1997 Ford Pickup F150

GENERATOR - MITSUBISHI 1997 STARTING & CHARGING SYSTEMS Ford Motor Co. - Generators - Mitsubishi

GENERATOR - MITSUBISHI

1997 STARTING & CHARGING SYSTEMS Ford Motor Co. - Generators - Mitsubishi

DESCRIPTION
The Mitsubishi 215-amp generator is an external-fan, brushless unit that is self-current limiting and temperature
compensating. The voltage regulator is internal and integral with the rear half of the generator.

ADJUSTMENTS
BELT TENSION

Inspect condition and tension of generator drive belt prior to performing any on-vehicle charging system tests.
Replace belt and/or repair tensioner mechanism if necessary.

TROUBLE SHOOTING

NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article in GENERAL

INFORMATION.

ON-VEHICLE TESTING
GENERAL INSPECTION

Ensure battery posts and cables are clean and tight. Check drive belt tension. Ensure connections at alternator,
regulator and engine ground are clean and tight. Check fusible links and replace as necessary.

Turn ignition on and ensure charge warning light operates. Check bulb and circuit if necessary. Start engine and
verify charge warning light goes out. If warning light goes out, see AMPERAGE OUTPUT TEST . If warning
light does not go out, see NO-LOAD TEST . There are 4 conditions that can cause charge indicator light to
come on:

No Generator Output

Overcharging

Generator Output Wire Open

Voltage Sensing Wire (Terminal "A" circuit) Open

Check 300-amp megafuse in B+ circuit. Check 20-amp "A" circuit fuse, located in power distribution box.

BASE VOLTAGE TEST

NOTE: Prior to performing BASE VOLTAGE TEST, turn on headlights for 10-15
seconds to remove any surface charge from battery.
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GENERATOR - MITSUBISHI 1997 STARTING & CHARGING SYSTEMS Ford Motor Co. - Generators - Mitsubishi

Ensure battery is in good condition and fully charged. Connect negative voltmeter lead to negative battery post,
and positive voltmeter lead to positive battery post. Record battery voltage. This measurement is base voltage.

VOLTAGE OUTPUT TEST

1. Ensure battery is fully charged. Turn ignition switch to RUN position and leave engine off. Battery
voltage should be present at terminals "B+" and "A" at alternator connector. Approximately one volt
should be present at terminal "I". If voltages are correct, go to next step. If voltages are not correct go to
step 3).
2. Start engine and run at 2000 RPM. With alternator connected, check voltage at terminals "B+", "A" and
"I". At terminals "B+" and "A", 14.1-14.7 volts should be present. At terminal "I", 13-14 volts should be
present (engine running). If voltages are not correct, go to next step. If voltages are correct, go to step 4).
3. Check 300-amp megafuse and 20-amp fuse in in "A" circuit. If fuses are okay, test "B+", "A" and "I"
circuits for opens, shorts and excessive resistance. Repair as necessary. If okay, go to next step.
4. Perform voltage drop test on "B+" circuit (between positive battery and terminal "B+" on alternator). If
voltage drops .5 volt or more, repair wire between terminal "B+" and positive battery. If voltage is still
not correct, repair or replace alternator.

OVERCHARGE TEST

1. Disconnect voltage regulator connector. Measure voltage at wiring harness connector terminal "A". See
Fig. 1 . If battery voltage is present, go to next step. If battery voltage is not present, check for blown fuse
or open circuit in "A" circuit wiring. 2) Check ground connections of alternator, engine and battery. If
ground connection are okay, repair or replace generator assembly.

Fig. 1: Identifying Regulator Harness Connector Terminals

Courtesy of FORD MOTOR CO.
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 1997 Ford Pickup F150
GENERATOR - MITSUBISHI 1997 STARTING & CHARGING SYSTEMS Ford Motor Co. - Generators - Mitsubishi

AMPERAGE OUTPUT TEST

1. Ensure drive belt is in good condition and properly tightened. Connect charging system load tester in
accordance with manufacturer's instructions. Start and run engine at 1500-2000 RPM and apply load until
alternator output levels off.
2. Maximum alternator output should be at least 160 amps. If alternator output is within 20 percent of rated
output amperage, alternator output is okay. If alternator does not produce rated output, go to NO-LOAD
TEST.

NO-LOAD TEST

1. Connect voltmeter positive lead to B+ terminal on generator and negative lead to ground. Start and run
engine at 2000 RPM with no electrical load (foot off brake and doors closed). Read voltmeter when
voltage stabilizes. This may require waiting a few minutes. Voltage should be 13-15 volts.
2. If voltage increases to proper level, proceed to AMPERAGE OUTPUT TEST . If voltage increases
beyond proper level, proceed to OVERCHARGE TEST . If there is no voltage increase, proceed to
VOLTAGE OUTPUT TEST .

CHARGING SYSTEM CIRCUIT TEST

1. Turn ignition off. Unplug 3-pin connector from generator. Turn ignition on. Connect jumper wire
between Light/Green Red wire at harness connector and ground. If charge indicator light comes on, go to
next step. If charge indicator light does not come on, repair Light Green/Red wire, by-pass resistor, or
charge indicator bulb.
2. Turn ignition off. Test for battery voltage at Yellow/White wire at 3-pin harness connector. If battery
voltage exists, go to next step. If battery voltage does not exist, repair Yellow/White wire between engine
compartment fuse panel and generator, or replace defective fuse "K".
3. Test for battery voltage at generator output stud. If battery voltage exists, replace generator. If battery
voltage does not exist, repair wire between output stud and battery, or replace defective 300-amp
megafuse, located beneath generator.

REMOVAL & INSTALLATION

CAUTION: When batteries are disconnected, vehicle computer and memory systems
may lose memory data. Driveability problems may exist until computer
systems have completed a relearn cycle. See COMPUTER RELEARN
PROCEDURES article in GENERAL INFORMATION before disconnecting
battery.

REMOVAL & INSTALLATION

Removal & Installation

Disconnect both negative battery cables. Disconnect wiring from generator. Disengage drive belt. Remove
attachment bolts and generator. Reverse removal procedure to install.

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 1997 Ford Pickup F150
GENERATOR - MITSUBISHI 1997 STARTING & CHARGING SYSTEMS Ford Motor Co. - Generators - Mitsubishi

BENCH TESTING & OVERHAUL

Manufacturer recommends generator be serviced only as an assembly.

WIRING DIAGRAMS

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 1997 Ford Pickup F150
GENERATOR - MITSUBISHI 1997 STARTING & CHARGING SYSTEMS Ford Motor Co. - Generators - Mitsubishi

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 1997 Ford Pickup F150
GENERATOR - MITSUBISHI 1997 STARTING & CHARGING SYSTEMS Ford Motor Co. - Generators - Mitsubishi

Fig. 2: Charging System Wiring Diagram

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