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Output Current Test (2.4L DOCH)

This test determines if the generator output current is normal.

WARNING: Never use clips to connect the line. Use bolts and nuts otherwise loose connections (e.g. using clips) may lead to a serious accident and personal injury because of the high current.
NOTE: The battery used should be slightly discharged. The load needed by a fully-charged battery is insufficient for an accurate test.
NOTE: An inductive-type ammeter which enables measurements to be taken without disconnecting the generator output wire is recommended.
NOTE: If the voltage is 0 V, the cause is probably an open circuit in the wire or fusible link between the generator "B" terminal and the battery (+) terminal.
NOTE: For the nominal current output, refer to the Generator Specifications. Because the current from the battery will soon drop after the engine is started, Step #10 should be carried out as quickly as possible in order to obtain the maximum current output value. The current output value will depend on the electrical load and the temperature of the generator body. If insufficient electrical load is used while testing, the specified level of current may not be output even though the generator is normal. In such case, increase the electrical load by leaving the headlights on with the engine off to discharge the battery before testing. The specified level of current also may not be output if the temperature of the generator body and/or ambient temperature is too high. In such cases, allow the generator to cool before testing.
  1. Before testing, be sure to check the following:
    • Generator installation and wiring connections. See Fig 1.
      Fig 1: Checking Output Current Test
      G00312657Courtesy of KIA MOTORS AMERICA, INC.
    • Battery.
    • Generator drive belt tension.
    • Fusible link.
    • Abnormal noise from the generator while the engine is running.
  2. Turn the ignition switch to the "OFF" position.
  3. Disconnect the negative battery cable.
  4. Disconnect the generator output wire from the generator "B" terminal. Connect a DC test ammeter with a range of 0-100A in series between the "B" terminal and the disconnected output wire. (Connect the (+) lead of the ammeter to the "B" terminal. Connect the (-) lead of the ammeter to the disconnected output wire.)
  5. Connect a voltmeter with a range of 0-20 V between the generator "B" terminal and the ground. (Connect the (+) lead of the voltmeter to the "B" terminal, and then connect the (-) lead of the voltmeter to the ground)
  6. Connect the negative battery cable.
  7. Connect a tachometer or the scan tool.
  8. Leave the hood open.
  9. Check that the reading on the voltmeter is equal to battery voltage.
  10. Start the engine, and turn the headlights on.
  11. Switch the headlights to high beam, turn the heater blower switch to High, increase the engine speed to approx. 2,500 r/min, and read the maximum current output displayed on the ammeter. Limit: 70% of nominal output current
  12. The reading on the ammeter should be above the limit value. If the reading is below the limit value and the generator output wire is normal, remove the generator from the engine and check the generator.
  13. Run the engine at idle speed after the test.
  14. Turn the ignition switch to the "OFF" position.
  15. Disconnect the tachometer or the scan tool.
  16. Disconnect the negative battery cable.
  17. Disconnect the ammeter and voltmeter.
  18. Connect the generator output wire to the generator "B" terminal.
  19. Connect the negative battery cable.
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