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HOMESERVICE MANUALSCHEVROLET2000CHEVY EXPRESS G3500, VAN CARGO EXTENDED, 6.5 FREPAIR AND DIAGNOSIS (SINGLE PAGE)ELECTRICALCHARGING SYSTEMSON-VEHICLE TESTINGCHARGING SYSTEM TEST
2000 Chevrolet Chevy Express G3500, Van Cargo Extended, 6.5 F

Charging System Test

2000 Chevrolet Chevy Express G3500, Van Cargo Extended, 6.5 FSECTION Charging System Test
  1. Start engine and observe charge indicator light on Instrument Panel Cluster (IPC). If charge indicator light illuminates, go to next step. If charge indicator light does not illuminate, problem is probably intermittent.
    2. NOTE: Green POWER lamp of tester should remain illuminated while tester is being used.
  2. Turn ignition off. Using CS Electronic Generator Tester (J41450-B), connect Red lead to generator output terminal and Black lead to metal generator housing. If Green POWER lamp is not on, go to next step. If Green power lamp is on, go to step  4 .
  3. Using a DVOM, measure voltage between output terminal of generator and battery negative terminal. If battery voltage exists, go to step  10 . If battery voltage does not exist, go to step  9 .
    4. CAUTION: Make sure load is completely turned off before connecting or disconnecting carbon pile load tester to battery.
  4. Connect carbon pile tester to battery. Connect inductive ammeter to output circuit of generator. Disconnect generator harness connector. Locate matching harness connector on CS Electronic Generator Tester (J41450-B) and connect it to generator. If Red DIAGNOSTIC lamp is on, go to next step. If Red DIAGNOSTIC lamp is off, go to step  11 .
  5. Start engine and allow to idle for 30 seconds. Increase engine speed to 2500 RPM. If Red DIAGNOSTIC lamp is off, go to next step. If Red DIAGNOSTIC lamp is on, go to step  11 .
  6. Maintain engine speed at 2500 RPM. Turn on load of carbon pile tester and increase load until load is equal to test value of generator (K60 is 70 amps; K68 is 73 amps; KW2 is 86 amps; KG9 is 98 amps). If Red DIAGNOSTIC lamp is not on, go to next step. If Red DIAGNOSTIC lamp is on, go to step  11 .
  7. Maintain engine speed at 2500 RPM and continue to operate generator at load test value. Using a DVOM, measure voltage drop between generator output terminal and positive battery terminal. If voltage drop is less than 0.5 volt, go to next step. If voltage drop is more than 0.5 volt, go to step  9 .
  8. Maintain engine speed at 2500 RPM and continue to operate generator at load test value. Using a DVOM, measure voltage drop between generator metal housing and negative battery terminal. If voltage drop is less than 0.5 volt, go to step  12 . If voltage drop is more than 0.5 volt, go to step  10 .
  9. Repair high resistance or open in Black wire between generator output terminal and positive battery terminal. See WIRING DIAGRAMS  . Go to step  12 .
  10. Repair high resistance or open in ground circuit of generator. See WIRING DIAGRAMS  . Go to step  12 .
  11. Check generator connector for poor connections. If connector is good, replace generator. See GENERATOR  under REMOVAL & INSTALLATION. Go to next step.
  12. Retest system to verify repair.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.