Battery - Test; Charging System - Test - Perkins 1204F-E44TA Systems Operation Testing And Adjusting

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Electrical System
e. The current is below 0.015 amperes. The
alternator is operating correctly. There is an
electrical load on the machine. Go to step 8.
f. The current is above 0.015 amperes. There is
an internal fault with the alternator. Replace the
alternator. Refer to Disassembly and Assembly,
"Alternator - Remove and Install" for the correct
procedure.
8. Turn off all electrical accessories. Turn the
keyswitch to the OFF position.
a. Connect a current probe or an ammeter to a
digital multimeter. Ensure that the probe is
zeroed. Clamp the current probe or an ammeter
to the main ground cable. Clamp the tool with
the positive side away from the battery.
b. Monitor the current and remove the fuses and
circuit breakers one at a time. Check the current
after each fuses or each of the circuit breakers
are removed. After removing a fuse and
checking the current, replace the fuse. Start with
the main fuses and proceed to the smaller
circuits.
c. If removing a fuse causes a current drop, then
the problem is within that circuit.
d. Check if any components on the circuit are on.
e. If all components are switched off, disconnect
electrical components on that circuit one at a
time and monitor the current.
f. After all components on the circuit have been
disconnected, check the current. If the problem
still exists, check the wiring for corrosion. Check
if there is a short to ground.
Note: The standard current is 0.05 amperes. A
current value above this figure usually indicates a
problem. However, some large machines with
multiple control modules have a higher acceptable
limit.

Battery - Test

Most of the tests of the electrical system can be done
on the engine. The wiring insulation must be in good
condition. The wire and cable connections must be
clean, and both components must be tight.
This document has been printed from SPI2. NOT FOR RESALE
Never disconnect any charging unit circuit or bat-
tery circuit cable from the battery when the charg-
ing unit is operated. A spark can cause an
explosion from the flammable vapor mixture of
hydrogen and oxygen that is released from the
electrolyte through the battery outlets. Injury to
personnel can be the result.
The battery circuit is an electrical load on the
charging unit. The load is variable because of the
condition of the charge in the battery.
The charging unit will be damaged if the connections
between the battery and the charging unit are broken
while the battery is being charged. Damage occurs
because the load from the battery is lost and because
there is an increase in charging voltage. High voltage
will damage the charging unit, the regulator, and oth-
er electrical components.
The correct procedures to test the battery can be
found in the manual that is supplied by the OEM.

Charging System - Test

The condition of charge in the battery at each regular
inspection will show if the charging system is
operating correctly. An adjustment is necessary when
the battery is constantly in a low condition of charge
or a large amount of water is needed. A large amount
of water would be more than 28 mL (1 oz) per cell
per week or per every 100 service hours. There are
no adjustments on maintenance free batteries.
When it is possible, make a test of the charging unit
and voltage regulator on the engine, and use wiring
and components that are a permanent part of the
system. Off-engine testing or bench testing will give a
test of the charging unit and voltage regulator
operation. This testing will give an indication of
needed repair. After repairs are made, perform a test
in order to prove that the units have been repaired to
i01899136
the original condition of operation.
Alternator
The charging rate of the alternator should be
checked when an alternator is charging the battery
too much or not charging the battery enough.
UENR4490-01
NOTICE
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