Copyright 1991, 2005 Caterpillar Inc. All Rights Reserved.

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JSM 797B TRUCK Troubleshooting

Media Number RENR2631-02 Publication Date 2004/04/01 Update Date 2004/04/01

Charging System
SMCS Code: 1406-038

System Operation Description:

Table 10

Alternator Specifications    

   Peak Current Minimum Peak

Rating (Amps) Current (Amps)
     

12 Volt Alternators

8C-5535 32 28

7N-4784, OR-5201 40 36

6T-1396, 7T-2096, 8C-5908, OR-3654 51 46

9W-2648, 9W-2949, 8T-9700, 105-2811(IG), 55 49

OR-4327(IG), 105-2812(IG), OR-9273(IG), 34-
3268, 68-4139, 3E-7295(D+), 7T-2876(D+),
100-8223

7G-7889 60 54
8C-5510(I), OR5200 61 55
8N-2268 75 68

3E-7892, OR-3616 85 77

105-2813(IG), OR-9274(IG), 105-2814(IG), OR- 90 81

4328(IG), 149-2064(REG), OR-9410(REG), 9X-
0341(D+)

8C-6163, OR-1699, 107-2519 105 95

167-7816 110 99

9X-6796, 9X-9096, 121-4134, 121-4136, OR- 115 104

3527

3E-8827, 121-4135, 117-1379(I) 130 117

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152-8746 135 122

125-9597, OR-8332 145 131

24 Volt Alternators

2P-1204, 3Y-8200 19 17

2Y-8310 21 19

6T-1395, 7T-2095, OR-3653 33 30

6N-9294, OR-5217, OR-3482 35 32

5N-5692, OR-2698 45 41

5S-9088, 100-5047, 112-5041, 3E-7578, OR- 50 45

5206, OR-3667, OR-3668

109-2362, 9W-3043 55 50
, OR-3652(D+), 112-8032

3E-7772(IG), OR-9437(IG), 105-3132(IG), 4N- 60 54

3986, OR-5203

155-7434, 132-2156(I), 107-7977(I), OR-8279 70 63

(I)

169-4319, 167-7812 75 67.5

107-7976, 114-2401, OR-8997, 3E-7577, OR- 75 68

3615

165-5140 100 90

9X-7803, OR-3749 100 90

Parts-Service Only Discontinued 12 Volt Alternators

6T-1193 18 16

7N-6118, 6N-5460, 4N-4540 40 36

6T-1195 42 38

7X-1340 45 41

9G-6079, 6T-1194 63 57

Parts-Service Only Discontinued 24 Volt Alternators

9G-6081, 6T-1196 40 36

D+ - Diode trio output. Alternator requires external excitation.

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REG - Regulator Terminal. Alternator requires external excitation.

I - Ignition Terminal. Alternator can be externally excited through this terminal.

IG - Ignition Terminal. System voltage must be supplied to this terminal to turn on

the alternator. Some of these alternators use the IG terminal as a sense terminal.

Often when problems with the charging system are being investigated, the alternator
is not the problem. If a low battery condition is present test the batteries first. See
Special Instruction, SEHS7633, "Battery Test Procedure" for more information. If the
engine cranks slowly, then test the starting system. See Service Magazine,
SEPD0020, "Testing The Starter On The Engine" for more information. If a warning
indicator for the charging system is ON, see Service Magazine, SEBD1751,
"Difference Between Alternator Indicator In Electronic Monitoring System (EMS) And
Low Voltage Indicator In Operating Monitoring System (OMS)".

Note: Severely discharged batteries can cause low system voltage. This can occur
even while the engine is running above idle, and the alternator is working properly.
Proper low engine idle is also important.

Test Step 1. DETERMINE THE ALTERNATOR EXCITATION METHOD.

A. Check the rear of your alternator in order to determine the method of excitation.
See table 1 in order to verify the proper alternator excitation.

Expected Result:

Test method 1. These alternators have a "1", "REG", or "D+" terminal. Test method 2.
These alternators are self-excited. Test method 3. These alternators have a "IG"
terminal.

Results:

· Method 1 - The alternator has a "1", "REG", or "D+" terminal. Proceed to test step 2.
· Method 2 - The alternator is self-excited. Proceed to test step 4.
· Method 3 - The alternator has an "IG" terminal. Proceed to test step 3.
Test Step 2. CHECK THE RESISTANCE IN THE EXCITATION CIRCUIT.

A. Turn the key start switch to the ON position.

B. Verify voltage at the excitation terminal. Connect the red lead from a multimeter to
the excitation terminal. Connect the black lead to a ground source (alternator case

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ground).

C. Read the voltage that is shown on the multimeter.

Expected Result:

The voltage reads at least .2 volts.

Results:

· YES - The voltage reads .2 volts or more. The excitation circuit is correct. Proceed to
test step 4.

· NO - The voltage is less than .2 volts. There is a problem in the wiring harness to
the alternator or there is a poor electrical connection. Correct the problem and
operate the machine. Watch for a recurrence of the problem. STOP.

Test Step 3. CHECK THE RESISTANCE IN THE EXCITATION CIRCUIT

(CONTINUED).

Note: This step is only for alternators with external excitation when the terminal for
excitation is labelled: "IG".

A. Turn the key start switch to the ON position.

B. Verify voltage at the excitation terminal. Connect the red lead from a multimeter to
the excitation terminal. Connect the black test lead to a ground source (alternator
case ground).

Note: For G3B, K3A, and L3A alternators, Insert a 7X-1710 Multimeter Probe Group
into the rear of the middle wire in the connector. See figure 92 below. Insert the
probes spoon lead between the seal and the wire that surrounds the wire and the
outer shell of the connector. Do not insert the probe between the wire insulation and
the black seal. This terminal (IG) is the terminal for excitation.

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Illustration 92

Special wire probe technique for G3B, Y3A, and L3A alternators.

C. Read the voltage that is shown on the multimeter.

Expected Result:

The voltage measurement is within .5 volts of the battery voltage.

Results:

· YES - The voltage reads battery voltage. The excitation circuit is correct. 4.
· NO - The voltage that is measured is more than a .5 volt less than the battery
voltage. There is a problem in the wiring harness to the alternator or there is a poor
electrical connection. Correct the problem and operate the machine. Watch for a
recurrence of the problem. STOP.

Test Step 4. CHECK THE SYSTEM VOLTAGE.

A. Before you start the machine, connect a voltmeter between the "B+" terminal and
the case of the alternator. Turn OFF all electrical loads.

B. Turn the key to the ON position but do not start the engine. Read the voltage on
the voltmeter. Make a note of the voltage that was measured.

Expected Result:

This voltage should be approximately system voltage.

Results:

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· YES - The voltage is approximately system voltage. Proceed to test step 5.

· NO - The voltage is less than system voltage. Proceed to test step 7.
Test Step 5. CHECK THE OPERATION OF THE ALTERNATOR.

A. The voltmeter remains connected between the "B+" terminal and the case of the
alternator.

B. Start the machine. Set the throttle to at least 75 percent. Read the voltage on the
voltmeter. Make a note of the voltage that was measured.

Expected Result:

The voltage measurement is greater than the voltage that was recorded in the
previous test step "Check The System Voltage".

Results:

· VOLTAGE HIGHER - The voltage measurement is greater than the voltage that was
observed in the previous test step "Check The System Voltage". The voltage is also
less than the maximum voltage that is listed in the specifications for the alternator.
The alternator is partially charging the battery. Proceed to test step 6.

· VOLTAGE TOO HIGH - The voltage measurement is greater than the voltage that
was observed in the previous test step "Check The System Voltage". The voltage is
also greater than the maximum voltage that is listed in the specifications for the
alternator. The alternator is over charging. Proceed to test step 19.

· VOLTAGE LOWER - The voltage is not higher than the voltage that was observed in
the previous test step. Proceed to test step 7.

Test Step 6. TEST THE ALTERNATOR OUTPUT.

Note: For the proper output current, refer to table 10.

A. Ensure that the batteries are NOT fully charged.

Note: A fully charged battery may have open circuit voltage above 12.5 volts on 12
volt systems. 24 volt systems may be as high as 25 volts.

B. If the batteries are fully charged, then crank the engine for 30 seconds. This action
reduces the battery voltage. Operate the lights for 10 minutes while the engine is off
as an alternative.

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C. Connect the 9U-5795 Current Probe or 8T-0900 Ammeter to a DMM (digital

multimeter). The multimeter must have a peak hold feature. Clamp the probe around
the alternator output wire "B+". Before you clamp the probe around the wire, ensure
that the probe is "zeroed".

D. Set the digital multimeter to "peak hold" or "max mode" on the "mV" scale.

E. Turn on all electrical accessories: lights, air conditioning and radio.

F. Start the machine, and immediately set the throttle to at least 75%. The peak
current will appear on the voltmeter in "peak hold" or "max" mode.

Expected Result:

The current reading should be at least 90% of the specified peak output.

Results:

· YES - The current is at least 90% of the specified peak output. Proceed to test step
13.

· NO - The current is less than 90% of the specified peak output. Proceed to test step
7.

Test Step 7. CHECK THE DRIVE SYSTEM OF THE ALTERNATOR.

A. Check the condition of the alternator drive belt. Clean the pulley and replace the
drive belt if the drive belt is oily. Dry the drive belt if the belt is wet. Replace the drive
belt, if the belt is worn.

B. Check the tension of the alternator drive belt. Adjust the drive belt to the correct
tension.

C. Check the nut on the alternator pulley. Tighten the nut if the nut is loose.

Expected Result:

The drive system of the alternator is functioning correctly. No corrections to the drive
system were necessary.

Results:

· YES - The drive system of the alternator is functioning correctly. No corrections

were necessary. Proceed to test step 8.

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· NO - The drive system of the alternator was not functioning correctly. Corrections
were necessary.

Repair:

Ensure that the problems have been corrected. Exit this procedure and retest the
alternator charging system. STOP.

Test Step 8. TEST THE CHARGING CIRCUIT.

A. Verify that the nut on the "B+" alternator terminal is tight. Also, verify that the
wire has a good connection to the "B+" terminal.

B. Many Caterpillar machines are equipped with a connector for the 6V-2150
Starting/Charging Analyzer. Use of this tester replaces the remainder of this test
step. To operate the analyzer, refer to Tool Operating Manual, SEHS7768, "Using the
6V-2150".

C. Start the engine and set the throttle to at least 75 percent. Turn ON all electrical
accessories for the remainder of this test step. Allow the engine to run for at least 3
minutes before continuing.

D. Measure the voltage between the "B+" alternator terminal and the alternator case
ground. Make a note of the measured voltage. Perform the next measurement
immediately.

E. Measure the voltage across the battery. Put the red lead on the battery positive
terminal, and put the black lead on the battery negative terminal. Make a note of the
voltage that was measured.

Expected Result:

The voltage at the battery should be less than the voltage at the alternator. The
difference in voltages should not be more than 1 volt on 12 volt systems. The
difference should not be more than 2 volts on 24 volt systems.

Results:

· YES - The voltage at the battery is less than the voltage at the alternator. Also, the
difference in voltages is less than 1 volt for 12 volt systems and the difference is less
than 2 volts for 24 volt systems. The wiring that is related to the alternator is correct
at this time.

Repair:

There is an internal problem with the alternator. Repair or replace the alternator.
STOP.

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· NO - The voltage at the battery is less than the voltage at the alternator. However,
the difference in voltages is greater than 1 volt for 12 volt systems and the difference
is greater than 2 volts for 24 volt systems. Proceed to test step 9.

Test Step 9. TEST THE POSITIVE SIDE OF THE CHARGING CIRCUIT.

A. Measure the voltage between the frame ground and the "B+" alternator terminal.
Make a note of the voltage that was measured. Perform the next measurement
immediately.

B. Measure the voltage between the frame ground and the + battery post. Make a
note of the voltage that was measured.

Expected Result:

The voltage difference does not exceed 1 volt on 24 volt systems or 0.5 volts on 12
volt systems.

Results:

· YES - The voltage difference does not exceed the tolerance. The positive circuit is
good. Proceed to test step 10.

· NO - The voltage difference exceeds the tolerance.

Repair:

There is high resistance in the positive side of the charging circuit that is caused by
one of the following conditions:

· An electrical connection has loosened.

· An electrical connection has corroded.
· The main relay has failed.
· A circuit breaker has failed.
Repair the problem or replace any component that has failed. Exit this procedure and
retest the alternator charging system. STOP.

Test Step 10. TEST THE NEGATIVE SIDE OF THE CHARGING CIRCUIT.

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A. Check the voltage between the negative battery post and the alternator case
ground.

Expected Result:

The voltage does not exceed 1 volt on 24 volt systems or 0.5 volts on 12 volt systems.

Results:

· YES - The voltage difference does not exceed the tolerance. The negative circuit is
good. Proceed to test step 11.

· NO - The voltage difference exceeds the tolerance.

Repair:

There is high resistance in the negative side of the charging circuit that is caused by
one of the following conditions:

· An electrical connection has loosened.

· The alternator ground has loosened.
· The engine ground has opened.
Repair the problem or replace any component that has failed. Exit this procedure and
retest the alternator charging system. STOP.

Test Step 11. TEST THE CIRCUIT OF THE "R" TERMINAL.

A. Start the engine and set the throttle to at least 75%.

B. Connect a voltmeter between the "B+" terminal and the alternator case ground.

C. Disconnect the wire from the "R" terminal. Select "YES" if the "R" terminal is not
used on the machine.

Expected Result:

The voltage does not change.

Results:

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· YES - The voltage does not change. Proceed to test step 12.
· NO - The voltage rises and the alternator begins charging.
Repair:

The wire to the "R" terminal is shorted. Repair the wiring or replace the wiring. Exit
this procedure and retest the alternator charging system. STOP.

Test Step 12. RESTORE THE RESIDUAL MAGNETISM OF THE ROTOR.

A. Connect one end of a jumper wire to the "B+" terminal (D+ terminal for K1, N1,
and N3) of the alternator.

B. Connect the other end of the jumper wire to the "R" terminal of the alternator for
two seconds.

Expected Result:

The voltage output rises on the "B+" terminal. The residual magnetism of the rotor
has been restored.

Results:

· YES - The voltage output rises. The residual magnetism of the rotor has been
restored. The alternator is now charging.

Repair:

Exit this procedure and retest the alternator charging system. STOP.

· NO - The voltage output does not rise.

Repair:

There is an internal problem with the alternator. Repair or replace the alternator.
STOP.

Test Step 13. TEST FOR UNDESIRABLE CURRENT FLOW IN THE ALTERNATOR
CHARGING SYSTEM.

A. Turn off all of the accessories. Turn the keyswitch to the OFF position.

B. Clamp a 9U-5795 Current Probe or 8T-0900 Ammeter around the main ground
cable. Clamp the tool with the positive side away from the battery. Reset the probe

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(zero) before you clamp the probe around the wire. Read the current on the meter.
Make a note of the current that was measured.

Expected Result:

The current is below 2 amperes. The "YES" selection is dependent on the presence of
a main disconnect switch on the machine that is being tested.

Results:

· YES - WITH DISCONNECT SWITCH - The current is below 2 amperes. For

machines with a main disconnect switch, proceed to test step 14.

· YES - WITHOUT DISCONNECT SWITCH - The current is below 2 amperes. For

machines without a main disconnect switch, proceed to test step 15.

· NO - The current is above 2 amperes. There is a current draw in the system.

Proceed to test step 16.

Test Step 14. MEASURE THE CURRENT OF THE SYSTEM BY USING THE MAIN
DISCONNECT SWITCH.

A. Turn the disconnect switch to the ON position.

B. Connect an ammeter across the disconnect switch terminals. Connect the red lead
to the terminal on the frame side. Connect the black lead to the terminal on the
battery side. If a multimeter is being utilized for this test, use the 10A connections in
order to avoid damage.

C. Turn the disconnect switch to the OFF position and read the current. Make a note
of the measured current.

Note: The standard acceptable current draw is 50 milliamperes. A current draw

above 50 milliamperes usually indicates a problem. However, some large machines
with multiple electronic control modules have a higher acceptable limit. For more
information, contact a Caterpillar dealer or contact the business unit that produces
the machine.

Expected Result:

The current is below 0.050 amperes (50 milliamperes).

Results:

· YES - The current is below 0.050 amperes. The charging system is functioning

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properly at this time. The failure is possibly an intermittent draw in the system. The
batteries may have failed. Ensure that NO accessories were ON during the test. Exit
this procedure and retest the alternator charging system. STOP.

· NO - The current is above 0.050 amperes. There is a draw in the system. Proceed to
test step 16.

Test Step 15. MEASURE THE CURRENT OF THE SYSTEM BY REMOVING THE
NEGATIVE BATTERY CABLE.

A. Disconnect the ground cable from the negative battery post. There may be more
than one battery that is connected to ground. Disconnect all of the batteries that are
connected to ground. Do not disconnect cables that are between batteries that are
connected in series.

B. Connect an ammeter between the disconnected battery ground cable and one of
the negative battery terminals. Connect the red positive lead of the ammeter to the
cable. The negative lead should be connected to the battery terminal. If a multimeter
is being utilized for this test, use the 10 ampere connections in order to avoid
damage.

Note: The standard acceptable current draw is 50 milliamperes. A current draw

above 50 milliamperes usually indicates a problem. However, some large machines
with multiple electronic control modules have a higher acceptable limit. For more
information, contact a Caterpillar dealer or contact the business unit that produces
the machine.

Expected Result:

The current is below .050 amperes (50 milliamperes).

Results:

· YES - The current is below 0.050 amperes. The charging system is currently good.
The problem is a possible intermittent current draw in the system. The batteries may
have failed. Check that NO accessories were ON during the test. STOP.

· NO - The current is above 0.050 amperes. There is excessive current flow in the
system. Proceed to test step 16.

Test Step 16. TEST THE CURRENT OF THE ALTERNATOR OUTPUT BELOW 2
AMPERES.

A. Turn the keyswitch to the OFF position.

B. Connect the 9U-5795 Current Probe or 8T-0900 Ammeter to a DMM (digital

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multimeter). Clamp the probe around the "B+" wire of the alternator. Before you
clamp the probe around the wire, ensure that the probe is "zeroed".

C. Read the current on the meter. Make a note of the current that was measured.

Expected Result:

The current is under 2 amperes.

Results:

· YES - The current is under 2 amperes. Proceed to test step 17.

· NO - The current is over 2 amperes.
Repair:

There is an internal problem with the alternator. Repair or Replace the alternator.
STOP.

Test Step 17. TEST THE OUTPUT CURRENT OF THE ALTERNATOR BELOW
0.015 AMPERES.

A. Disconnect the wire from the "B+" terminal of the alternator. Set the multimeter on
the 10 amp scale. Connect the red lead of the multimeter to the wire that was
disconnected. Connect the black lead of the multimeter to the "B+" terminal of the
alternator. Make a note of the current that was measured.

Expected Result:

The current is less than 0.015 amperes.

Results:

· YES - The current is under 0.015 amperes. The alternator is operating correctly.
There may be a current draw on the machine. Proceed to test step 18.

· NO - The current is over 0.015 amperes.

Repair:

There is an internal problem with the alternator. Repair or replace the alternator.
STOP.

Test Step 18. IDENTIFY THE SOURCE OF EXCESSIVE CURRENT DRAW.

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A. Make sure that every electrical component is turned OFF. Make sure that the
keyswitch is turned OFF. Make sure that the dome lights are OFF.

B. Clamp a 9U-5795 Current Probe or 8T-0900 Ammeter around the main ground
cable. Clamp the tool with the positive side away from the battery. Reset the probe
(zero) before clamping the probe around the wire. Use the current probe if the draw is
above approximately 2 amperes. Use the Ammeter if the draw is below approximately
2 amperes.

C. Remove the fuses or open the circuit breakers one at a time. Check the current
after each fuse has been removed or each circuit breaker has been opened. After
observing the current, reinstall the fuse or close the circuit breaker. Start with the
main circuits first, and proceed to smaller circuits.

D. Check if any components on the circuit are ON.

E. If everything is OFF, then disconnect electrical components on the circuit one at a

time. Monitor the current after each component is disconnected.

F. All of the components in the circuit should be disconnected. If the problem still
exists, then check the wiring in the circuit. There may be circuit leakage through
corrosion or circuit leakage through a short.

Note: The standard acceptable current draw is 50 milliamperes. A current draw

above 50 milliamperes usually indicates a problem. However, some large machines
with multiple electronic control modules have a higher acceptable limit. For more
information, contact a Caterpillar dealer or contact the business unit that produces
the machine.

Expected Result:

The source of the excessive current draw was determined.

Results:

· YES - The source of the excessive current draw was determined.

Repair:

Repair the problem or replace any component that has failed. Exit this procedure and
retest the alternator charging system. STOP.

· NO - The source of the excessive current draw was not determined.

Repair:

Exit this procedure and retest the alternator charging system. STOP.

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Test Step 19. TEST FOR AN OVERCHARGING CONDITION FROM THE

ALTERNATOR.

A. Verify that the nut on the "B+" alternator terminal is tight. Also, verify that the
wire has a good connection to the "B+" terminal.

B. Many Caterpillar machines are equipped with a connector for the 6V-2150
Starting/Charging Analyzer. Use of this tester replaces the remainder of this test
step. To operate the analyzer, refer to Tool Operating Manual, SEHS7768, "Using the
6V-2150".

C. Start the engine and set the throttle to at least 75 percent. Turn ON all electrical
accessories for the remainder of this test step. Allow the engine to run for at least 3
minutes before continuing.

D. Measure the voltage between the "B+" terminal of the alternator and the case of
the alternator. Make a note of the voltage that was measured. Perform the next
measurement immediately.

E. Measure the voltage across the battery. Put the red lead on the positive terminal of
the battery, and put the black lead on the negative terminal of the battery. Make a
note of the voltage that was measured.

Expected Result:

The voltage at the battery should be less than the voltage at the alternator. On
systems that are 12 volt, the difference in voltages should not be more than 1 volt.
On systems that are 24 volt, the difference should not be more than 2 volts.

Results:

· YES - The voltage at the battery is less than the voltage at the alternator. Also, the
difference in voltages is less than 1 volt for 12 volt systems and the difference is less
than 2 volts for 24 volt systems. The wiring that is related to the alternator is correct
at this time.

Repair:

There is an internal problem with the alternator. Repair or Replace the alternator.
STOP.

· NO - The voltage at the battery is less than the voltage at the alternator. However,
the difference in voltages is greater than 1 volt for 12 volt systems and the difference
is greater than 2 volts for 24 volt systems. Proceed to test step 20.

Test Step 20. TEST THE POSITIVE SIDE OF THE CHARGING CIRCUIT.

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A. Measure the voltage between the frame of the machine and the "B+" terminal of
the alternator. Make a note of the voltage that was measured. Perform the next
measurement immediately.

B. Measure the voltage between the frame of the machine and the positive terminal of
the battery. Make a note of the voltage that was measured.

Expected Result:

The voltage difference does not exceed 1 volt on 24 volt systems or 0.5 volts on 12
volt systems.

Results:

· VOLTAGE OK - ALT. WITHOUT IG/S TERM. - The voltage difference does not
exceed the tolerance. The positive circuit is good.

Repair:

There is an internal problem with the alternator. Repair or Replace the alternator.
STOP.

· VOLTAGE EXCESSIVE - ALL ALT. - The voltage difference exceeds the tolerance.
Repair:

There is high resistance in the positive side of the charging circuit that is caused by
one of the following conditions:

· An electrical connection has loosened.

· An electrical connection has corroded.
· The main relay has failed.
· A circuit breaker has failed.
Correct the problem. Exit this procedure and retest the alternator charging system.
STOP.

· VOLTAGE OK - ALT. WITH IG/S TERM. - The voltage difference does not exceed the
tolerance. The positive circuit is good. Proceed to test step 21.

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Test Step 21. ALTERNATOR OVERCHARGING TEST.

A. Start the engine and set the throttle to at least 75 percent.

B. Measure the voltage between the sense terminal (S) and/or the "IG" terminal to the
case of the alternator.

Expected Result:

The voltage at the "S" terminal and/or "IG" terminal is above the specification.

Results:

· YES - The measured voltage exceeds the specification. There is an internal

malfunction in the alternator. See the appropriate service manual for the alternator
in order to test the internal components and connections. STOP.

· NO - The measured voltage is below the measurement that was taken in the initial
tests (B+ to alternator case). The sense circuit in the generator set has high
resistance. Correct the problem. Exit this procedure and retest the alternator
charging system. STOP.

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