Charging System - Test 320D L
Charging System - Test 320D L
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Product: EXCAVATOR
Model: 320D EXCAVATOR A6F
Configuration: 320D & 320D L Excavators A6F00001-UP (MACHINE) POWERED BY C6.4 Engine
i04810832
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)". When a problem with the charging system is
suspected, then complete the testing that is outlined in this Special Instruction.
See "Initial Troubleshooting Procedure" in order to begin troubleshooting. The procedures in this
Special Instruction are designed to guide you to the problem with as little testing as possible. In most
cases, you will only use a few of the tests to diagnose a problem. The tests are labeled as T1 - T8 for
easy reference. A descriptive title for each test is included as well.
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 ground).
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Results:
◾ YES - The voltage reads .2 volts or more. The excitation circuit is correct. Proceed
to Step 3.
◾ NO - The voltage is less than .2 volts. There is a failure 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.
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. The case of the alternator
can be used as a good source of ground.
Note: For Denso G3B, K3A, and L3A alternators, Insert a 7X-1710 Multimeter Probe
Group into the rear of the middle wire in the connector. See figure 1 below. Insert the
probe (spoon lead) between the black seal 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.
Illustration 1 g00496660
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Results:
◾ YES - The voltage reads battery voltage. The excitation circuit is correct. Proceed
to Step 3.
◾ NO - The voltage is more than .5 volts less than battery voltage. There is a failure
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.
a. Before starting 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.
Results:
◾ NO - The voltage is less than system voltage. Verify that the batteries are good and
verify that battery connections are good. Go to ""T4 Alternator Drive System -
Check"" if the batteries are good.
b. Start the machine. Set the throttle to at least 75 percent. Read the voltage on the
voltmeter.
Expected Result: The voltage is higher than the voltage that was recorded in the
previous Step 3.
Results:
◾ YES - The voltage is higher than the voltage observed in the previous Step 3. The
voltage is also lower than the maximum voltage that is listed in the specifications
for the alternator. The alternator is partially charging. See the following diagnostic
flow chart for reference in continued testing. Proceed to ""T1 Alternator Output -
Test"".
◾ YES - The voltage is higher than the voltage observed in the previous Step 3. The
voltage is also higher than the maximum voltage that is listed in the specifications
for the alternator. The alternator is over charging. Proceed to ""T8 Alternator
Overcharging - Test"".
◾ NO - The voltage is not higher than the voltage observed in Step 3. Proceed to
""T4 Alternator Drive System - Check"".
Note: Severely discharged batteries can cause low system voltage. Severely discharged batteries can
occur even while the engine is running above idle, and the alternator is working properly. Proper low
engine idle is also important. Most of the alternators in Caterpillar applications are self-excited. These
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alternators must exceed a turn-on speed before charging will begin. Alternator output can be low at
idle.
Illustration 2 g00508188
a. Fully charged batteries have open circuit voltage above 12.5 V on 12 V systems or 25 V
on 24 V systems.
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.
2. Connect the 9U-5795 Current Probe to a DMM (digital multimeter) or use a 225-8266
Ammeter Tool Gp . The multimeter must have a peak hold feature. Clamp the probe around
alternator output wire "B+". Before clamping the probe around the wire, ensure that the probe
is "zeroed" .
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3. Set the digital multimeter to "peak hold" or "max mode" on the "mV" scale.
5. Start the machine, and immediately set the throttle to at least 75 percent. The peak current will
appear on the voltmeter in "peak hold" or "max" mode.
Expected Result: This current reading should be at least 90 percent of the specified peak
output.
Results:
◦ NOT OK - The current is less than 90 percent of the specified peak output. Go to ""T4
Alternator Drive System - Check"".
2. Clamp a 9U-5795 Current Probe or 225-8266 Ammeter Tool Gp 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. Read the current.
Results:
3. Turn the disconnect switch to the ON position. Connect a multimeter 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. Use the 10A connections in order to avoid damage.
Note: The standard acceptable current draw is 50 mA. A current draw above 50 mA usually
indicates a problem. However, some large machines with multiple electronic control modules
have a higher acceptable limit. Contact a Caterpillar dealer for more information.
Results:
◦ YES - The current is below 0.050 A. The charging system is currently good. The fault is
possibly an intermittent draw in the system. The batteries may be faulty. Check that NO
accessories were ON during the test.
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◦ NO - The current is above 0.050 A. There is a draw in the system. Go to ""T5 Alternator
Current - Test"".
2. Clamp a 9U-5795 Current Probe or 225-8266 Ammeter Tool Gp around the main ground cable.
Clamp the tool with the positive side away from the battery. Reset the probe (zero) before
clamping around the wire. Read the current.
Results:
3. Remove the ground cable from the battery terminal. For systems with 4 batteries, or 12 V
systems with 2 batteries, disconnect the ground cables from both negative batteries.
4. Connect a multimeter 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. Use the
10A connections in order to avoid damage.
Note: The standard acceptable current draw is 50 mA. A current draw above 50 mA usually
indicates a problem. However, some large machines with multiple electronic control modules
have a higher acceptable limit. Contact a Caterpillar dealer for more information.
Results:
◦ YES - The current is below 0.050 A. The charging system is currently good. The fault is
possibly an intermittent draw in the system. The batteries may be faulty. Check that NO
accessories were ON during the test.
◦ NO - The current is above 0.050 A. There is a draw in the system. Go to ""T5 Alternator
Current - Test"".
Note: The following alternators have a connector for a regulator: 6T-1193 , 6T-1194 , 6T-1195 , 6T-
1196 , 9G-6079 and 9G-6081 . Disconnect the regulator connector from the alternator. Recheck the
current that was found in the previous Step. If the current is below 0.050 A (50 mA), the regulator is
faulty.
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2. Many Caterpillar machines are equipped with a connector for the 6V-2150 Starting/Charging
Analyzer . Use of this tester replaces the testing below. See Systems Operation, SENR2947,
"Starting and Charging Systems".
3. Start the engine and set the throttle to at least 75 percent. Turn ON all electrical accessories for
all test steps below. Allow the engine to run for at least 3 minutes before continuing to Step 4.
The following table will assist in making calculations during this test.
Table 1
Test Step Voltage Voltage should be below this Voltage should be below this
Reading for 12 V system for 24 V system
4
5
4 minus 5 1.0 V 2.0 V
=
6
7
6 minus 7 0.5 V 1.0 V
=
8 0.5 V 1.0 V
4. Measure the voltage between the alternator B+ terminal and the alternator case ground.
5. Measure the voltage across the battery. Put the red lead on the + battery terminal, and put the
black lead on the negative battery terminal. Step 5 should be completed as quickly as possible
after Step 4.
Expected Result: The voltage is less than the voltage or the voltage is equal to the voltage that
was recorded in Step 4 for a 12 V system. However, the voltage is within 1 V. On 24 V
systems, the voltage is within 2 V.
Results:
◦ YES - If the voltage in Step 4 is not more than 1 V for 12 V systems (2 V for 24 V
systems) higher than the voltage in Step 5, this test is complete and the related wiring is
correct at this time. Replace the alternator or disassemble the alternator and repair.
6. Check the voltage between the machine frame and the alternator B+ terminal. Record the
voltage.
7. Check the voltage between the machine frame and the + battery post. Step 7 should be
completed as quickly as possible after Step 6.
Expected Result: The voltage difference between Step 6 and Step 7 does not exceed 1 V on 24
V systems or 0.5 V on 12 V systems.
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Results:
◦ YES - The voltage difference does not exceed the tolerance. The charging circuit is good.
Go to Step 8.
◦ NO - The voltage difference exceeds the tolerance. There is high resistance in the
charging circuit: loose cables, corroded cables, damaged cables and faulty circuit
breaker. Correct the problem and retest the system.
8. Check the voltage between the negative battery post and the alternator case ground.
Expected Result: The voltage does not exceed 1 V on 24 V systems or 0.5 V on 12 V systems.
Results:
◦ YES - The voltage difference does not exceed the tolerance. The ground circuit is good.
There is an internal problem with the alternator. Go to ""T6 Residual Magnetism
Restoration"".
◦ NO - The voltage difference exceeds the tolerance. There is high resistance in the ground
circuit: loose cables, corroded cables, loose alternator mounting and poor engine ground.
Correct the problem and retest the system.
2. Check the tension of the alternator drive belt. If the tension is off, adjust the tension.
3. Check the nut on the alternator pulley. If the nut is loose, tighten the nut and retest the system.
4. If all of the previous steps find no problems, go to ""T3 Charging System - Test"".
2. Connect the 9U-5795 Current Probe to a DMM (digital multimeter) or use a 225-8266
Ammeter Tool Gp . Clamp the probe around the alternator output wire ("B+"). Before
clamping the probe around the wire, ensure that the probe is "zeroed" .
Results:
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4. Disconnect the B+ terminal wire from the alternator. 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. Set the multimeter on the 10 amp scale. Read the current.
Results:
◦ YES - The current is under 0.015 A. The alternator is operating correctly. There is a
current draw on the machine. Go to ""T7 Identifying Source Of Current Draw - Test"".
◦ NO - The current is greater than 0.015 A. There is an internal problem with the
alternator. Go to ""T6 Residual Magnetism Restoration"".
2. Connect a voltmeter between the "B+" terminal and the alternator case ground.
Results:
◦ NO - The voltage rises and the alternator begins charging. The wire to the "R" terminal is
shorted. Repair the wiring or replace the wiring. Go to "Initial Troubleshooting
Procedure" and retest the system.
4. Connect one end of a jumper wire to the "B+" terminal of the alternator.
5. Connect the other end of the jumper wire to the "R" terminal ("D+" terminal for Bosch) of the
alternator for 2 seconds.
Results:
◦ NOT OK - The voltage output does not rise. Proceed to Step 6, if the alternator has a
wire that is connected to the "I" terminal. Disassemble the alternator and repair the
alternator. Replace the alternator if the alternator cannot be repaired.
6. Remove the wire that is connected to the "I" terminal. Check for a rise in voltage on the "B+"
terminal.
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Results:
◦ YES - The voltage rises. There is a short in the wiring to the terminal. Repair the wiring
or replace the wiring. Go to "Initial Troubleshooting Procedure" and retest the system.
◦ NOT OK - The voltage output does not rise. Disassemble the alternator and repair the
alternator. Replace the alternator if the alternator cannot be repaired.
2. Clamp a 9U-5795 Current Probe or 225-8266 Ammeter Tool Gp 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
A. Use the Ammeter if the draw is below approximately 2 A.
3. Monitor the current and remove fuses and breakers one at a time. Check the current after each
fuse (breaker) is removed. After removing a fuse (breaker) and observing the current, reinstall
the fuse (breaker). Start with the main fuses (circuit breakers) first, and proceed to smaller
circuits.
4. If a removal of a fuse causes the current to drop, then the problem is in that circuit.
b. If everything is OFF, disconnect electrical components on that circuit one at a time and
monitor current.
c. After all of the components in that circuit have been disconnected, check the current. If
the problem still exists, then check the wiring for corrosion or shorts to ground.
Note: The standard acceptable current draw is 50 mA. A current draw above 50 mA usually indicates
a problem. However, some large machines with multiple electronic control modules have a higher
acceptable limit. Contact a Caterpillar dealer for more information.
1. Clean the connection and tighten the connection to the wiring terminal on the alternator.
2. Verify that the alternator B+ terminal nut is tight and verify that the wire has a good connection
to the "B+" terminal.
3. Many Caterpillar machines are equipped with a connector for the 6V-2150 Starting/Charging
Analyzer . See Systems Operation, SENR2947, "Starting and Charging Systems". Use of this
analyzer replaces the testing below through Step 8. Therefore, if the testing is good, go to Step
9. If the analyzer finds a problem, correct the problem and retest the system. Go to "Initial
Troubleshooting Procedure".
4. Start the engine and set the throttle to at least 75 percent. Turn ON all electrical accessories for
all test steps below. Allow the engine to run for at least 3 minutes before continuing to Step 5.
The following table will assist in making calculations during this test.
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Table 2
Test Step Voltage Voltage should be below this Voltage should be below this
Reading for 12 V system for 24 V system
5
6
5 minus 6 1.0 V 2.0 V
=
7
8
7 minus 8 0.5 V 1.0 V
=
5. Measure the voltage between the "B+" terminal of the alternator and the case of the alternator.
6. Measure the voltage across the battery. Put the red lead on the + battery terminal, and put the
black lead on the negative battery terminal. Step 6 should be completed as quickly as possible
after Step 5.
Expected Result: The voltage is within 1 V of the voltage that is recorded in Step 5 for 12 V
systems. The voltage is within 2 V for 24 V systems.
Results:
◦ YES - If the voltage in Step 5 is not more than 1 V for 12 V systems (2 V for 24 V
systems) higher than the voltage in Step 6, this step is complete and the related wiring is
correct at this time. Go to Step 9.
7. Check the voltage between the machine frame and the alternator B+ terminal. Record the
voltage.
8. Check the voltage between the machine frame and the + battery post. Step 8 should be
completed as quickly as possible after Step 7.
Expected Result: The voltage difference between Step 7 and Step 8 does not exceed 1 V on 24
V systems or 0.5 V on 12 V systems.
Results:
◦ YES - The voltage difference does not exceed the tolerance. The charging circuit is good.
Go to Step 9.
◦ NO - The voltage difference exceeds the tolerance. There is high resistance in the
charging circuit: loose cables, corroded cables, damaged cables, faulty circuit breaker
and faulty main relay. Correct the problem. Go to "Initial Troubleshooting Procedure"
and retest the system.
9. Start the engine and set the throttle to at least 75 percent. Turn OFF all of the accessories.
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Illustration 3 g00496660
Note: The following information is used only for the Denso G3B, K3A, and L3A alternators:
Insert a 7X-1710 Multimeter Probe Group into the rear of the middle wire in the connector. See
figure 3. Insert the probe (spoon lead) between the black seal 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.
10. Measure the voltage between the sense terminal and the case of the alternator.
Expected Result: The voltage at the sense terminal is above the specification.
Results:
◦ NO - The voltage is below that found in the initial tests (B+ to alternator case). The sense
circuit in the machine has high resistance. Correct the problem and retest the system . Go
to "Initial Troubleshooting Procedure".
1. Clean the connection and tighten the connection to the wiring terminal on the alternator.
2. Verify that the nut on the "B+" terminal of the alternator is tight. Verify that the wire has a
good connection to the "B+" terminal.
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3. Many Caterpillar machines are equipped with a connector for the 6V-2150 Starting/Charging
Analyzer . See Systems Operation, SENR2947, "Starting and Charging Systems". Use of this
analyzer replaces the testing below. If the analyzer finds a problem, correct the problem and
retest the system. Go to "Initial Troubleshooting Procedure".
4. Run the engine at 75 percent. Turn ON all electrical accessories for all test steps below. Allow
the engine to run for at least 3 minutes before continuing to Step 5. The following table
describes the measurements that are taken during this test.
Table 3
Test Step Voltage Voltage should be below this Voltage should be below this
Reading for 12 V system for 24 V system
5
6
5 minus 6 1.0 V 2.0 V
=
7
8
7 minus 8 0.5 V 1.0 V
=
5. Measure the voltage between the "B+" terminal of the alternator and the case of the alternator.
6. Measure the voltage across the battery. Put the red lead on the + battery terminal, and put the
black lead on the negative battery terminal. Step 6 should be completed as quickly as possible
after Step 5.
Expected Result: The voltage is within 1 V of the voltage that was recorded in Step 5 for 12 V
systems. The voltage is within 2 V for 24 V systems.
Results:
◦ YES - If the voltage in Step 5 is not more than 1 V for 12 V systems (2 V for 24 V
systems) higher than the voltage in Step 6, this step is complete and the related wiring is
correct at this time. 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.
7. Check the voltage between the machine frame and the "B+" terminal of the alternator. Record
the voltage.
8. Check the voltage between the machine frame and the + battery post. Step 8 should be
completed as quickly as possible after Step 7.
Expected Result: The voltage difference between Step 7 and Step 8 does not exceed 1 V on 24
V systems or 0.5 V on 12 V systems.
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Results:
◦ YES - The voltage difference does not exceed the tolerance. The charging circuit is good.
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.
◦ NO - The difference in the voltage exceeds the tolerance. There is high resistance in the
charging circuit: loose cables, corroded cables, damaged cables, failed circuit breaker
and failed main relay. Correct the problem. Go to "Initial Troubleshooting Procedure"
and retest the system.
12 V 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), OR-4327 55 49
(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-4328 90 81
(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-3527 115 104
3E-8827 , 121-4135 , 117-1379 (I) 130 117
152-8746 135 122
125-9597 , OR-8332 145 131
24 V Alternators
2P-1204 , 3Y-8200 19 17
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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-5206 , OR 50 45
-3667 , OR-3668
109-2362 , 9W-3043 55 50
, OR-3652 (D+), 112-8032
3E-7772 (IG), OR-9437 (IG), 105-3132 (IG), 4N-3986 , 60 54
OR-5203
155-7434 , 132-2156 (I), 107-7977 (I), OR-8279 (I) 70 63
169-4319 , 167-7812 75 67.5
107-7976 , 114-2401 , OR-8997 , 3E-7577 , OR-3615 75 68
165-5140 100 90
9X-7803 , OR-3749 100 90
Parts-Service Only Discontinued 12 V 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 V Alternators
9G-6081 , 6T-1196 40 36
D+ - Diode trio output. Alternator requires external excitation.
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.
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All Rights Reserved.
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