Charging System - General Information Ford Cutaway E350

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

The charging system is a negative ground system consisting of the following

1. generator(s)
2. internal voltage regulator
3. charging system warning indicator
4. storage battery
5. necessary wiring and cables

The generator(s) are belt-driven by the engine accessory drive system. For additional information, refer to ACCESSORY DRIVE .

The battery is a 12-volt direct current source connected in a negative ground system. The battery case is sealed and includes 2 vent holes to release gases. The battery has 3 major functions

1. engine cranking power source
2. voltage stabilizer for the electrical system
3. temporary power when electrical loads exceed the generator output current

The single generator system consists of the generator mounted on the top right of the engine (diesel) or top center of the engine (gasoline). The gasoline engine uses a 3G 115-amp generator with a 2.52:1 pulley ratio. The 6.0L diesel engine uses a 6G 110-amp generator with a 2.79:1 pulley ratio.

The dual generator package consists of an upper/lower dual generator system. The 6.0L upper generator is a VR42 140-amp generator with a 2.79:1 pulley ratio. The 6.0L lower generator is a 4G 120-amp generator with a 3.00:1 pulley ratio. The upper and lower generators are not interchangeable.

This system is also monitored and controlled by the PCM. The PCM monitors both the upper and lower generator I circuits to determine the output of both generators and sets possible diagnostic trouble codes (DTCs). The PCM controls the lower generator by turning it off when the glow plug system is commanded on by the PCM to avoid possible damage (excessive voltage) to the glow plugs. As soon as the glow plug system stops cycling, the PCM will supply voltage to the lower generator.

The generators operate independently of the other. Control is through internal voltage regulators. If one generator fails, the other generator can maintain system performance under light load conditions. Under heavy load, the PCM detects a concern, sets a DTC and illuminates the warning indicator.

On the dual generator system, the PCM controls the charging system warning indicator and commands the light on if the PCM detects a concern on the monitored circuits.

Refer to SYSTEM WIRING DIAGRAMS for schematic and connector information.

Special Tool(s)

SPECIAL TOOLS 73III Automotive Meter 105-R0057 or equivalent SABRE Premium Battery and Electrical System Tester 010-00736 or equivalent

Scheme 41

Scheme 42

Scheme 43

GASOLINE ENGINE CONNECTORS

Scheme 44

DIESEL ENGINE CONNECTOR

Functionality

In a single generator system, with the key in the ON position, voltage is applied through the warning indicator I circuit to the voltage regulator. This turns the regulator on, allowing current to flow from the battery sense A circuit to the generator field coil. When the engine is started, the generator begins to generate alternating current (AC) which is internally converted to direct current (DC). This current is then supplied to the electrical system through the output terminal (B+) of the generator.

Once the generator begins generating current, a voltage signal is taken from the generator stator and fed back to the regulator S circuit 4 (WH/BK) (gasoline engine only). The stator circuit is external on gas engines and internal on diesel engines. This voltage feedback signal (typically half of the battery voltage) is used to turn off the charging system warning indicator on gasoline engines.

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. The regulator controls the generator field current to maintain the correct generator output.

The set voltage varies with temperature and is typically higher in cold temperatures than in warm temperatures. This allows for better battery recharge in the winter and reduces the chance of overcharging in the summer.

Positive Battery Output (B+) Circuit 38 (BK/OG)

The generator output is supplied through the battery positive output (B+) terminal on the rear of the generator to the battery and electrical system.

I Circuit 904 (LG/RD) - Single Generator

The I (ignition) circuit is used to turn on the voltage regulator. This circuit is powered up when the key is in the ON position. Voltage is supplied from the ignition switch to the central junction box (CJB) fuse 45 (10A), then to the instrument cluster and through the charging system warning indicator (battery icon) to the generator. This circuit is also used to turn the charging system warning indicator on if there is a fault in the charging system operation.

A Circuit 35 (OG/LB)

The A (battery sense) circuit 35 (OG/LB) is used to sense the battery voltage. This voltage is used by the regulator to determine the generator output. This circuit is used to supply current to the generator field (rotor). The amount of current supplied to the rotor determines the generator output.

S Circuit 4 (WH/BK)

The S (stator) circuit 4 (WH/BK) is used to feed back a voltage signal from the generator to the regulator. This voltage is used by the regulator to turn off the charging system warning indicator. The S circuit is fed back externally on gasoline engines and internally on diesel engines.

Inspection and Verification

Note. All voltage measurements are referenced to the negative (-) battery post unless otherwise specified.

Note. When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) relearns its fuel trim. The vehicle may need to be driven to relearn the strategy.

1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical or electrical damage. VISUAL INSPECTION CHART Mechanical Electrical Battery case, posts, hold-down clamp, cables and connections Generator drive belt for condition and to make sure there is proper tension between the belt and the pulley. Refer to «ACCESSORY DRIVE»(/ford/cutaway-e350/2004-2007/remont/accessory-drive-belts/#accessory-drive-system) . Battery charge Generator pulley Battery junction box (BJB) fuse(s): Mega fuse 23 (10A) Central junction box (CJB) fuse(s): 14 (5A) 23 (10A) Circuitry Charging system warning indicator Cables Fusible links
3. Check the operation of the charging system warning indicator in the instrument cluster. Normal operation is as follows: With the key OFF, the charging system warning indicator should be off. With the key ON and the engine off, the charging system warning indicator should be on. With the engine running, the charging system warning indicator should be off.
4. Verify the battery condition. Refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) . NORMAL CHARGING SYSTEM VOLTAGES AND CHARGING SYSTEM WARNING INDICATOR OPERATION Key Position A Circuit 35 (OG/LB) S Circuit 4 (WH/BK) (gasoline engines only) I Circuit 904 (LG/RD) Generator B+ Circuit 38 (BK/OG) Battery Engine to Battery Ground Charging System Warning Indicator Operation OFF 12 volts 0 volts 0 volts 12 volts 12 volts 0 volts Off ON-engine off 12 volts 0 volts 1-3 volts 12 volts 12 volts 0 volts Illuminated ON-engine running 13-15 volts 6-8 volts 8-9 volts 13-15 volts 13-15 volts 0 volts Off
5. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
6. If the cause is not visually evident, verify the symptom and GO to «SYMPTOM CHART»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-general-information__symptom-chart) .

Symptom Chart

CHARGING SYSTEM SYMPTOM CHART

Pinpoint Tests

Note. All voltage measurements are referenced to the negative (-) battery post unless otherwise specified.

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

Note. 6.0L diesel generator is shown; all others are similar.

Scheme 45

Scheme 46

1. A1 CHECK THE BATTERY CONDITION Carry out the Battery - Condition Test to determine if the battery can hold a charge and is OK for use. Refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) . Does the battery pass the condition test? Yes : GO to A2. No : INSTALL a new battery. REFER to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) . TEST the system for normal operation.
2. A2 CHECK THE GENERATOR OUTPUT Carry out the Generator On-Vehicle Load Test and No Load Test. Refer to «COMPONENT TESTS»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-general-information) . Does the generator pass the component tests? Yes : GO to A3. No : INSTALL a new generator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) .
3. A3 CHECK FOR CURRENT DRAINS Carry out the Battery - Drain Testing. Refer to «COMPONENT TESTS»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-general-information) . Are any circuits causing excessive current drains? Yes : REPAIR as necessary. TEST the system for normal operation. No : GO to A4.
4. A4 CHECK THE VEHICLE GROUNDS Key in START position. Measure the voltage drop between the generator housing and the negative battery terminal. Is the voltage drop less than 0.1 volt? Yes : GO to A5. No : CHECK the engine ground, generator ground, and the battery for corrosion. REPAIR as necessary. TEST the system for normal operation.
5. A5 CHECK THE VOLTAGE DROP IN B+ CIRCUIT 38 (BK/OG) Measure the voltage drop between the generator B+ circuit 38 (BK/OG) connection and the positive battery terminal. Is the voltage drop less than 0.1 volt? Yes : VERIFY if the customer left any component(s) on or if there is an intermittent excessive battery draw. TEST the system for normal operation. No : CHECK for corrosion in the battery positive cable and/or connections. REPAIR as necessary. TEST the system for normal operation.

PINPOINT TEST B: THE CHARGING SYSTEM WARNING INDICATOR IS ON WITH THE ENGINE RUNNING (THE CHARGING SYSTEM VOLTAGE DOES NOT INCREASE)

Note. 6.0L diesel generator is shown; all others are similar.

Scheme 47

Scheme 48

Scheme 49

1. B1 CHECK THE GENERATOR B+ CIRCUIT 38 (BK/OG) Measure the voltage between the generator B+ terminal, circuit 38 (BK/OG), component side and ground. Is the voltage equal to battery positive voltage (B+)? Yes : GO to B2. No : REPAIR the circuit. TEST the system for normal operation.
2. B2 CHECK THE A CIRCUIT 35 (OG/LB) FOR VOLTAGE Disconnect: Generator C102a. Measure the voltage between the generator C102a-3, circuit 35 (OG/LB), harness side and ground. Is the voltage equal to battery positive voltage (B+)? Yes : GO to B3. No : REPAIR the circuit. TEST the system for normal operation.
3. B3 CHECK THE I CIRCUIT 904 (LG/RD) FOR AN OPEN Key in ON position. With the key in the ON position and the engine off, measure the voltage between the generator C102a-1, circuit 904 (LG/RD), harness side and ground. Is the voltage equal to battery positive voltage (B+)? Yes : GO to B4. No : REPAIR the circuit. TEST the system for normal operation.
4. B4 CHECK FOR VOLTAGE DROP IN B+ CIRCUIT 38 (BK/OG) Key in OFF position. Connect: Generator C102a. Key in START position. With the engine running, turn the headlamps on and the blower motor to the HIGH position. With the engine at 2,000 rpm, measure the voltage drop between the generator B+ terminal, circuit 38 (BK/OG), component side and the positive battery terminal. Is the voltage drop less than 0.5 volt? Yes : If the generator has an external stator circuit 4 (WH/BK), GO to B5. If the generator has an internal stator circuit, INSTALL a new generator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . No : REPAIR the high resistance in the B+ circuit 38 (BK/OG). TEST the system for normal operation.
5. B5 CHECK THE GENERATOR INTEGRITY With the engine running at approximately 2,000 rpm, full-field the generator by grounding the F (field) terminal on the voltage regulator. Does the charging system achieve approximately 75% of full output? Yes : INSTALL a new regulator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . No : INSTALL a new generator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) .

Scheme 50

1. C1 CHECK FOR A VOLTAGE DROP IN THE A CIRCUIT 35 (OG/LB) Disconnect: Generator C102a. Key in ON position. Measure the voltage drop between the generator C102a-3, circuit 35 (OG/LB), harness side and the positive battery terminal. Is the voltage drop less than 0.5 volt? Yes : If the generator has an external stator circuit 4 (WH/BK), GO to C2. If the generator has an internal stator circuit, INSTALL a new generator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . No : REPAIR the high resistance in A circuit 35 (OG/LB). TEST the system for normal operation.
2. C2 CHECK THE GENERATOR AND BATTERY GROUND CONNECTIONS Key in OFF position. Check the ground connections between the generator and the engine, and the battery and the engine. Are all ground connections clean and tight? Yes : INSTALL a new regulator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . TEST the system for normal operation. No : REPAIR the ground connections as necessary. TEST the system for normal operation.

Scheme 51

1. D1 CHECK THE I CIRCUIT 904 (LG/RD) FOR A SHORT TO GROUND Key in OFF position. Disconnect: Generator C102a. Key in ON position. With the key in the ON position, check the charging system warning indicator. Is the charging system warning indicator illuminated? Yes : REPAIR I circuit 904 (LG/RD). TEST the system for normal operation. No : If the generator has an external stator circuit 4 (WH/BK), GO to D2. If the generator has an internal stator circuit, INSTALL a new generator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) .
2. D2 CHECK THE S CIRCUIT 4 (WH/BK) INTEGRITY Key in OFF position. Connect: Generator C102a. Key in START position. With the engine running at approximately 2,000 rpm, measure the voltage between the generator S terminal C102b, circuit 4 (WH/BK) (back-probed), harness side and ground. Is the voltage greater than 5 volts? Yes : INSTALL a new regulator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . TEST the system for normal operation. No : INSTALL a new generator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . TEST the system for normal operation.

Scheme 52

1. E1 CHECK THE CHARGING SYSTEM WARNING INDICATOR Key in OFF position. Disconnect: Generator C102a. With the engine off, connect a fused (15A) jumper wire between the generator C102a-1, circuit 904 (LG/RD), harness side and ground. Key in ON position. Is the charging system warning indicator illuminated? Yes : If the generator has an external stator circuit 4 (WH/BK), INSTALL a new regulator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . If the generator has an internal stator circuit, INSTALL a new generator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . TEST the system for normal operation. No : REFER to «INSTRUMENT CLUSTER»(ref-231355) for the diagnosis and testing of the instrument cluster.

PINPOINT TEST F: THE CHARGING SYSTEM WARNING INDICATOR FLICKERS OR IS INTERMITTENT

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

Scheme 53

Scheme 54

Scheme 55

1. 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.
2. 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.
3. 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. 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.
4. 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.
5. F5 CHECK THE GENERATOR BRUSHES Remove the generator. Refer to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . Measure the resistance between the A and F terminals on the voltage regulator. Is the resistance less than 5 ohms? Yes : INSTALL a new generator. Refer to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . TEST the system for normal operation. No : GO to F6.
6. F6 CHECK FOR A GROUNDED SLIP RING Remove the voltage regulator. Refer to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . Measure the resistance between the generator slip rings. Is the resistance greater than 10,000 ohms? Yes : INSTALL a new generator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-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»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . If the generator has an internal stator circuit, INSTALL a new generator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . TEST the system for normal operation.

PINPOINT TEST G: THE GENERATOR IS NOISY

1. G1 CHECK FOR ACCESSORY DRIVE BELT NOISE AND LOOSE MOUNTING BRACKETS Key in OFF position. Check the accessory drive belt for damage and correct installation. Refer to «ACCESSORY DRIVE»(/ford/cutaway-e350/2004-2007/remont/accessory-drive-belts/#accessory-drive-system) . Check the accessory mounting brackets and generator pulley for looseness or misalignment. Is the accessory drive free of damage and correctly installed? Yes : GO to G2. No : REPAIR as necessary. TEST the system for normal operation.
2. G2 CHECK THE GENERATOR FOR EXCESSIVE ELECTRICAL NOISE Disconnect: Generator C102c. Key in START position. With the engine running, determine if the generator is still noisy. Is the noise still present? Yes : GO to G3. No : INSTALL a new generator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . TEST the system for normal operation.
3. G3 CHECK THE GENERATOR FOR MECHANICAL NOISE Turn all accessories off. With the engine running, use a stethoscope or equivalent listening device to probe the generator for unusual mechanical noise. Is the generator the noise source? Yes : INSTALL a new generator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . TEST the system for normal operation. No : REFER to «ENGINE SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-system-general-information) to diagnose the source of the engine noise.

PINPOINT TEST H: RADIO INTERFERENCE

1. H1 VERIFY THE GENERATOR IS THE SOURCE OF RADIO INTERFERENCE NOTE: If the original equipment manufactured (OEM) audio unit has been replaced with an aftermarket unit, the vehicle may not pass this test. Return the vehicle to OEM condition before following this pinpoint test. Key in START position. Start and run the engine. Tune the radio to a station where the interference is present. Key in OFF position. Disconnect: Generator C102c. Key in START position. With the engine running, determine if the interference is still present. Is the interference present with the generator disconnected? Yes : REFER to «ENTERTAINMENT SYSTEM - GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/entertainment-systems/#entertainment-system-general-information) for diagnosis and testing of the in-vehicle entertainment system. No : INSTALL a new generator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . TEST the system for normal operation.

Battery - Drain Tests

Note. No production vehicle should have more than a 50 mA (0.050 amp) draw.

Note. Many modules draw 10 mA (0.010 amp) or more continuously.

Note. Use an in-line ammeter between the battery positive or negative post and its respective cable.

Note. Typically, a drain of approximately 1 amp can be attributed to an engine compartment lamp, glove compartment lamp, or interior lamp staying on continually. Other component failures or wiring shorts may be located by selectively pulling fuses to pinpoint the location of the current drain. When the current drain is found, the meter reading will fall to an acceptable level. If the drain is still not located after checking all the fuses, it may be due to the generator.

Note. To accurately test the drain on a battery, an in-line digital ammeter must be used. Use of a test lamp or voltmeter is not an accurate method due to the number of electronic modules.

Check for current drains on the battery in excess of 50 milliamps (0.050 amp) with all the electrical accessories off and the vehicle at rest. Current drains can be tested with the following procedure

1. Make sure the junction box/fuse panels are accessible without turning on the interior or underhood lights.
2. Drive the vehicle at least 5 minutes at over 48 km/h (30 mph) to turn on and operate the vehicle systems.
3. Allow the vehicle to sit with the key OFF for at least 40 minutes to allow the modules to time out/power down.
4. Connect a fused jumper wire between the negative battery cable and the negative battery post to prevent modules from resetting and to catch capacitive drains.
5. Disconnect the negative battery cable from the post without breaking the connection of the jumper wire.
6. Connect the tester between the negative battery cable and the post. The meter must be capable of reading milliamps and should have a 10 amp capability.
7. Remove the jumper wire.
8. If the draw is found to be excessive, pull the fuses from the battery junction box/central junction box one at a time and note the current drop. Do not reinstall the fuses until you are finished testing.
9. Check SYSTEM WIRING DIAGRAMS for any circuits that run from the battery without passing through the battery/central junction box. Disconnect these circuits if the draw is still excessive.

Battery - Electronic Drains Which Shut Off When the Battery Cable is Disconnected

1. Repeat the steps of the battery drain testing.
2. Make sure all the doors are closed and all accessories are off. Without starting the engine, turn the key to the ON position for a moment and then OFF. Wait 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 50 mA (0.05 amp). If the current drain exceeds 50 mA (0.05 amp), and if this drain did not show in previous tests, the drain is most likely caused by an inoperative electronic component. As in previous tests, remove the fuses from the battery/central junction box one at a time to locate the problem circuit.

Generator On-Vehicle Tests

Note. The battery posts and cable clamps must be clean and tight for accurate meter indications.

Note. Refer to the battery tester manual for complete directions for testing the charging system.

1. Turn off all lamps and electrical components.
2. Place the vehicle in NEUTRAL and apply the parking brake.
3. Carry out the Load Test and No-Load Test according to the following component tests

Scheme 56

1. Switch the tester to the ammeter function.
2. Connect the positive and negative leads of the battery tester to the corresponding battery terminals.
3. Connect the current probe to the generator B+ output terminal, circuit 38 (BK/OG).
4. With the engine running at approximately 2,000 rpm, adjust the tester load bank to determine the output of the generator. The generator output should be at least 87 amps.
5. With the engine running, turn the A/C on (if equipped), the blower motor on high speed, and the headlamps on high beam.
6. Increase the engine speed to approximately 2,000 rpm. The voltage should increase a minimum of 0.5 volt above the base voltage. If the voltage does not increase as specified, carry out the Generator On-Vehicle Tests - No Load Test in this section. If the voltage increases as specified, the charging system is operating normally.

Generator On-Vehicle Tests - No-Load Test

1. Switch the tester to the voltmeter function.
2. Connect the voltmeter positive lead to the generator B+ terminal and the negative lead to ground.
3. Turn all electrical accessories off.
4. With the engine running at approximately 2,000 rpm, check the generator output voltage. The voltage should be between 13.0 and 15.0 volts. If not, GO to «SYMPTOM CHART»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-general-information__symptom-chart) or refer to the «PINPOINT TEST»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-general-information__pinpoint-tests) .

Charging System - Dual Generators

Refer to SYSTEM WIRING DIAGRAMS Cell 12, Charging System for schematic and connector information.

SPECIAL TOOLS 73III Automotive Meter 105-R0057 or equivalent SABRE Premium Electrical System Tester 010-00736 or equivalent Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool Micro 490 Digital Battery Analyzer 162-00004 or equivalent

Scheme 57

Scheme 58

Principles of Operation

DIESEL ENGINE CONNECTORS

Scheme 59

DIESEL ENGINE CONNECTOR

With the key 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 the upper generator and through the I circuit 1185 (YE) from the PCM to the I circuit 1183 (WH/YE) at the lower generator. If the glow plug system is not cycling, the PCM maintains voltage to the lower generator. If the glow plug system is cycling, the PCM supplies voltage to the lower generator momentarily to verify there is a volt drop, then shuts off the voltage on the lower generator I circuit 1185 (YE)/1183 (WH/YE). Once the glow plug system stops cycling, the PCM supplies voltage on the lower generator I circuit 1185 (YE)/1183 (WH/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 voltage on the upper generator I circuit 1183 (WH/YE) / 904 (LG/RD), which turns on the regulator, allowing 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 one-half of the battery voltage) is used by the PCM to turn off the charging system 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.

The set voltage varies with temperature and is typically higher in cold temperatures and lower in warm temperatures. This allows for more efficient battery recharge in the winter and reduces the chance of overcharging in the summer.

Battery Positive Output (B+) Circuit 1119 (RD) (Upper Generator), 2037 (RD) (Lower Generator)

The generator output is supplied through the battery positive output (B+) terminal on the rear of the generator to the battery and the electrical system.

I Circuit - Dual Generator

The I (ignition) circuit is used to turn on the voltage regulator(s). This circuit is powered up when the key is in the ON position. When the PCM detects the key is in the ON position, the PCM provides voltage to the upper generator I circuit 1183 (WH/YE)/904 (LG/RD) and to the lower generator I circuit 1185 (YE)/1183 (WH/YE). The voltage to the lower generator is only momentary unless the glow plug system is not cycling. Once the glow plugs stop cycling, the PCM provides constant voltage on the lower generator I circuit 1185 (YE)/1183 (WH/YE).

A Circuit

The A circuit or battery sense circuit is used to sense battery voltage. This voltage is used by the regulator to determine the generator output.

Note. While carrying out any pinpoint test, disregard any DTCs set while following any specific pinpoint test. After the completion of any test, be sure to clear all codes in the PCM.

Note. All voltage measurements are referenced to the negative (-) battery post unless otherwise specified.

Note. When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) relearns its fuel trim. The vehicle may need to be driven to relearn the strategy.

1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical or electrical damage. VISUAL INSPECTION CHART Mechanical Electrical 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. Refer to «ACCESSORY DRIVE»(/ford/cutaway-e350/2004-2007/remont/accessory-drive-belts/#accessory-drive-system) . Battery condition Generator pulley Battery junction box (BJB) fuse 23 (10A) Charging system warning indicator Circuitry Cables
3. If the inspection reveals obvious concern(s) that can be readily identified, service as necessary.
4. Verify the battery condition. Refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
5. Observe the charging system warning indicator status under the following conditions: The charging system warning indicator illuminates with the key in the ON position and with the engine OFF. The charging system warning indicator is off with the engine running. The charging system warning indicator is off with the key in the OFF position.
6. Check the battery voltage before and after starting the engine to determine if the battery voltage increases. Refer to the «NORMAL CHARGING SYSTEM VOLTAGES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-general-information) NORMAL CHARGING SYSTEM VOLTAGES Key Position A Circuit 35 (OG/LB) I Circuit 904 (LG/RD) Generator B+ Circuit 1119 (RD) (Upper Generator), 2037 (RD) (Lower Generator) Battery Engine to Battery Ground Charging System Warning Indicator Operation Key OFF 12 0V 12V 12V OV Off Key ON -engine off 12V 1-3V (glow plugs off) 12V 12V 0V Illuminated Engine running 13-15V 8-9V 13-15V 13-15V 0V Off
7. If the concern remains after the inspection, connect the diagnostic tool to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the diagnostic tool menu. If the vehicle selection cannot be entered: Check that the program card is correctly installed. Check the connections to the vehicle. Check the ignition switch position.
8. If the diagnostic tool still does not communicate with the vehicle, refer to diagnostic tool operating manual.
9. 9. Carry out the diagnostic tool data link test. If the diagnostic tool responds with: CAN or ISO circuits fault; all electronic control units no response/not equipped, refer to «MODULE COMMUNICATIONS NETWORK»(/ford/cutaway-e350/2004-2007/remont/communication-devices/#module-communications-network) . No response/not equipped for powertrain control module (PCM), see «INTRODUCTION - GASOLINE»(/ford/cutaway-e350/2004-2007/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) and/or «INTRODUCTION -- 6.0L DIESEL»(/ford/cutaway-e350/2004-2007/remont/testing-diagnostics/#engine-controls-introduction-60l-diesel) articles. System passed, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs, and carry out the self-test diagnostics for the PCM.
10. 10. If the DTCs retrieved are related to the concern, go to the «Powertrain Control Module (PCM) Diagnostic Trouble Code (DTC) Index»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-general-information) or the «INSTRUMENT CLUSTER DIAGNOSTIC TROUBLE CODE (DTC) INDEX»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-general-information) .
11. 11. If no DTCs related to the concern are retrieved, GO to «SYMPTOM CHART»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-general-information__symptom-chart) to continue diagnostics.

POWERTRAIN CONTROL MODULE (PCM) DIAGNOSTIC TROUBLE CODE (DTC) INDEX

INSTRUMENT CLUSTER DIAGNOSTIC TROUBLE CODE (DTC) INDEX

CHARGING SYSTEM DUAL GENERATORS SYMPTOM CHART

Note. While carrying out any pinpoint test, disregard any DTCs set while following any specific pinpoint test. After the completion of any test, make sure to clear all codes in the powertrain control module (PCM).

Note. The dual generator I circuit/bulb circuit 4-way connector MUST be connected before disconnecting or connecting the battery. The PCM relearns its parameters every time it is disconnected and connected to power. Failure to follow this procedure causes the PCM to misinterpret the charging system as a single generator system, causing the loss of DTC capability and control.

Note. All voltage measurements are referenced to the negative (-) battery post unless otherwise specified.

Scheme 60

Scheme 61

Scheme 62

Scheme 63

1. I1 CHECK THE DTCS IN THE POWERTRAIN CONTROL MODULE (PCM) Connect the diagnostic tool. Key in ON position. With the key in the ON position, and the engine OFF, check the PCM for DTCs with the diagnostic tool. Do generator fault codes exist? Yes : GO to the appropriate Pinpoint Test. No : GO to I2.
2. I2 CHECK I CIRCUIT 904 (LG/RD) FOR VOLTAGE Key in OFF position. Disconnect the diagnostic tool. Disconnect: Upper Generator C102a. Key in ON position. With the key in the ON position, and the engine OFF, measure the voltage at the upper generator C102a-1, I circuit 904 (LG/RD), harness side and ground. Is the voltage greater than 10 volts? Yes : GO to I4 . No : GO to I3.
3. I3 CHECK I CIRCUIT 1183 (WH/YE)/904 (LG/RD) FOR AN OPEN Key in OFF position. Disconnect: PCM C176c. Measure the resistance between the PCM C176c-1, circuit 1183 (WH/YE), harness side and the upper generator C102a-1, circuit 904 (LG/RD), harness side. Is the resistance less than 5 ohms? Yes : GO to I8 . No : REPAIR I circuit 1183 (WH/YE)/904 (LG/RD). TEST the system for normal operation.
4. I4 CHECK THE VOLTAGE TO THE LOWER GENERATOR Key in OFF position. Disconnect: Lower Generator C1251a. Key in ON position. Measure the voltage between the lower generator C1251a-1, circuit 1183 (WH/YE), harness side and ground. Is the voltage greater than 10 volts? Yes : GO to I6 . No : GO to I5.
5. I5 CHECK THE LOWER GENERATOR I CIRCUIT 1185 (YE)/1183 (WH/YE) FOR AN OPEN Key in OFF position. Connect: Upper Generator C102a. Disconnect: Lower Generator C1251a. Disconnect: PCM C176c. Measure the resistance between the PCM C176c-4, circuit 1185 (YE), harness side and the lower generator C1251a-1, circuit 1183 (WH/YE), harness side. Is the resistance less than 5 ohms? Yes : GO to I8 . No : REPAIR I circuit 1185 (YE)/1183 (WH/YE). TEST the system for normal operation.
6. I6 CHECK THE UPPER GENERATOR OUTPUT Connect: PCM C176c. Key in START position. Carry out the generator load test on the upper generator. Refer to Component Tests, «GENERATOR ON-VEHICLE TESTS»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-general-information__generator-on-vehicle-tests) . Is the upper generator OK? Yes : GO to I7. No : INSTALL a new upper generator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . TEST the system for normal operation.
7. I7 CHECK THE LOWER GENERATOR OUTPUT Key in OFF position. Connect: Lower Generator C1251a. Disconnect: Upper Generator C102a. Key in START position. Carry out the generator load test on the lower generator. Refer to Component Tests, «GENERATOR ON-VEHICLE TESTS»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-general-information__generator-on-vehicle-tests) . Is the lower generator OK? Yes : GO to I8. No : INSTALL a new lower generator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . TEST the system for normal operation.
8. I8 CHECK FOR CORRECT PCM OPERATION Disconnect all the PCM connectors. Check for: corrosion pushed-out pins Connect all the PCM connectors and make sure they seat correctly. Operate the system and verify the concern is still present. Is the concern still present? Yes : INSTALL a new PCM. REFER to «ELECTRONIC ENGINE CONTROLS - GASOLINE ENGINES»(/ford/cutaway-e350/2004-2007/remont/removal-installation/#electronic-engine-controls-diesel-engine-e350-e450) . REPEAT the PCM self-test. TEST the system for normal operation. No : The system is operating correctly at this 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.

Scheme 64

1. J1 CHECK THE DTCS IN THE POWERTRAIN CONTROL MODULE (PCM) Connect the diagnostic tool. Key in ON position. With the key in the ON position, and the engine OFF, check the PCM for DTCs with the diagnostic tool. Do generator fault codes exist? Yes : GO to the appropriate Pinpoint Test. No : GO to J2.
2. J2 CHECK THE CHARGING SYSTEM WARNING INDICATOR OPERATION Key in OFF position. Disconnect the diagnostic tool. Disconnect: PCM C176a. Key in ON position. With the key in the ON position, and the engine OFF, connect a fused (15A) jumper wire between the PCM C176a-30, circuit 904 (LG/RD), harness side and ground. Does the charging system warning indicator illuminate? Yes : GO to J3. No : REFER to «INSTRUMENT CLUSTER»(ref-231355) .
3. J3 CHECK FOR CORRECT PCM OPERATION Disconnect all the PCM connectors. Check for: corrosion pushed-out pins Connect all the PCM connectors and make sure they seat correctly. Operate the system and verify the concern is still present. Is the concern still present? Yes : INSTALL a new PCM. REFER to «ELECTRONIC ENGINE CONTROLS - GASOLINE ENGINES»(/ford/cutaway-e350/2004-2007/remont/removal-installation/#electronic-engine-controls-diesel-engine-e350-e450) . CLEAR the DTCs. REPEAT the PCM self-test. No : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test.

Scheme 65

Scheme 66

Scheme 67

1. K1 CHECK THE DTCS IN THE POWERTRAIN CONTROL MODULE (PCM) Connect the diagnostic tool. Key in ON position. With the key in the ON position, and the engine OFF, check the PCM for DTCs with the diagnostic tool. Are generator fault codes present? Yes : GO to the appropriate Pinpoint Test. No : GO to K2.
2. 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. Is the voltage greater than 15.5 volts? Yes : GO to «PINPOINT TEST O»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-general-information) . No : GO to K3.
3. K3 CHECK THE CHARGING SYSTEM WARNING INDICATOR OPERATION Key in OFF position. Connect: Lower Generator C1251a. Disconnect: PCM C176a. Key in ON position. With the key in the ON position, and the engine OFF, monitor the charging system warning indicator. Is the indicator illuminated? Yes : GO to K4. No : GO to K5 .
4. K4 CHECK THE WARNING INDICATOR CIRCUIT Key in OFF position. Disconnect: Instrument Cluster C220b. Measure the resistance between the PCM C176a-30, circuit 904 (LG/RD) harness side and ground. Is the resistance greater than 10,000 ohms? Yes : REFER to «INSTRUMENT CLUSTER»(ref-231355) . No : REPAIR the circuit. TEST the system for normal operation.
5. K5 CHECK THE LOWER GENERATOR A CIRCUIT Key in OFF position. Connect: Upper Generator C102a. Disconnect: Lower Generator C1251a. With the key in the ON position, and the engine OFF, measure the voltage at the lower generator connector C1251a-3, A circuit 35 (OG/LB), harness side and ground. Is the voltage equal to battery voltage? Yes : GO to K6. No : CHECK lower generator A circuit 35 (OG/LB). REPAIR as necessary. TEST the system for normal operation.
6. K6 CHECK FOR CORRECT PCM OPERATION Disconnect all the PCM connectors. Check for: corrosion pushed-out pins Connect all the PCM connectors and make sure they seat correctly. Operate the system and verify the concern is still present. Is the concern still present? Yes : INSTALL a new PCM. REFER to «ELECTRONIC ENGINE CONTROLS - GASOLINE ENGINES»(/ford/cutaway-e350/2004-2007/remont/removal-installation/#electronic-engine-controls-diesel-engine-e350-e450) . CLEAR the DTCs. REPEAT the PCM self-test. No : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test.

Scheme 68

1. L1 CHECK THE DTCS IN THE POWERTRAIN CONTROL MODULE (PCM) Connect the diagnostic tool. Key in ON position. With the key in the ON position, and the engine OFF, check the PCM for DTCs with the diagnostic tool. Do generator fault codes exist? Yes : GO to the appropriate Pinpoint Test. No : GO to L2.
2. L2 CHECK THE UPPER AND LOWER GENERATOR CONNECTIONS Key in OFF position. Disconnect the diagnostic tool. Check the battery terminals and all the generator connectors for corrosion, damage, and correct connection. Are all the connections clean and tight? Yes : GO to L3. No : REPAIR the connections as necessary. TEST the system for normal operation.
3. L3 CHECK THE OUTPUT (B+) CIRCUIT 1119 (RD) OF THE UPPER GENERATOR Check the voltage at the upper generator B+ terminal, circuit 1119 (RD), harness side and ground. Is the voltage equal to battery voltage? Yes : GO to L4. No : REPAIR upper generator output (B+) circuit 1119 (RD) (including the fusible links) as necessary. TEST the system for normal operation.
4. L4 CHECK THE OUTPUT (B+) CIRCUIT 2037 (RD) OF THE LOWER GENERATOR Check the voltage at the lower generator B+ terminal, circuit 2037 (RD), harness side and ground. Is the voltage equal to battery voltage? Yes : GO to L5. No : REPAIR lower generator output (B+) circuit 2037 (RD) (including the fusible links) as necessary. TEST the system for normal operation.
5. L5 CHECK THE BATTERY CONDITION Carry out the Battery - Condition Test to determine if the battery can hold a charge and is OK for use. Refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) . Are the batteries OK? Yes : GO to L6. No : INSTALL a new applicable battery. TEST the system for normal operation.
6. L6 CHECK THE UPPER GENERATOR OUTPUT Disconnect: Lower Generator C1251a. Check the upper generator output. Refer to Component Tests, «GENERATOR ON-VEHICLE TESTS»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-general-information__generator-on-vehicle-tests) . Is the upper generator OK? Yes : GO to L7. No : INSTALL a new generator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . CLEAR the DTCs. TEST the system for normal operation.
7. L7 CHECK THE LOWER GENERATOR OUTPUT Key in OFF position. Connect: Lower Generator C1251a. Disconnect: Upper Generator C102a. Check the lower generator output. Refer to Component Tests, «GENERATOR ON-VEHICLE TESTS»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-general-information__generator-on-vehicle-tests) . Is the lower generator OK? Yes : The system is OK. VERIFY the symptoms from the Symptom Chart and TEST the system for normal operation. COMPARE to a similar vehicle. No : INSTALL a new lower generator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . CLEAR the DTCs. TEST the system for normal operation.

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

1. M1 CHECK THE DTCS IN THE POWERTRAIN CONTROL MODULE (PCM) Connect the diagnostic tool. Key in ON position. With the key in the ON position, and the engine OFF, check the PCM for DTCs with the diagnostic tool. Are generator fault codes present? Yes : GO to the appropriate Pinpoint Test. No : GO to M2
2. M2 CHECK THE BATTERY CONDITION Key in OFF position. Disconnect the diagnostic tool. Carry out the Battery - Condition Test to determine if the battery can hold a charge and is OK for use. Refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) . Is the battery(s) OK? Yes : GO to M3. No : INSTALL a new battery(s). TEST the system for normal operation.
3. M3 CHECK THE BATTERY DRAIN Make sure all interior lights and switches are off and all doors are closed. Carry out the battery drain test. Refer to Component Tests, «BATTERY - DRAIN TESTING»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-general-information__battery-drain-testing) . Is the drain greater than 0.05 amp? Yes : REPAIR the battery drain as necessary. TEST the system for normal operation. No : GO to M4
4. M4 CHECK THE UPPER GENERATOR OUTPUT Disconnect: Lower Generator C1251a. Key in START position. With the key in the ON position, and the engine running, check the upper generator output. Refer to Component Tests, «GENERATOR ON-VEHICLE TESTS»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-general-information__generator-on-vehicle-tests) . Is the upper generator OK? Yes : GO to M5. No : INSTALL a new upper generator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . CLEAR the DTCs. TEST the system for normal operation.
5. M5 CHECK THE LOWER GENERATOR OUTPUT Key in OFF position. Connect: Lower Generator C1251a. Disconnect: Upper Generator C102a. Key in START position. With the key in the ON position, and the engine running, check the lower generator output. Refer to Component Tests, «GENERATOR ON-VEHICLE TESTS»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-general-information__generator-on-vehicle-tests) . Is the lower generator OK? Yes : GO to M6. No : INSTALL a new lower generator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . CLEAR the DTCs. TEST the system for normal operation.
6. M6 CHECK THE OTHER SYSTEMS FOR DRAINS Check for drains from the electronic modules. Refer to Component Tests, «BATTERY - ELECTRONIC DRAINS WHICH SHUT OFF WHEN THE BATTERY CABLE IS DISCONNECTED»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-general-information) . Are the electronic modules OK? Yes : CHARGE the batteries. TEST the system for normal operation. No : REPAIR as necessary. TEST the system for normal operation.

PINPOINT TEST N: THE CHARGING SYSTEM WARNING INDICATOR FLICKERS OR IS INTERMITTENT

1. N1 CHECK THE DTCS IN THE POWERTRAIN CONTROL MODULE (PCM) Connect the diagnostic tool. Key in ON position. With the key in the ON position, and the engine OFF, check the PCM for DTCs with the diagnostic tool. Do generator fault codes exist? Yes : GO to the appropriate Pinpoint Test. No : GO to N2.
2. N2 CHECK THE BATTERY VOLTAGE Key in START position. With the key in the ON position, and the engine running, and all accessories turned off, measure the voltage at the battery while varying the engine rpm. Is the voltage greater than 15.5 volts? Yes : GO to «PINPOINT TEST O»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-general-information) . No : GO to N3.
3. N3 CHECK THE CHARGING SYSTEM INDICATOR OPERATION Key in OFF position. Key in ON position. With the key in the ON position, and the engine OFF, enter the following diagnostic mode on the diagnostic tool: Active Commands. Command the charging system warning indicator on. Does the charging system warning indicator illuminate? Yes : GO to N4. No : REFER to «INSTRUMENT CLUSTER»(ref-231355) .
4. N4 CHECK THE PCM OPERATION Key in OFF position. Disconnect the diagnostic tool. Key in ON position. With the key in the ON position, and the engine OFF, monitor the charging system warning indicator. Is the lamp illuminated? Yes : The PCM is operating correctly. CHECK the generator circuits (including the generators) for intermittent shorts or opens. TEST the system for normal operation. No : GO to N5.
5. N5 CHECK FOR CORRECT PCM OPERATION Disconnect all the PCM connectors. Check for: corrosion pushed-out pins Connect all the PCM connectors and make sure they seat correctly. Operate the system and verify the concern is still present. Is the concern still present? Yes : INSTALL a new PCM. REFER to «ELECTRONIC ENGINE CONTROLS - GASOLINE ENGINES»(/ford/cutaway-e350/2004-2007/remont/removal-installation/#electronic-engine-controls-diesel-engine-e350-e450) . CLEAR the DTCs. REPEAT the PCM self-test. No : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test.

Scheme 69

Scheme 70

1. O1 CHECK THE DTCS IN THE POWERTRAIN CONTROL MODULE (PCM) Connect the diagnostic tool. Key in ON position. With the key in the ON position, and the engine OFF, check the PCM for DTCs with the diagnostic tool. Are generator fault codes present? Yes : GO to the appropriate Pinpoint Test. No : GO to O2.
2. O2 CHECK THE BATTERY VOLTAGE Key in OFF position. Disconnect the diagnostic tool. Key in START position. With the key in the ON position, and the engine running and all accessories turned off, measure the voltage at either battery while varying the engine rpm. Is the voltage greater than 15.5 volts? Yes : GO to O3. No : GO to O7 .
3. 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 2 minutes for the glow plugs to turn off. With the key in the ON position, and the engine running and all accessories turned off, measure the voltage at either battery while varying the engine rpm. Is the voltage greater than 15.5 volts? Yes : GO to O4. No : GO to O5 .
4. O4 CHECK THE UPPER GENERATOR A CIRCUIT Key in OFF position. Connect: Lower Generator C1251a. Disconnect: Upper Generator C102a. Key in ON position. With the key in the ON position, and the engine OFF, measure the voltage drop between the upper generator C102a-3, A circuit 35 (OG/LB) harness side and the battery positive terminal. Is the voltage drop less than 0.5 volt? Yes : INSTALL a new upper generator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . 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 operation.
5. 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 2 minutes for the glow plugs to turn off. With the key in the ON position, and the engine running and all accessories turned off, measure the voltage at either battery while varying the engine rpm. Is the voltage greater than 15.5 volts? Yes : GO to O6. No : GO to O7 .
6. O6 CHECK THE LOWER GENERATOR A CIRCUIT Key in OFF position. Connect: Upper Generator C102a. Disconnect: Lower Generator C1251a. Key in ON position. With the key in the ON position, and the engine OFF, measure the voltage drop between the lower generator C1251a-3, A circuit 35 (OG/LB) harness side and the positive battery terminal. Is the voltage drop less than 0.5 volt? Yes : INSTALL a new lower generator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . 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 operation.
7. O7 CHECK THE GROUNDS Key in OFF position. Check the ground connections between the generators and the engine, and the batteries and the engine. Are all the ground connections clean and tight? Yes : CHECK both upper and lower generator A circuits for intermittent opens/shorts. REPAIR as necessary. CLEAR the DTCs. TEST the system for normal operation. No : REPAIR as necessary.

PINPOINT TEST P: BATTERY LEAKAGE OR DAMAGE

1. P1 CHECK FOR ACID LEAKAGE AND DAMAGE Check for acid damage to both the battery wire harness and to the body. Is acid damage present? Yes : REPAIR the damaged areas as necessary. TEST the system for normal operation. No : GO to P2.
2. P2 CHECK THE 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. Is the voltage greater than 15.5 volts? Yes : GO to «PINPOINT TEST O»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-general-information) . No : GO to P3.
3. P3 CHECK THE BATTERY MOUNTING Key in OFF position. Check both batteries for correct mounting in the battery trays. Are the batteries correctly mounted? Yes : GO to P4. No : REPAIR as necessary. TEST the system for normal operation.
4. P4 CHECK FOR BATTERY CONTACT Check both batteries to make sure there are no fasteners or other parts contacting the battery case causing excess pressure. Is anything contacting the battery case? Yes : REPAIR as necessary. TEST the system for normal operation. No : GO to P5.
5. P5 CHECK THE BATTERY CASE FOR DAMAGE Check both battery cases for damage, such as cracks or poor seals. Are the batteries OK? Yes : GO to P6. No : INSTALL a new battery. REFER to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) . TEST the system for normal operation.
6. P6 CHECK THE BATTERY CAPACITY Check the battery capacity of both batteries. Refer to Battery - Condition Test in «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) . Are the batteries OK? Yes : The system is OK. TEST the system for normal operation. No : INSTALL a new applicable battery. TEST the system for normal operation.

PINPOINT TEST Q: THE VOLTAGE GAUGE READS HIGH OR LOW

1. 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. Is the battery voltage more than 15.5 volts or less than 13 volts? Yes : For readings more than 15.5 volts, GO to «PINPOINT TEST O»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-general-information) . For readings less than 13 volts, GO to «PINPOINT TEST M»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-general-information__pinpoint-test-m-the-battery-is) . No : GO to Q2.
2. Q2 CHECK THE VOLTAGE GAUGE OPERATION With the engine still running, monitor the voltage gauge reading and the battery voltage. Are the voltage readings consistent? Yes : The voltage gauge is operating normally. No : The voltage gauge is inaccurate. REFER to «INSTRUMENT CLUSTER»(ref-231355) to continue diagnostics.

PINPOINT TEST R: THE GENERATOR (S) IS NOISY

1. 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 «ACCESSORY DRIVE»(/ford/cutaway-e350/2004-2007/remont/accessory-drive-belts/#accessory-drive-system) . Check the generator mounting brackets for loose bolts or misalignment. Are the accessory drive and generator mounting brackets OK? Yes : GO to R2. No : REPAIR as necessary. TEST the system for normal operation.
2. R2 CHECK THE GENERATOR PULLEY(S) Check for a bent, loose, or misaligned generator pulley(s). Are the generator pulley(s) OK? Yes : GO to R3. No : INSTALL a new pulley(s) as necessary. TEST the system for normal operation.
3. R3 CHECK THE LOWER GENERATOR FOR ELECTRICAL NOISE Disconnect: Lower Generator C1251a. Key in START position. With the engine running, use a stethoscope or equivalent listening device to probe the lower generator for noise. Is the lower generator noisy? Yes : INSTALL a new lower generator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . TEST the system for normal operation. No : GO to R4.
4. R4 CHECK THE UPPER GENERATOR FOR ELECTRICAL NOISE Key in OFF position. Disconnect: Upper Generator C102a. Key in START position. With the engine running, use a stethoscope or equivalent listening device to probe the upper generator for noise. Is the upper generator noisy? Yes : INSTALL a new upper generator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . CLEAR the DTCs. TEST the system for normal operation. No : REFER to «ENGINE SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-system-general-information) to diagnose the source of the engine noise.

PINPOINT TEST S: RADIO INTERFERENCE

1. 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. Start and run the engine. Tune the radio to a station where the interference is present. Key in OFF position. Disconnect: Upper Generator C102a. Key in START position. Start and run the engine. Is interference present with the upper generator disconnected? Yes : GO to S2. No : INSTALL a new upper generator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . TEST the system for normal operation.
2. S2 VERIFY THERE IS RADIO INTERFERENCE Key in OFF position. Connect: Upper Generator C102a. Disconnect: Lower Generator C1251a. Key in START position. Verify the interference is present with the lower generator disconnected. Is the interference still present? Yes : REFER to «ENTERTAINMENT SYSTEM - GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/entertainment-systems/#entertainment-system-general-information) for diagnosis and testing of the in-vehicle entertainment system. No : INSTALL a new lower generator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . CLEAR the DTCs. TEST the system for normal operation.

Scheme 71

Scheme 72

1. T1 CHECK THE UPPER GENERATOR CONNECTIONS Key in OFF position. Disconnect: Upper Generator C102c and C102a. Check the upper generator connectors for damage and correct connection. Connect: Upper Generator C102c and C102a. Are the upper generator connectors OK and correctly connected? Yes : GO to T2. No : REPAIR the connections as necessary. CLEAR the DTCs. TEST the system for normal operation.
2. T2 CHECK THE UPPER GENERATOR B+ VOLTAGE Measure the voltage between the B+ terminal of the upper generator C102c, circuit 1119 (RD) harness side and ground. Is the voltage equal to battery voltage? Yes : GO to T3. No : CHECK B+ circuit 1119 (RD), including the fusible links. REPAIR as necessary. CLEAR the DTCs. TEST the system for normal operation.
3. T3 CHECK THE UPPER GENERATOR A CIRCUIT Disconnect: Upper Generator C102a. With the upper generator connector disconnected, measure the voltage between the upper generator C102a-3, A circuit 35 (OG/LB), harness side and ground. Is the voltage equal to battery voltage? Yes : GO to T4. No : CHECK upper generator A circuit 35 (OG/LB) including the fusible links. REPAIR as necessary. CLEAR the DTCs. TEST the system for normal operation.
4. T4 CHECK THE UPPER GENERATOR I CIRCUIT VOLTAGE Key in ON position. With the key in the ON position, and the engine OFF, measure the voltage between the upper generator C102a-1, I circuit 904 (LG/RD), harness side and ground. Is the voltage greater than 10 volts? Yes : GO to T6 . No : GO to T5.
5. T5 CHECK THE UPPER GENERATOR I CIRCUIT FOR AN OPEN OR A SHORT TO GROUND Key in OFF position. Disconnect: PCM C176c. With the key in the OFF position and the upper generator C102a disconnected, check the resistance between the upper generator C102a-1, I circuit 904 (LG/RD) harness side and the powertrain control module (PCM) C176c-1, circuit 1183 (WH/YE) harness side; and between the upper generator C102a-1, I circuit 904 (LG/RD) harness side and ground. Is the resistance less than 5 ohms between the generator and the PCM; and greater than 10,000 ohms between the generator and ground? Yes : GO to T8 . No : REPAIR I circuit 1183 (WH/YE) / 904 (LG/RD). CLEAR the DTCs. TEST the system for normal operation.
6. T6 CHECK THE UPPER GENERATOR VOLTAGE Connect: PCM C176c. Disconnect: Lower Generator C1251a. Connect: Upper Generator C102a. Key in START position. NOTE: After starting the engine, wait at least 2 minutes for the glow plugs to stop cycling. With the engine running, measure the voltage at the battery. Is the voltage greater than 13 volts? Yes : GO to T7. No : INSTALL a new upper generator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . CLEAR the DTCs. TEST the system for normal operation.
7. T7 CHECK THE UPPER GENERATOR OUTPUT With the lower generator connector C1251a disconnected, check the upper generator output. Refer to Component Tests, «GENERATOR ON-VEHICLE TEST - LOAD TEST»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-general-information__generator-on-vehicle-test-load-test) . Is the upper generator OK? Yes : The system is operating normally. CONNECT all the connectors, CLEAR the DTCs. TEST the system for normal operation. No : INSTALL a new upper generator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . CLEAR the DTCs and TEST the system for normal operation.
8. T8 CHECK FOR CORRECT PCM OPERATION Disconnect all the PCM connectors. Check for: corrosion pushed-out pins Connect all the PCM connectors and make sure they seat correctly. Operate the system and verify the concern is still present. Is the concern still present? Yes : INSTALL a new PCM. REFER to «ELECTRONIC ENGINE CONTROLS - GASOLINE ENGINES»(/ford/cutaway-e350/2004-2007/remont/removal-installation/#electronic-engine-controls-diesel-engine-e350-e450) . CLEAR the DTCs. REPEAT the self-test. No : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test.

Scheme 73

1. U1 CHECK THE LOWER GENERATOR CONNECTIONS Key in OFF position. Disconnect: Lower Generator C1251c, C1251a. Check the lower generator connectors for damage and correct connection. Connect: Lower Generator C1251c, C1251a. Are the lower generator connectors OK and correctly connected? Yes : GO to U2. No : REPAIR the connectors as necessary. CLEAR the DTCs. TEST the system for normal operation.
2. U2 CHECK THE LOWER GENERATOR B+ VOLTAGE Measure the voltage between the B+ terminal of the lower generator and ground. Is the voltage equal to battery voltage? Yes : GO to U3. No : CHECK the B+ circuit 2037 (RD) including the fusible links. REPAIR as necessary. CLEAR the DTCs. TEST the system for normal operation.
3. U3 CHECK THE LOWER GENERATOR A CIRCUIT Disconnect: Lower Generator C1251a. Measure the voltage between the lower generator harness C1251a-3, A circuit 35 (OG/LB), harness side and ground. Is the voltage greater than 10 volts? Yes : GO to U4. No : CHECK lower generator A circuit 35 (OG/LB) including the fusible links. REPAIR as necessary. CLEAR the DTCs. TEST the system for normal operation.
4. U4 CHECK THE LOWER GENERATOR I CIRCUIT FOR VOLTAGE Key in ON position. NOTE: Wait at least 2 minutes for the glow plugs to stop cycling. With the key in the ON position, and the engine OFF, measure the voltage between the lower generator C1251a-1, circuit 1183 (WH/YE), harness side and ground. Is the voltage greater than 10 volts? Yes : GO to U6 . No : GO to U5
5. U5 CHECK THE LOWER GENERATOR I CIRCUIT FOR AN OPEN OR A SHORT TO GROUND Key in OFF position. Disconnect: PCM C176c. Key in ON position. With the key in the ON position and the lower generator C1251a disconnected, measure the resistance between the lower generator C1251a-1, I circuit 1185 (YE), harness side and the PCM C176c-4, circuit 1183 (WH/YE), harness side; and between the lower generator C1251a-1, I circuit 1183 (WH/YE) harness side and ground. Is the resistance less than 5 ohms between the generator and the PCM; and greater than 10,000 ohms between the generator and ground? Yes : GO to U8. No : REPAIR the I circuit 1185 (YE)/1183 (WH/YE). CLEAR the DTCs. TEST the system for normal operation.
6. U6 CHECK THE LOWER GENERATOR VOLTAGE Connect: PCM C176c. Disconnect: Upper Generator C102a. Connect: Lower Generator C1251a. Key in START position. NOTE: After starting the engine, wait at least 2 minutes for the glow plugs to stop cycling. With the engine running, measure the voltage at the battery. Is the voltage greater than 13 volts? Yes : GO to U7. No : INSTALL a new lower generator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . CLEAR the DTCs. TEST the system for normal operation.
7. U7 CHECK THE LOWER GENERATOR OUTPUT With the upper generator still disconnected, check the lower generator output. Refer to Component Tests, «GENERATOR ON-VEHICLE TEST - LOAD TEST»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-general-information__generator-on-vehicle-test-load-test) . Is the lower generator OK? Yes : The system is operating normally. CONNECT all the connectors, CLEAR the DTCs. TEST the system for normal operation. No : INSTALL a new lower generator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . CLEAR the DTCs. TEST the system for normal operation.
8. U8 CHECK FOR CORRECT PCM OPERATION Disconnect all the PCM connectors. Check for: corrosion pushed-out pins Connect all the PCM connectors and make sure they seat correctly. Operate the system and verify the concern is still present. Is the concern still present? Yes : INSTALL a new PCM. REFER to «ELECTRONIC ENGINE CONTROLS - GASOLINE ENGINES»(/ford/cutaway-e350/2004-2007/remont/removal-installation/#electronic-engine-controls-diesel-engine-e350-e450) . CLEAR the DTCs. REPEAT the self-test. No : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test.

Scheme 74

1. V1 CHECK THE LOWER GENERATOR I CIRCUIT FOR A SHORT TO B+ Key in OFF position. Disconnect: PCM C176c. Disconnect: Lower Generator C1251a. Key in ON position. With the key in the ON position, and the engine OFF, measure the voltage between the powertrain control module (PCM) C176c-4, circuit 1185 (YE), harness side and ground. Is the voltage greater than 0 volts? Yes : REPAIR the I circuit 1185 (YE) for a short to B+. CLEAR the DTCs. TEST the system for normal operation. No : GO to V2
2. V2 CHECK THE LOWER GENERATOR I CIRCUIT Key in OFF position. Connect: Lower Generator C1251a. Connect: PCM C176c. Key in START position. NOTE: After starting the engine, wait at least 2 minutes for the glow plugs to stop cycling. With the key in the ON position, and the engine running, measure the voltage between C1251a-1, I circuit 1183 (WH/YE), harness side and ground. Is the voltage greater than 0 volts? Yes : GO to V4 . No : GO to V3
3. V3 CHECK THE PCM OPERATION Key in OFF position. Connect: PCM C176c. Key in ON position. With the key in the ON position, and the engine OFF and lower generator C1251a still disconnected, carry out a glow plug test with the diagnostic tool (See «INTRODUCTION - GASOLINE»(/ford/cutaway-e350/2004-2007/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) and/or «INTRODUCTION -- 6.0L DIESEL»(/ford/cutaway-e350/2004-2007/remont/testing-diagnostics/#engine-controls-introduction-60l-diesel) articles for the test procedures). Measure the voltage at the lower generator C1251a-1, I circuit 1183 (WH/YE) harness side and ground while carrying out the glow plug test. Is the voltage greater than 0 volts with the glow plugs on? Yes : GO to V4. No : INSTALL a new lower generator. REFER to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . CLEAR the DTCs. TEST the system for normal operation.
4. V4 CHECK FOR CORRECT PCM OPERATION Disconnect all the PCM connectors. Check for: corrosion pushed-out pins Connect all the PCM connectors and make sure they seat correctly. Operate the system and verify the concern is still present. Is the concern still present? Yes : INSTALL a new PCM. REFER to «ELECTRONIC ENGINE CONTROLS - GASOLINE ENGINES»(/ford/cutaway-e350/2004-2007/remont/removal-installation/#electronic-engine-controls-diesel-engine-e350-e450) . CLEAR the DTCs. REPEAT the PCM self-test. No : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test.

Battery - Drain Testing

Check for current drains on the battery in excess of 50 milliamps with all the electrical accessories off and the vehicle at rest. Current drains can be tested with the following procedure.

Note. Many modules draw 10 mA (0.010 amp) or more continuously.

Note. Use an in-line ammeter between the battery positive or negative post and its respective cable.

Note. Typically, a drain of approximately 1 amp can be attributed to an engine compartment lamp, glove compartment lamp, or interior lamp staying on continuously. Other component failures or wiring shorts may be located by selectively pulling fuses to pinpoint the location of the current drain. When the current drain is found, the meter reading will fall to an acceptable level. If the drain is still not located after checking all the fuses, it may be due to the generator.

Note. To accurately test the drain on a battery, an in-line digital ammeter must be used. Using a test lamp or voltmeter is not an accurate method due to the number of electronic modules.

1. Make sure engine compartment and interior fuse panels are accessible without turning on interior and underhood lamps.
2. Drive the vehicle at least 5 minutes at over 30 mph to turn on and activate the vehicle systems.
3. Allow vehicle to sit with the key off for at least 45 minutes to allow modules to time out/power down.
4. Connect a jumper wire between the negative battery cable and negative battery post to prevent modules from resetting and to catch capacitive drains.
5. Disconnect the negative battery cable from the post without breaking the connection of the jumper wire.
6. Connect the tester between the negative battery cable and the post. The meter must be capable of reading milliamps and should have a 10 amp capability.
7. Remove the jumper wire.
8. No production vehicle should have more than 50 mA draw.
9. If the draw is found to be excessive, pull the fuses from the interior fuse panel one at a time and note the current drop. Do not reinstall the fuses until you are finished testing.
10. If the draw is still excessive, remove the fuses from the engine compartment fuse panel one at a time and note the current drop. Do not reinstall the fuses until you are finished testing.
11. Check the wiring schematic in the wiring diagram for any circuits that run from the battery without passing through the battery junction box (BJB). Disconnect these circuits if the draw is still excessive.

1. Repeat the steps of the battery drain testing.
2. Make sure all the doors are closed and accessories are off. Without starting the engine, turn the key to the ON position 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 circuit.

Note. Battery posts and cable clamps must be clean and tight for accurate meter indications.

Note. Refer to battery tester manual for complete directions on checking out the charging system.

1. Turn off all lamps and electrical components.
2. Place the vehicle in NEUTRAL and apply the parking brake.
3. Carry out the Load Test and No-Load Test according to the following component tests.

Generator On-Vehicle Test - Load Test

1. Switch the tester to the ammeter function.
2. Connect the positive and negative leads of the tester to the corresponding battery terminals.
3. Connect the current probe to the generator B+ output lead, circuit 1119 (RD) (single or upper generator, diesel), or circuit 2037 (RD) (lower generator, diesel).
4. With the engine running at 2,000 rpm, adjust the tester load bank to determine the output of the generator. The generator output should be at least 87 amps. Refer to the «Symptom Chart»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-general-information__symptom-chart) for diagnostic procedures.
5. With the engine running, turn the A/C on (if equipped), the blower motor on high, and the headlamps on high beam.
6. Increase the engine speed to approximately 2,000 rpm. The voltage should increase a minimum of 0.5 volt above the base voltage. Backprobe the I circuit at the generator connector (connector plugged in) and measure the I circuit voltage. If the voltage is less than 2 volts, install a new generator. Refer to «GENERATOR AND REGULATOR»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-generator-and-regulator) . If the voltage does not increase as specified, carry out the «GENERATOR ON-VEHICLE TEST - No-Load Test»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-general-information__generator-on-vehicle-test-no-load-test) . If the voltage increases as specified, the charging system is operating normally. Proceed to the following battery tests.

Generator On-Vehicle Test - No-Load Test

1. Switch the tester to the voltmeter function.
2. Connect the voltmeter positive lead to the generator B+ terminal and the negative lead to ground.
3. Turn all electrical accessories off.
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, GO to «SYMPTOM CHART»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-general-information__symptom-chart) or refer to the «PINPOINT TEST»(/ford/cutaway-e350/2004-2007/remont/charging-system/#charging-system-general-information__pinpoint-tests) for diagnostic procedures.

See also:
• ACCESSORY DRIVE
• BATTERY, MOUNTING AND CABLES
• GENERATOR AND REGULATOR
• ENGINE SYSTEM-GENERAL INFORMATION
• ENTERTAINMENT SYSTEM - GENERAL INFORMATION
• MODULE COMMUNICATIONS NETWORK
• INTRODUCTION - GASOLINE
• INTRODUCTION -- 6.0L DIESEL
• ELECTRONIC ENGINE CONTROLS - GASOLINE ENGINES
• SYMPTOM CHART
• PINPOINT TEST A
• PINPOINT TEST B
• PINPOINT TEST C
• PINPOINT TEST F
• PINPOINT TEST G
• PINPOINT TEST H
• PINPOINT TEST
• PINPOINT TEST Q
• PINPOINT TEST M
• PINPOINT TEST N
• PINPOINT TEST P
• PINPOINT TEST R
• PINPOINT TEST S
• GENERATOR ON-VEHICLE TESTS
• BATTERY - DRAIN TESTING
• GENERATOR ON-VEHICLE TEST - LOAD TEST
• GENERATOR ON-VEHICLE TEST - No-Load Test