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Heavy Duty Alternator Charging System Troubleshooting
Technical Assistance 800-372-0222
Alternator Charging System Troubleshooting
12345
Perform Visual Inspection
TroubleshootingComplete
MeasureVoltage at Battery
TestAlternator Output
Troubleshoot perService Manual
Inspect BatteryBattery Voltage Test
Battery Load Test
Squealing noises under the hood?
Headlight bulbs blow out repeatedly or dim?
Is the dash voltmeter gauge out of range - either too high or too low? These are common indicators that something may be wrong with the charging system. If any of these symptoms are evident, then follow these five steps to pinpoint the issue.
Helpful Hint: If you find something wrong at any step, it’s wise to complete the remaining steps anyway to ensure you’ve given the charging system a thorough review.
Visit http://tinyurl.com/delcoremyvideosto watch our Tech Tip videos
Visit http://tinyurl.com/delcoremyvideos to watch the Alternator Charging System Tech Tip video
1 Perform Visual Inspection
Perform a visual inspection under the hoodLook at the belt tension and condition. Next, check electrical connections and cables for corrosion and proper tightness. Finally, make sure the alternator is mounted properly.
Perform Repairs
Visual InspectionsComplete
Perform Repairs
Perform Repairs
BeltTension andCondition
OK?
ElectricalConnections
OK?
AlternatorMounted
OK?
No
Yes
No
Yes
No
Yes
Technical Assistance 800-372-0222
2.A Inspect Batteries
Visually inspect and test the batteriesInspect the batteries for any signs of physical damage, cracks in the casing, loose terminals or leaking fluid. Clean, repair connection and replace any damaged batteries found. Ensure that all batteries used in the same circuit are of the same manufacturer, CCA rating type and age. Then test the batteries using a standard battery test. Remember that realistic testing, as well as successful operation, requires a fully charged battery, capable of supplying the starting system’s current needs.
Perform Repairs
Visual InspectionComplete
Replace Battery
Perform BatteryVoltage Test
Corrosionor Loose
Connections?
BatteryDamaged?
Yes
Yes
No
No
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Battery VoltageTest Complete
Recharge Battery
Perform BatteryLoad Test
Connect Voltmeterto Battery
With Engine Off, Remove Surface Chargeand Wait Two Minutes
MeasureVoltage
< 12.4 Volts
≥ 12.4 Volts
DC AMP DC VOLTS
12.4
2.B Battery Voltage Test
Test the batteries using a standard battery test. Remember that realistic testing, as well as successful operation, requires a fully charged battery, capable of supplying the starting system’s current needs.
Visit http://tinyurl.com/delcoremyvideos to watch the Alternator Charging System Tech Tip video
Technical Assistance 800-372-0222
2.C Battery Load Test
Battery LoadTest Complete
Replace Battery
Battery Passes
Connect Carbon Pileand Voltmeter
to Battery
Adjust Carbon Pile toOne-half the Cold CrankingAmp Rating for 15 Seconds
RecordLowestVoltage
< MinimumLoaded Voltage
≥ Minimum Loaded Voltage
12.5
Visit http://tinyurl.com/delcoremyvideos to watch the Alternator Charging System Tech Tip video
Visit http://tinyurl.com/delcoremyvideos to watch the Alternator Charging System Tech Tip video
3.A Measure Voltage at Battery
Fig 1. With the engine running, use a voltmeter to measure voltage at the battery. If voltage is greater than or equal to 13.8 volts, you can move on to Step 4.
Fig 2. However, if it is less than 13.8 volts, then you should measure voltage at Alternator B+ and the alternator case. (Note: If the model is insulated, you have to use a ground stud to get a reading.)
At that point, if the voltage falls between 12.6 and 13.7 volts, you need to replace your alternator. If it’s greater than or equal to 13.8 volts, a voltage drop test needs to be performed.
Learn how to perform a voltage drop test by visiting our YouTube page and watching our Tech Tip - Voltage Drop Test video. Link: tinyurl.com/delcoremyvideos.
Fig 1
Fig 2
DC AMP DC VOLTS
13.0
DC AMP DC VOLTS
12.4
Visit http://tinyurl.com/delcoremyvideos to watch the Alternator Charging System Tech Tip video
Visit http://tinyurl.com/delcoremyvideos to watch the Alternator Charging System Tech Tip video
Technical Assistance 800-372-0222
3.B Measure Voltage at Battery
Voltage at BatteryMeasured
Connect Voltmeter toAlternator B+ and
Ground Post
Perform VoltageDrop Test
Connect Voltmeterto Battery
Turn Engine On
MeasureBatteryVoltage
MeasureVoltage
ReplaceAlternator
< 13.8 Volts
12.6 to 13.7 Volts
≥ 13.8 Volts
≥ 13.8 Volts
Visit http://tinyurl.com/delcoremyvideos to watch the Alternator Charging System Tech Tip video
You can use either an automated tester or a manual process to determine the output of the alternator. If the alternator doesn’t pass this test, then it needs to be replaced.
4 Test Alternator Output
Alternator OutputTest Complete
Replace Alternator
Connect Carbon Pile,Ammeter and
Amp Clamp
Engine Running atGovernor Speed andElectrical Loads Off
RecordOutput
Load Carbon Pile until Ammeter
Reads Highest Value
< 90% of Rated Capacity
≥ 90% of Rated Capacity
Visit http://tinyurl.com/delcoremyvideos to watch the Alternator Charging System Tech Tip video
Technical Assistance 800-372-0222
If you’ve passed through the first four steps, then the alternator is working as designed and your problem is likely caused by something external to the alternator.
5 Troubleshoot Using the Service Manual
12345
Perform Visual Inspection
TroubleshootingComplete
MeasureVoltage at Battery
TestAlternator Output
Troubleshoot perService Manual
Inspect BatteryBattery Voltage Test
Battery Load Test
Remy International, Inc.600 Corporation DrivePendleton, IN 46064 USAFor Technical Assistance call 1-800-372-0222
Delco Remy is a registered trademark of General Motors Corporation, icensed to Remy Inc., Pendleton, IN 46064 ©2013 Remy International, Inc.
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