Page 1
TG0048A
Table of Contents
Section 1: Wiring .......................................................... 2
Section 2: CAN/J1939 Diagnostics ............................... 3
Section 3: Basic Troubleshooting ................................. 4
Section 4: Advanced Troubleshooting ....................... 5-6
Battery Conditions
Until temperatures of electrical
system components stabilize, these
conditions may be observed during
cold start voltage tests.
• Maintenance or low maintenance battery:
— Immediately after engine starts, system volts are
lower than regulator setpoint with medium amps.
— 3-5 Minutes into charge cycle, system volts are
higher and amps are dropping.
— 5-10 Minutes into charge cycle, system volts are
at, or nearly at, regulator setpoint and amps are
reduced to a minimum.
— Low maintenance battery has same characteris-
tics with slightly longer recharge times.
• Maintenance-free battery:
— Immediately after engine start, system volts
are lower than regulator setpoint with low
charging amps.
— 15-30 minutes into charge cycle, volts and amps
are still low.
— 15-30 minutes into charge cycle, volts increase
several tenths. Amps increase gradually, then
quickly, to medium to high amps.
— 20-35 minutes into charge cycle, volts increase
to setpoint and amps decrease.
• High-cycle maintenance-free battery:
— These batteries respond better than standard
maintenance-free. Charge acceptance of these
batteries may display characteristics similar to
maintenance batteries.
NOTICE
Hazard Defi nitions
These terms are used to bring attention to presence of hazards of
various risk levels or to important information concerning product
life.
NOTICE
500 Series Troubleshooting Guide
for C520 Alternators
Charge Volt and Amp Values
The volt and amp levels are a function of the battery state
of charge. If batteries are in a state of discharge, as after
extended cranking time to start the engine, the system
volts, when measured after the engine is started will be
lower than the regulator setpoint and the system amps
will be high. This is a normal condition for the charging
system. The measured values of system volts and amps
will depend on the level of battery discharge. In other
words, the greater the battery discharge level, the lower
the system volts and higher the system amps will be.
The volt and amp readings will change, system volts
reading will increase up to regulator setpoint and the
system amps will decrease to low level (depending on
other loads) as the batteries recover and become
fully charged.
• Low Amps: A minimum or lowest charging system
amp value required to maintain battery state of
charge, obtained when testing the charging system
with a fully charged battery and no other loads ap-
plied. This value will vary with battery type.
• Medium Amps: A system amps value which can
cause the battery temperature to rise above the ad-
equate charging temperature within 4-8 hours of
charge time. To prevent battery damage, the charge
amps should be reduced when battery temperature
rises. Check battery manufacturer’s recommenda-
tions for proper rates of charge amps.
• High Amps: A system amps value which can cause
the battery temperature to rise above adequate charg-
ing temperature within 2-3 hours. To prevent battery
damage, the charge amps should be reduced when
the battery temperature rises. Check battery manu-
facturer’s recommendations for proper rates
of charge amps.
• Battery Voltage: Steady-state voltage value as mea-
sured with battery in open circuit with no battery
load. This value relates to battery state of charge.
• Charge Voltage: A voltage value obtained when the
charging system is operating. This value will be high-
er than battery voltage and must never exceed the
regulator voltage setpoint.
• B+ Voltage: A voltage value obtained when measur-
ing voltage at battery positive terminal or alternator
B+ terminal.
• Surface Charge: A higher than normal battery volt-
age occurring when the battery is removed from a
battery charger. The surface charge must be removed
to determine true battery voltage and state of charge.
• Significant Magnetism: A change in the strength or
intensity of a magnetic field present in the alternator
rotor shaft when the field coil is energized. The mag-
netic field strength when the field coil is energized
should feel stronger than when the field is not ener-
gized.
• Voltage Droop or Sag: A normal condition which
occurs when the load demand on the alternator is
greater than rated alternator output at given rotor
shaft RPM.
Indicates presence of hazards that
will or can cause minor personal
injury or property damage if
ignored.
Indicates special instructions on
installation, operation or mainte-
nance that are important but not
related to personal injury hazards.
CAUTION
(4 paginas)
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