Heavy Duty Alternator

Charging System Troubleshooting

 Alternator Charging System Troubleshooting

1
Squealing noises under the
hood? Perform
Visual Inspection

Headlight bulbs blow out

repeatedly or dim?

Is the dash voltmeter gauge

out of range - either too high
or too low?
2 Inspect Battery
Battery Voltage Test
Battery Load Test

3
These are common indicators that
Measure
something may be wrong with the Voltage at Battery
charging system. If any of these
symptoms are evident, then follow these

4
five steps to pinpoint the issue.
Test
Helpful Hint: Alternator Output
If you find something wrong at any
step, its wise to complete the remaining

5
steps anyway to ensure youve given the
charging system a thorough review. Troubleshoot per
Service Manual

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to watch our Tech Tip videos
Troubleshooting
Complete

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1 Perform Visual Inspection

Perform a visual inspection under the hood

Look 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.

Belt
No
Tension and Perform Repairs
Condition
OK?

Yes

Electrical No
Connections Perform Repairs
OK?

Yes

Alternator No

Mounted Perform Repairs

OK?

Yes

Visual Inspections
Complete

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 2.A Inspect Batteries

Visually inspect and test the batteries

Inspect 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 systems current needs.

Corrosion Yes
or Loose Perform Repairs
Connections?

No

Yes
Battery
Replace Battery
Damaged?

No

Perform Battery
Voltage Test

Visual Inspection
Complete

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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 12.4
of supplying the starting systems current needs. DC AMP DC VOLTS

Connect Voltmeter
to Battery

With Engine Off,

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and Wait Two Minutes the Alternator Charging System Tech Tip video

< 12.4 Volts

Measure
Recharge Battery
Voltage

12.4 Volts

Perform Battery
Load Test

Battery Voltage
Test Complete

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 2.C Battery Load Test

Connect Carbon Pile

and Voltmeter
to Battery

12.5
Adjust Carbon Pile to
One-half the Cold Cranking
Amp Rating for 15 Seconds
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< Minimum
Loaded Voltage
Record
Lowest Replace Battery
Voltage

Minimum Loaded Voltage

Battery Passes

Battery Load
Test Complete

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3.A Measure Voltage at Battery

Fig 1. With the engine running, use a voltmeter

to measure voltage at the battery. If voltage is 12.4
greater than or equal to 13.8 volts, you can
DC AMP DC VOLTS

move on to Step 4.

Fig 1
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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 13.0
is insulated, you have to use a ground stud to DC AMP DC VOLTS

get a reading.)

At that point, if the voltage falls between

12.6 and 13.7 volts, you need to replace
your alternator. If its 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. Fig 2
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 3.B Measure Voltage at Battery

Connect Voltmeter
to Battery

Turn Engine On

< 13.8 Volts

Measure Connect Voltmeter to
Battery Alternator B+ and
Voltage Ground Post

13.8 Volts

12.6 to 13.7 Volts

Measure Replace
Voltage Alternator

13.8 Volts

Perform Voltage
Drop Test

Voltage at Battery
Measured

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4 Test Alternator Output

You can use either an automated tester or a manual process to determine the output
of the alternator. If the alternator doesnt pass this test, then it needs to be replaced.

Connect Carbon Pile,

Ammeter and
Amp Clamp

Engine Running at
Governor Speed and
Electrical Loads Off

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Load Carbon Pile
until Ammeter
Reads Highest Value

< 90% of
Rated Capacity
Record
Output Replace Alternator

90% of Rated Capacity

Alternator Output
Test Complete

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 5 Troubleshoot Using the Service Manual

1
If youve passed through the first four
steps, then the alternator is working as Perform
designed and your problem is likely Visual Inspection

caused by something external to the

alternator.

2 Inspect Battery
Battery Voltage Test
Battery Load Test

3 Measure
Voltage at Battery

4 Test
Alternator Output

5 Troubleshoot per
Service Manual

Troubleshooting
Complete

Remy International, Inc.

600 Corporation Drive
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Pendleton, IN 46064 USA Delco Remy is a registered trademark of General Motors Corporation,
For Technical Assistance call 1-800-372-0222 icensed to Remy Inc., Pendleton, IN 46064 2013 Remy International, Inc.

Technical Assistance 800-372-0222