ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and QSL9 Engines – 013-001   Alternator

Check the drive belt and alternator pulley to be sure the alternator is rotating.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

Check the battery and all wiring connections.

Inspect the wiring for defects.

Check all connections for tightness and cleanliness, including the slip connectors at the alternator and engine compartment bulkhead, and connections at the battery.

NOTE: This test applies to Bosch® alternators.

With the ignition switch “ON” and all wiring harness leads connected, connect a voltmeter from:

Bosch®

• Alternator “BAT” “B+” terminal to ground
• Alternator Number 1 to ground
• Alternator Number 2 to ground
• Alternator D+ K1 to ground.

A zero reading indicates an open circuit between the alternator connections and the battery.

Locate and repair the open circuit.

Digital Multimeter, Part Number 3164488; Clamp-on Current Probe, Part Number 3823574:

Connect a carbon pile load (battery tester) across the battery posts of the battery boxes.

Clamp an induction pickup type amp meter around the battery cable, or use the digital multimeter, Cummins® Part Number 3164488, with the clamp-on current probe, Cummins® Part Number 3823574.

Digital Multimeter, Part Number 3164488:

Disconnect any cables that lead to any other battery boxes in the circuit, negative (-) cables first.

Operate the engine at high idle and measure the alternator voltage output to the batteries with digital multimeter, Part Number 3164488. See the alternator manufacturer’s specifications.

Operate the engine at high idle and adjust the systems analyzer/battery tester to apply the maximum rated amperage load to the alternator. See the alternator manufacturer’s specifications.

NOTE: The alternator maximum rated amperage output is normally stamped or labeled on the alternator.

Measure the alternator amperage output. See the alternator manufacturer’s specifications.

If the gauge on the carbon pile load testing equipment does not indicate approximately the same output as the induction-type ampmeter, determine which is defective and replace it. See the alternator manufacturer’s specifications.

If the alternator output (amps) is not within 10 percent of rated output, repair or replace the alternator. See the alternator manufacturer’s instructions for repair procedures.

Shut off the engine and remove the test equipment.

Connect all battery cables, negative (-) cable last.

NOTE: This test applies to Delco alternators.

NOTE: Any multimeter reading of zero voltage indicates an open circuit.

Check for open circuits.

Turn the keyswitch to the ON position.

Connect a multimeter, Cummins® Part Number 3164488 or 3164489, to the following locations:

Delco Alternators

• Alternator “BAT” terminal to ground
• Alternator blade terminal “Number 1” to ground
• Alternator blade terminal “Number 2” to ground

Locate and repair the open circuit.

Connect a carbon-pile load (battery/alternator tester) across the battery posts of the battery boxes.

Clamp an induction pickup-type ampere-hour meter around the battery cable; or use the digital multimeter, Part Number 3164488 or 3164489, with the clamp-on current probe, Part Number 3164490.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

WARNING  Acid is extremely dangerous and can damage the machinery and can also cause serious burns. Always provide a tank of strong soda water as a neutralizing agent when servicing the batteries. Wear goggles and protective clothing to reduce the possibility of serious personal injury.

Disconnect any cables that lead to any other battery boxes in the circuit, negative (-) cables first.

Operate the engine at high idle; and measure the alternator voltage output to the batteries with digital multimeter, Part Number 3164488 or 3164489. Refer to the OEM specifications.

Operate the engine at high idle and adjust the carbon-pile load-testing equipment to apply the maximum rated amperage load to the alternator. Refer to the OEM specifications.

NOTE: The alternator maximum rated amperage output is normally stamped or labeled on the alternator.

Measure the alternator amperage output. Refer to the OEM specifications.

If the alternator output (amps) is not within 10 percent of rated output, repair or replace the alternator. Refer to the OEM service manual for repair procedures.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

WARNING  Acid is extremely dangerous and can damage the machinery and can also cause serious burns. Always provide a tank of strong soda water as a neutralizing agent when servicing the batteries. Wear goggles and protective clothing to reduce the possibility of serious personal injury.

Shut off the engine and remove the test equipment.

Connect all battery cables, negative (-) cable last.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

Remove and tag all wires and complete the following steps:

• Disconnect the batteries. Refer to Procedure 013-009 in Section 13.
• Disconnect the battery ground cable.
• Remove the belt guard, if equipped. Refer to Procedure 008-001 in Section 1.
• Remove the drive belt from the alternator pulley. Refer to Procedure 008-002 in Section 8.
• Tag and label wires attached to the alternator.
• Remove the wires attached to the alternator.

Remove the alternator link capscrew.

Remove the alternator mounting capscrew.

Remove the alternator.

Loosen the alternator link capscrew at the engine mounting location.

Loosen the alternator link capscrew at the alternator.

Loosen the alternator mounting capscrew.

Remove the alternator link capscrew at the alternator.

Remove the alternator mounting capscrew.

Remove the alternator.

Install the alternator and alternator capscrews in the reverse order of removal.

Install the alternator link capscrew.

Install the alternator upper mounting bracket capscrew. Do not tighten at this time.

Install the alternator link capscrew at the alternator.

Tighten the upper mounting bracket capscrew.

Tighten the lower mounting link at the alternator and engine mounting location.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Install the drive belt. Refer to Procedure 008-002 in Section 8.
• Install the belt guard, if equipped. Refer to Procedure 008-001 in Section 8.
• Operate the engine and verify proper alternator operation.