1993 DODGE TRUCK Service Repair Manual

8A
- 16
ELECTRICAL

CHARGING
SYSTEM DIAGNOSTICS

IMPROPER
CHARGING

CHECK
BATTERY CONDITION

SEE
BATTERY
SECTION
FOR
DETAILS

CORRODED

BATTERY CABLES OR TERMINALS
DRIVE BELTS
LOOSE
LOOSE
OR

CORRODED
WIRING
CONNECTIONS
AT
GENERATOR

LOOSE
OR

CORRODED
WIRING
CONNECTIONS
AT
TERMINAL BLOCK

LOOSE

CHASSIS
TO

BATTERY GROUND
CABLE

LOOSE

GENERATOR
GROUND WIRE

LOOSE
OR

CORRODED
WIRING
CONNECTIONS
AT
BULKHEAD
DISCONNECT

CHECK
FOR

APPROXIMATELY
12 VOLTS
AT
FIELD
INPUT
BRUSH
TERMINAL
WIHT

IGNITION
SWITCH
"ON"
UNS'

OR
CHAF rEADY
LOW
K3ING
TEST
GENERATOR

OUTPUT
WIRE
RESISTANCE

CHARGING

RESISTANCE
TOO
HIGH

CORRODED
OR

SHORTED CABLES OR
HIGH

RESISTANCE

ACROSS
FUSIBLE LINK

RESISTANCE
O.K.
TEST
GENERATOR CURRENT
OUTPUT

CURRENT
OUTPUT
O.K.

REFER
TO

USING ON-BOARD DIAGNOSTIC SYSTEM
o

CHAR
/ER

.GING
GROUNDED
GENERATOR FIELD WIRE, FIELD
TERMINAL,
OR

CONNECTIONS
1 NO
1
ALTERf

ISY

MATOR

WORN
OR
FRAYED
DRIVE BELT

REFER
TO

USING ON-BOARD DIAGNOSTIC SYSTEM GENERATOR

MOUNTING
LOOSE

FAULTY

GENERATOR
FAULTY

GENERATOR •FOR MORE INFORMATION REFER
TO

THE POWERTRAIN DIAGNOSTIC PROCEDURES
MANUAL COVERING
THE
VEHICLE INVOLVED

*SEE
GROUP
8W,
WIRING DIAGRAMS
FOR

CIRCUIT
AND
COMPONENT INFORMATION

FAULTY

GENERATOR

J938A-V0

•

ELECTRICAL
8A - 17
DIAGNOSTIC
TROUBLE
CODES

Diagnostic trouble codes are 2 digit numbers
flashed on Malfunction Indicator lamp (Check En­
gine) that identify which circuit is bad. In most cases
they do not identify which component in a circuit is
bad. A DTC description can be read using the DRB II scan tool. Refer to Group 14 - Fuel Systems for more
information. Therefore, a DTC is only a result, not
necessarily the reason for the problem. However, in
some cases, as a result of the design of the driveabil- ity test procedure, a DTC can be the reason for the
problem. It is important that the test procedure be followed in order to understand what the DTC of the
on-board diagnostic system are trying to tell.

HOW
TO
USE
MALFUNCTION
INDICATOR
(CHECK

ENGINE)
LAMP
FOR
FAULT
CODES
To activate this function cycle the ignition switch
on-off-on-off-on within 5 seconds and any DTC stored
in the Powertrain Control Module will be displayed.
The Check Engine lamp will display a DTC by flash­ ing on and off. There is a short pause between
flashes and a longer pause between digits. All codes
displayed are two digit numbers with a four second
pause between codes. An example of a code is as follows:
(1) Lamp on for 2 seconds, then turns off.
(2) Lamp flashes 4 times pauses and then flashes

1.
(3) Lamp pauses for 4 seconds, flashes 4 times,
pauses and then flashes 7 times.
The two codes are 41 and 47. Any number of codes
can be displayed (maximum of 8 faults can be stored) as long as they are in memory. The lamp will flash
until all of them (including 55) are displayed (55 =
End of test).

CHARGING
SYSTEM
FAULT
CODES
See Generator Fault Code Chart for fault codes
which apply to the charging system. Refer to the
Powertrain Diagnostic Procedures Manual to diag­
nose an On-Board Diagnostic System, Fault Code.
GENERATOR
DIAGNOSTIC
TROUBLE
CODE
(DTC)

DTC
Type
Malfunction

Indicator
Lamp
Circuit
When
Monitored

By
the
Logic

Module
When
Put Into
Memory
Actuator

Test
Sensor

Read
Test

41 Fault
Yes
Generator Field

Control
(Charging
System)
All the
time
when
the ignition switch

is
on.
An
open or shorted condition in
the generator
field

control circuit.
Yes

None

46 Fault
Yes
Charging
System

Voltage
All the
time
when the

engine
is
running.
If the
battery
sense
voltage is
more than 1 volt
above
the

desired
control voltage for
more than 20
seconds.
None

Yes

47 Fault
Yes
Charging
System

Voltage
Engine
rpm
above

1,500 rpm Battery voltage
1
volt
less

than set point during engine
operation and no
change
in

voltage
during
internal
PCM
test performed on generator field.
None

Yes

J938A-20

8A
- 18
ELECTRICAL

• BATTERY SPECIFICATIONS

Load

Test

(Amps)
Cold

Cranking
Rating @ 0°F Reserve
Capacity
300 Amp 600 Amp 120 Minutes
405 Amp 810 Amp 133 Minutes
535 Amp 1075 Amp 170 Minutes

CRANKING
RATING
is the
current
a
battery
can deliver for 30
seconds
and maintain a
terminal
voltage of 7.2 volts or greater at specified
temperature.

RESERVE
CAPACITY RATING
is the length of
time
a
battery
can deliver 25 amps and maintain a minimum
terminal
voltage of 10.5 volts
at27°C
(80 °F).
J938A-25 GAS ENGINE STARTER
DIESEL ENGINE STARTER
Manufacturer
Nippondenso

Engine
Application 5.9L, 5.21 e\ 3.9L
Part Number and
53005984

Power Rating 1.4 Kw
Voltage 12

No.
of Fields 4

No.
of
Poles.
4

Brushes
4
Drive Reduction
Gear Train

Free
Running Test Voltage 11
Amperage Draw ............ 73
Amps

Minimum Speed rpm 3601 rpm

Solenoid
Closing
Voltage 7.5 Volts
Cranking Amperage Draw Test . . .
125-200
Amps*

*
Engine
should
be up to operating
temperature.
Extremely heavy oil or tight engine
will
increase
starter
amperage draw.
J938B-14
REDUCTION
GEAR
STARTER

Manufacturer
Nippondenso

Engine
Application 5.9L
Part Number and Power Rating ..............
4428221

3
kw
Voltage 12

No.
of Fields 4

No.
of
Poles
4

Brushes
.................... 4
Drive Conventional
Gear Train

Free
Running Test Voltage .
Amperage Draw
Minimum Speed rpm 11
220
Amps
Max.
4200
rpm Min.

Solenoid
Closing
Voltage. 8 Volts
Cranking Amperage Draw Test . .
450-550
Amps*

*
Engine
should be up to operating heavy oil or tight engine
will
increase
temperature.
Extremely

starter
amperage draw. J918B-21

SPECIFICATIONS

•

ELECTRICAL
8A - 19
GENERATOR SPECIFICATIONS

TYPE

PART
NUMBER
PULLEY
GROOVES ENGINE

RATING

NIPPONDENSO
53008646 7
ALL GASOLINE

75
AMPS
NIPPONDENSO
53008647

7
ALL GASOLINE

90
AMPS
NIPPONDENSO
53008651 7
ALL GASOLINE
120
AMPS
NIPPONDENSO
5234374

8
DIESEL

120
AMPS

J938B-28

• BATTERY/STARTER/GENERATOR
SERVICE
8B - 1

CONTENTS

page page

BATTERY
SERVICE
PROCEDURES
1 SPECIFICATIONS 9

GENERATOR
SERVICE
6 STARTER
SERVICE
PROCEDURES
4

BATTERY SERVICE PROCEDURES

GENERAL
INFORMATION This section will cover the Battery service, re­
moval, and installation procedures only. For diagnos­
tic procedures, see Group 8A - Battery/Starting/ Charging Systems Diagnostics. The Maintenance Free Battery (Fig. 1) does not
have removable battery cell caps. Water can not be added to this battery. The battery is sealed, except
for small vent holes in the top. The chemical compo­ sition inside of the battery produces an extremely
small amount of gases at normal charging voltages.
The battery is equipped with a test indicator (Fig. 1)
that display colored balls to indicate battery
state-of-
charge. Green Indicator = Full charge
Black Indicator = Discharged
Yellow Indicator = Battery replacement required Fig. 1 Maintenance Free Battery

BATTERY
VISUAL INSPECTION AND
SERVICE
(1) Make sure ignition switch is on OFF position
and all battery feed accessories are OFF. (2) Disconnect and remove battery cables at bat­
tery. Remove NEGATIVE cable first.
WARNING: WEAR
A
SUITABLE PAIR
OF
RUBBER

GLOVES
(NOT THE
HOUSEHOLD TYPE) WHEN
RE­
MOVING
A
BATTERY
BY
HAND. SAFETY
GLASSES

SHOULD ALSO
BE
WORN.
IF THE
BATTERY
IS

CRACKED
OR
LEAKING
THE
ELECTROLYTE
CAN
BURN
THE
SKIN
AND
EYES.

(3) Remove battery hold down (Fig. 2) and remove
battery from vehicle. Fig. 2 Battery
Holddown
BATTERY/STARTER/GENERATOR
SERVICE

8B
- 2
BATTERY/STARTER/GENERATOR SERVICE

• (4) Clean top of battery with a solution of clean
warm water and baking soda. Scrub area with a stiff
bristle brush and wipe off with a cloth moistened
with ammonia or baking soda in water (Fig. 3). be necessary to clean area with same solution de­
scribed in Step (4) (Fig. 4).
(7) Clean battery post with a suitable battery post
cleaning tool (Fig. 5).
TERMINAL

BRUSH

TEST
INDICATOR

BATTERY Fig.
3
Cleaning
Battery
CAUTION:
Care should
be
taken
to
ensure
that

solution
does
not
enter
vent holes.

(5) Inspect battery case and cover for cracks or
leakage. If cracks or leakage is present, battery must
be replaced.
(6) Inspect battery tray for damage caused by loss
of acid from battery. If acid damage is present it will J928B-30

Fig.
5
Cleaning
Battery
Post
(8)
Clean inside surfaces of terminal clamps with a
suitable battery terminal cleaning tool (Fig. 6). Re­
place damaged or frayed cables and broken terminal clamps.
BATTERY
CABLE
WASHER

NUT

BATTERY
HOLD
DOWN

HOLD DOWN STUD HOLD
DOWN
STUD
BATTERY TRAY

J928B-3f A

Fig.
4
Battery
Tray
J908B-13
Fig.
6
Cleaning
Battery
Cable Terminal

•

BATTERY/STARTER/GENERATOR
SERVICE
8B - 3

Fig.
7
Battery
Cables
Disconnected
(9) Inspect battery for proper or damaged hold
down ledge.
(10) Install battery in vehicle making sure that
battery is properly positioned on battery tray (Fig.
2).

(11) Install battery hold down clamp, making sure
that it is properly positioned on battery. Tighten bolt
to 12 N-m (100 in. lbs.). (12) Place felt oil washer onto Positive
(
+
)
battery
post. (13) Connect cable clamps to battery post making
sure top of clamp is flush with top of post (Fig. 7). (14) Tighten clamp nut securely.