
INSTALL a new lower generator. REFER
to Section 414-02. CLEAR the DTCs.
TEST the system for normal operation.
No
REPAIR the lower generator A circuit 35
(OG/LB) for high resistance. CLEAR the
DTCs. TEST the system for normal
• Is the voltage drop less than 0.5 volt? operation.
O7 CHECK THE GROUNDS
• Key in OFF position. Yes
• Check the ground connections between the generators and the CHECK both upper and lower generator A
engine, and the batteries and the engine. circuits for intermittent opens/shorts.
• Are all the ground connections clean and tight? REPAIR as necessary. CLEAR the DTCs.
TEST the system for normal operation.
No
REPAIR as necessary.

PINPOINT TEST P: BATTERY LEAKAGE OR DAMAGE

Test Step Result / Action to Take
P1 CHECK FOR ACID LEAKAGE AND DAMAGE
• Check for acid damage to both the battery wire harness and to Yes
the body. REPAIR damaged areas as necessary.
• Is acid damage present? TEST the system for normal operation.
No
GO to P2.
P2 CHECK CHARGING SYSTEM FOR OVERCHARGING
• Key in START position.
• With the engine running and all accessories off, increase the
engine speed to 2,000 rpm and measure the voltage at the
battery.

Yes
GO to Pinpoint Test O.
No
• Is the voltage greater than 15.5 volts? GO to P3.
(Continued)

2004 Excursion, F-Super Duty 250-550, 12/2004

414-00-18 Charging System — General Information 414-00-18
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST P: BATTERY LEAKAGE OR DAMAGE (Continued)
Test Step Result / Action to Take
P3 CHECK THE BATTERY MOUNTING
• Key in OFF position. Yes
Check both batteries for correct mounting in the battery trays. GO to P4.
• Are the batteries correctly mounted? No
REPAIR as necessary. TEST the system
for normal operation.
P4 CHECK FOR BATTERY CONTACT
• Check both batteries to make sure there are no fasteners or Yes
other parts contacting the battery case causing excess pressure. REPAIR as necessary. TEST the system
• Is anything contacting the battery case? for normal operation.
No
GO to P5.
P5 CHECK THE BATTERY CASE FOR DAMAGE
• Check both battery cases for damage, such as cracks or poor Yes
seals. GO to P6.
• Are the batteries OK? No
INSTALL a new battery. REFER to
Section 414-01. TEST the system for
normal operation.
P6 CHECK THE BATTERY CAPACITY
• Check the battery capacity of both batteries. Refer to Battery — Yes
Condition Test in Section 414-01. System is OK. TEST the system for
• Are the batteries OK? normal operation.
No
INSTALL a new applicable battery. TEST
the system for normal operation.

PINPOINT TEST Q: THE VOLTAGE GAUGE READS HIGH OR LOW

Test Step Result / Action to Take
Q1 CHECK THE BATTERY VOLTAGE
• Key in START position.
• With the engine running and all accessories turned off, increase
the engine speed to 2,000 rpm and measure the voltage at the
battery.

Yes
GO to Pinpoint Test O for readings more
than 15.5 volts.
GO to Pinpoint Test M for readings less
than 13 volts.
• Is the battery voltage more than 15.5 volts or less than 13 No
volts? GO to Q2.
(Continued)

2004 Excursion, F-Super Duty 250-550, 12/2004

414-00-19 Charging System — General Information 414-00-19
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST Q: THE VOLTAGE GAUGE READS HIGH OR LOW (Continued)
Test Step Result / Action to Take
Q2 CHECK THE VOLTAGE GAUGE OPERATION
• With the engine still running, monitor the voltage gauge reading
and the battery voltage.

Yes
The voltage gauge is operating normally.
No
The voltage gauge is inaccurate. REFER
• Are the voltage readings consistent? to Section 413-01 to continue diagnostics.

PINPOINT TEST R: THE GENERATOR (S) IS NOISY

Test Step Result / Action to Take
R1 CHECK THE DRIVE BELT AND MOUNTING BRACKETS
• Key in OFF position.
• Check the drive belt for damage and to verify correct installation;
refer to Section 303-05. Yes
• Check the generator mounting brackets for loose bolts or GO to R2.
misalignment. No
• Are the accessory drive and generator mounting brackets REPAIR as necessary. TEST the system
OK? for normal operation.
R2 CHECK THE GENERATOR PULLEY(S)
• Check for a bent, loose or misaligned generator pulley(s). Yes
• Are the generator pulley(s) OK? GO to R3.
No
INSTALL a new pulley(s) as necessary.
TEST the system for normal operation.
R3 CHECK THE LOWER GENERATOR FOR ELECTRICAL NOISE
• Disconnect: Lower Generator C1251a. Yes
• Key in START position. INSTALL a new lower generator. REFER
• With the engine running, use a stethoscope or equivalent to Section 414-02. TEST the system for
listening device to probe the lower generator for noise. normal operation.
• Is the lower generator noisy? No
GO to R4.
R4 CHECK THE UPPER GENERATOR FOR ELECTRICAL NOISE
• Key in OFF position. Yes
• Disconnect: Upper Generator C102a. INSTALL a new upper generator. REFER
• Key in START position. to Section 414-02. CLEAR the DTCs. Test
• With the engine running, use a stethoscope or equivalent the system for normal operation.
listening device to probe the upper generator for noise. No
• Is the upper generator noisy? REFER to Section 303-00 to diagnose the
source of the engine noise.

PINPOINT TEST S: RADIO INTERFERENCE

Test Step Result / Action to Take
S1 VERIFY RADIO INTERFERENCE
NOTE: If the original equipment manufactured (OEM) radio unit has
been replaced, the vehicle may not pass this test. Return the
vehicle to OEM condition before following this pinpoint test.
• Key in START position.
(Continued)

2004 Excursion, F-Super Duty 250-550, 12/2004

414-00-20 Charging System — General Information 414-00-20
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST S: RADIO INTERFERENCE (Continued)
Test Step Result / Action to Take
S1 VERIFY RADIO INTERFERENCE (Continued)
• Start and run the engine. Tune the radio to a station where the
interference is present.
• Key in OFF position. Yes
• Disconnect: Upper Generator C102a. GO to S2.
• Key in START position. No
Start and run the engine. INSTALL a new upper generator. REFER
• Is interference present with the upper generator to Section 414-02. TEST the system for
disconnected? normal operation.
S2 VERIFY THERE IS RADIO INTERFERENCE
• Key in OFF position. Yes
• Connect: Upper Generator C102a. REFER to Section 415-00 for diagnosis
• Disconnect: Lower Generator C1251a. and testing of the in-vehicle entertainment
• Key in START position. system.
• Verify the interference is present with the lower generator No
disconnected. INSTALL a new lower generator. REFER
• Is the interference still present? to Section 414-02. CLEAR the DTCs.
TEST the system for normal operation.

PINPOINT TEST T: DUAL GENERATOR UPPER FAULT DETECTED (P0620)

Test Step Result / Action to Take
T1 CHECK UPPER GENERATOR CONNECTIONS
• Key in OFF position.
• Disconnect: Upper Generator C102c and C102a. Yes
• Check the upper generator connectors for damage and correct GO to T2.
connection. No
• Connect: Upper Generator C102c and C102a. REPAIR the connections as necessary.
• Are the upper generator connectors OK and correctly CLEAR the DTCs. TEST the system for
connected? normal operation.
T2 CHECK THE UPPER GENERATOR B+ VOLTAGE
• Measure the voltage between the B+ terminal of the upper
generator C102c, circuit 36 (YE/WH) harness side and ground.

Yes
GO to T3.
No
CHECK B+ circuit 36 (YE/WH) including
fuse links. REPAIR as necessary. CLEAR
the DTCs. TEST the system for normal
• Is the voltage equal to battery voltage? operation.
T3 CHECK THE UPPER GENERATOR A CIRCUIT
• Disconnect: Upper Generator C102a.
(Continued)

2004 Excursion, F-Super Duty 250-550, 12/2004

414-00-21 Charging System — General Information 414-00-21
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST T: DUAL GENERATOR UPPER FAULT DETECTED (P0620) (Continued)
Test Step Result / Action to Take
T3 CHECK THE UPPER GENERATOR A CIRCUIT (Continued)
• With the upper generator connector disconnected, measure the
voltage between the upper generator C102a pin 3, A circuit 35
(OG/LB), harness side and ground.

Yes
GO to T4.
No
CHECK upper generator A circuit 35
(OG/LB) including fuse links. REPAIR as
necessary. CLEAR the DTCs. TEST the
• Is the voltage equal to battery voltage? system for normal operation.
T4 CHECK UPPER GENERATOR I CIRCUIT VOLTAGE
• Key in ON position.
• With the key ON, engine OFF, measure the voltage between the
upper generator connector C102a pin 1, I circuit 904 (LG/RD),
harness side and ground.

Yes
GO to T6.
No
• Is the voltage greater than 10 volts? GO to T5.
T5 CHECK THE UPPER GENERATOR I CIRCUIT FOR AN OPEN OR
SHORT TO GROUND
• Key in OFF position.
• Disconnect: PCM C1381c.
(Continued)

2004 Excursion, F-Super Duty 250-550, 12/2004

414-00-22 Charging System — General Information 414-00-22
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST T: DUAL GENERATOR UPPER FAULT DETECTED (P0620) (Continued)
Test Step Result / Action to Take
T5 CHECK THE UPPER GENERATOR I CIRCUIT FOR AN OPEN OR
SHORT TO GROUND (Continued)
• With the key OFF and the upper generator C102a still
disconnected, check the resistance between the generator
C102a pin 1, I circuit 904 (LG/RD) harness side and the PCM
C1381c, pin 1 circuit 1183 (WH/YE) harness side; and between
the generator C102a pin 1, I circuit 904 (LG/RD) harness side
and ground.

Yes
GO to T8.
No
• Is the resistance less than 5 ohms between the generator REPAIR I circuit 1183 (WH/YE) / 904
and the PCM and greater than 10,000 ohms between the (LG/RD). CLEAR the DTCs. TEST the
generator and ground? system for normal operation.
T6 CHECK THE UPPER GENERATOR VOLTAGE
• Connect: PCM C1381c.
• Disconnect: Lower Generator C1251a.
• Connect: Upper Generator C102a.
• Key in START position.
• NOTE: After starting the engine, wait at least two minutes for
the glow plugs to stop cycling.
With the engine running, measure the voltage at the battery.

Yes
GO to T7.
No
INSTALL a new upper generator. REFER
to Section 414-02. CLEAR the DTCs.
• Is the voltage greater than 13 volts? TEST the system for normal operation.
T7 CHECK THE UPPER GENERATOR OUTPUT
• With the lower generator connector C1251a still disconnected, Yes
check the upper generator output. Refer to Component Tests, The system is operating normally.
Generator On-Vehicle Test — Load Test in this section. RECONNECT all the connectors, CLEAR
• Is the upper generator OK? the DTCs. TEST the system for normal
operation.
No
INSTALL a new upper generator. REFER
to Section 414-02. CLEAR the DTCs.
TEST the system for normal operation.
(Continued)

2004 Excursion, F-Super Duty 250-550, 12/2004

414-00-23 Charging System — General Information 414-00-23
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST T: DUAL GENERATOR UPPER FAULT DETECTED (P0620) (Continued)
Test Step Result / Action to Take
T8 CHECK FOR CORRECT PCM OPERATION
• Disconnect all PCM connectors. Yes
• Check for: INSTALL a new PCM. REFER to Section
• corrosion 303-14B. CLEAR the DTCs. REPEAT the
• pushed-out pins self-test.
• Connect all PCM connectors and make sure they seat correctly. No
• Operate the system and verify the concern is still present. The system is operating correctly at this
• Is the concern still present? time. Concern may have been caused by
a loose or corroded connector. CLEAR the
DTCs. REPEAT the self-test.

PINPOINT TEST U: DUAL GENERATOR LOWER FAULT DETECTED (P1148)

Test Step Result / Action to Take
U1 CHECK THE LOWER GENERATOR CONNECTIONS
• Key in OFF position.
• Disconnect: Lower Generator C1251c, C1251a. Yes
• Check lower generator connectors for damage and correct GO to U2.
connection. No
• Connect: Lower Generator C1251c, C1251a. REPAIR the connectors as necessary.
• Are the lower generator connectors OK and correctly CLEAR the DTCs. TEST the system for
connected? normal operation.
U2 CHECK THE LOWER GENERATOR B+ VOLTAGE
• Measure the voltage between the B+ terminal of the lower
generator and ground.

Yes
GO to U3.
No
CHECK the B+ circuit 36 (YE/WH)
including fuse links. REPAIR as
necessary. CLEAR the DTCs. TEST the
• Is the voltage equal to battery voltage? system for normal operation.
U3 CHECK THE LOWER GENERATOR A CIRCUIT
• Disconnect: Lower Generator C1251a.
• Measure the voltage between the lower generator harness
C1251a pin 3, A circuit 35 (OG/LB), harness side and ground.

Yes
GO to U4.
No
CHECK lower generator A circuit 35
(OG/LB) including fuse links. REPAIR as
necessary. CLEAR the DTCs. TEST the
• Is the voltage greater than 10 volts? system for normal operation.
(Continued)

2004 Excursion, F-Super Duty 250-550, 12/2004

414-00-24 Charging System — General Information 414-00-24
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST U: DUAL GENERATOR LOWER FAULT DETECTED (P1148) (Continued)
Test Step Result / Action to Take
U4 LOWER GENERATOR I CIRCUIT VOLTAGE
• Key in ON position.
• NOTE: Wait at least two minutes for the glow plugs to stop
cycling.
With the key ON, engine OFF, measure the voltage between the
lower generator C1251a pin 1, circuit 1185 (YE), harness side
and ground.

Yes
GO to U6.
No
• Is the voltage greater than 10 volts? GO to U5.
U5 CHECK LOWER GENERATOR I CIRCUIT FOR AN OPEN OR A
SHORT TO GROUND
• Key in OFF position.
• Disconnect: PCM C1381c.
• Key in ON position.
• With the key ON and the lower generator C1251a disconnected,
measure the resistance between the lower generator C1251a pin
1, I circuit 1185 (YE), harness side and the PCM C1381c pin 4,
circuit 1185 (YE), harness side; and between the lower
generator C1251a pin 1, I circuit 1185 (YE) harness side and
ground.

Yes
GO to U8.
No
• Is the resistance less than 5 ohms between the generator REPAIR the I circuit 1185 (YE). CLEAR
and the PCM and greater than 10,000 ohms between the the DTCs. TEST the system for normal
generator and ground? operation.
U6 CHECK LOWER GENERATOR VOLTAGE
• Connect: PCM C1381c.
• Disconnect: Upper Generator C102a.
• Connect: Lower Generator C1251a.
• Key in START position.
(Continued)

2004 Excursion, F-Super Duty 250-550, 12/2004

414-00-25 Charging System — General Information 414-00-25
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST U: DUAL GENERATOR LOWER FAULT DETECTED (P1148) (Continued)
Test Step Result / Action to Take
U6 CHECK LOWER GENERATOR VOLTAGE (Continued)
• NOTE: After starting the engine, wait at least two minutes for
the glow plugs to stop cycling.
With the engine running, measure the voltage at the battery.

Yes
GO to U7.
No
INSTALL a new lower generator. REFER
to Section 414-02. CLEAR the DTCs.
• Is the voltage greater than 13 volts? TEST the system for normal operation.
U7 CHECK THE LOWER GENERATOR OUTPUT
• With the upper generator connector still disconnected, check the Yes
lower generator output. Refer to Component Tests, Generator System is operating normally.
On-Vehicle Test — Load Test in this section. RECONNECT all connectors, CLEAR the
• Is the lower generator OK? DTCs. TEST the system for normal
operation.
No
INSTALL a new lower generator. REFER
to Section 414-02. CLEAR the DTCs.
TEST the system for normal operation.
U8 CHECK FOR CORRECT PCM OPERATION
• Disconnect all PCM connectors. Yes
• Check for: INSTALL a new PCM. REFER to Section
• corrosion 303-14B. CLEAR the DTCs. REPEAT the
• pushed-out pins self-test.
• Connect all PCM connectors and make sure they seat correctly. No
• Operate the system and verify the concern is still present. The system is operating correctly at this
• Is the concern still present? time. Concern may have been caused by
a loose or corroded connector. CLEAR the
DTCs. REPEAT the self-test.

PINPOINT TEST V: DUAL GENERATOR LOWER CIRCUIT FAULT DETECTED (P1149)

Test Step Result / Action to Take
V1 CHECK THE LOWER GENERATOR I CIRCUIT FOR SHORT TO
B+
• Key in OFF position.
• Disconnect: PCM C1381c.
• Disconnect: Lower Generator C1251a.
• Key in ON position.
(Continued)

2004 Excursion, F-Super Duty 250-550, 12/2004

414-00-26 Charging System — General Information 414-00-26
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST V: DUAL GENERATOR LOWER CIRCUIT FAULT DETECTED (P1149) (Continued)
Test Step Result / Action to Take
V1 CHECK THE LOWER GENERATOR I CIRCUIT FOR SHORT TO
B+ (Continued)
• With the key ON, engine OFF, measure the voltage between the
PCM C1381c pin 4, circuit 1185 (YE), harness side and ground.

Yes
REPAIR the I circuit 1185 (YE) for a short
to B+. CLEAR the DTCs. TEST the
system for normal operation.
No
• Is the voltage greater than 0 volts? GO to V2.
V2 CHECK THE LOWER GENERATOR I CIRCUIT
• Key in OFF position.
• Connect: Lower Generator C1251a.
• Connect: PCM C1381c.
• Key in START position.
NOTE: After starting the engine, wait at least two minutes for
the glow plugs to stop cycling. Yes
With the key ON engine RUNNING, measure the voltage GO to V4.
between C1251a, I circuit 1185 (YE), harness side and ground. No
• Is the voltage greater than 0 volts? GO to V3.
V3 CHECK THE PCM OPERATION
• Key in OFF position.
• Connect: PCM C1381c.
• Key in ON position.
• With the key ON, engine OFF and lower generator connector
C1251a still disconnected, carry out a glow plug test with the
diagnostic tool (refer to Powertrain Control/Emissions Diagnosis
(PC/ED) manual for test procedures). Measure the voltage at
C1251a pin 1, I circuit 1185 (YE) harness side and ground
while carrying out the glow plug test.

Yes
GO to V4.
No
INSTALL a new lower generator. REFER
to Section 414-02. CLEAR the DTCs.
• Is the voltage greater than 0 volts with the glow plugs on? TEST the system for normal operation.
(Continued)

2004 Excursion, F-Super Duty 250-550, 12/2004

414-00-27 Charging System — General Information 414-00-27
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST V: DUAL GENERATOR LOWER CIRCUIT FAULT DETECTED (P1149) (Continued)
Test Step Result / Action to Take
V4 CHECK FOR CORRECT PCM OPERATION
• Disconnect all PCM connectors. Yes
• Check for: INSTALL a new PCM. REFER to Section
• corrosion 303-14B. CLEAR the DTCs. REPEAT the
• pushed-out pins PCM self-test.
• Connect all PCM connectors and make sure they seat correctly. No
• Operate the system and verify the concern is still present. The system is operating correctly at this
• Is the concern still present? time. Concern may have been caused by
a loose or corroded connector. CLEAR the
DTCs. REPEAT the self-test.

Component Tests 3. Allow vehicle to sit with the key off for at least
45 minutes to allow modules to time out/power
Battery — Drain Testing down.
Check for current drains on the battery in excess of 4. Connect a jumper wire between the negative
50 milliamps with all the electrical accessories off battery cable and negative battery post to
and the vehicle at rest. Current drains can be tested prevent modules from resetting and to catch
with the following procedure. capacitive drains.
WARNING: Do not attempt this test on a 5. Disconnect the negative battery cable from the
lead-acid battery that has recently been post without breaking the connection of the
recharged. Explosive gases can cause personal jumper wire.
injury. Failure to follow these instructions may
6. NOTE: It is very important continuity is not
result in personal injury.
broken between the battery and the negative
CAUTION: To prevent damage to the cable when connecting the meter. If this
meter, do not crank the engine or operate happens, the entire procedure must be repeated.
accessories that draw more than 10A. Connect the tester between the negative battery
NOTE: Many computers draw 10 mA or more cable and post. The meter must be capable of
continuously. reading milliamps and should have a 10 amp
NOTE: Use an in-line ammeter between the battery capability.
positive or negative post and its respective cable. 7. NOTE: If the meter settings need to be
NOTE: Typically, a drain of approximately one switched or the test leads need to be moved to
amp can be attributed to an engine compartment another jack, the jumper wire must be
lamp, glove compartment lamp, or interior lamp reinstalled to avoid breaking continuity.
staying on continuously. Other component failures Remove the jumper wire.
or wiring shorts may be located by selectively 8. NOTE: AMP draw will vary from vehicle to
pulling fuses to pinpoint the location of the current vehicle depending on the equipment package.
drain. When the current drain is found, the meter Compare to a similar vehicle for reference.
reading will fall to an acceptable level. If the drain
No stock vehicle should have more than 50 mA
is still not located after checking all the fuses, it
draw.
may be due to the generator.
9. If the draw is found to be excessive, pull fuses
NOTE: To accurately test the drain on a battery, an
from the interior fuse panel one at a time and
in-line digital ammeter must be used. Using a test
note the current drop. Do not reinstall the fuses
lamp or voltmeter is not an accurate method due to
until you are finished testing.
the number of electronic modules.
10. If the draw is still excessive, remove fuses from
1. Make sure engine compartment and interior
the engine compartment fuse panel one at a
fuse panels are accessible without turning on
time and note the current drop. Do not reinstall
interior and underhood lights.
the fuses until you are finished testing.
2. Drive the vehicle at least 5 minutes and over 30
mph to turn on and exercise vehicle systems.

2004 Excursion, F-Super Duty 250-550, 12/2004

414-00-28 Charging System — General Information 414-00-28
DIAGNOSIS AND TESTING (Continued)
11. Check the wiring schematic in the wiring 3. Connect the current probe to the generator B+
diagram for any circuits that run from the output lead, circuit 36 (YE/WH).
battery without passing through the engine 4. NOTE: Make certain to disconnect the
compartment fuse box. Disconnect these circuits generator that is not being tested.
if the draw is still excessive.
With the engine running at 2,000 rpm, adjust
Battery — Electronic Drains Which Shut Off the tester load bank to determine the output of
When the Battery Cable is Disconnected the generator. Generator output should be at
1. Repeat the steps of the battery drain testing. least 87 amps. Refer to the symptom chart in
this section for diagnostic procedures.
2. Make sure all doors are closed and accessories
are off. Without starting the engine, turn the
ignition switch to ON for a moment and then
OFF. Wait a few minutes for the illuminated
entry lamps to turn off, if equipped.
3. Connect the ammeter and read the amperage
draw.
The current reading (current drain) should be less
than 0.05 amp. If current drain exceeds 0.05 amp
after a few minutes, and if this drain did not show
in previous tests, the drain is most likely caused by
a malfunctioning electronic component. As in
previous tests, remove the fuses from the fuse
junction panel one at a time to locate the problem 5. With the engine running, turn the A/C on, (if
circuit. equipped) the blower motor on high speed and
the headlamps on high beam.
Generator On-Vehicle Tests
6. Increase the engine speed to approximately
CAUTION: To prevent damage to the 2,000 rpm. The voltage should increase a
generator, do not make jumper wire connections minimum of 0.5 volt above the base voltage.
except as directed.
• Backprobe the I circuit at the generator
CAUTION: Do not allow any metal object connector (connector plugged in) and
to come in contact with the housing and the measure the I circuit voltage. If the voltage
internal diode cooling fins with the key on or off. is less than 2 volts, install a new generator.
A short circuit will result and burn out the Refer to Section 414-02.
diodes. • If the voltage does not increase as specified,
NOTE: Battery posts and cable clamps must be carry out the Generator On-Vehicle Tests —
clean and tight for accurate meter indications. No-Load Test, in this section.
NOTE: Refer to the battery tester manual for • If the voltage increases as specified, the
complete directions on checking out the charging charging system is operating normally.
system. Proceed to the following battery tests.
1. Turn OFF all lamps and electrical components. Generator On-Vehicle Test — No-Load Test
2. Place the vehicle in transmission range 1. Switch the tester to the voltmeter function.
NEUTRAL and apply the parking brake.
2. Connect the voltmeter positive lead to the
3. Carry out Load Test and No-Load Test generator B+ terminal and the negative lead to
according to the following component tests. ground.
Generator On-Vehicle Test — Load Test 3. Turn all electrical accessories off.
1. Switch the tester to the ammeter function.
2. Connect the positive and negative leads of the
tester to the corresponding battery terminals.
2004 Excursion, F-Super Duty 250-550, 12/2004
414-00-29 Charging System — General Information 414-00-29
DIAGNOSIS AND TESTING (Continued)
4. With the engine running at 2,000 rpm, check
the generator output voltage. The voltage should
be between 13.0 and 15.5 volts. If not, refer
back to the pinpoint test or to the Symptom
Chart for diagnostic procedures.

2004 Excursion, F-Super Duty 250-550, 12/2004