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Service Bulletin
Please remove General Service Bulletin 191 iss 1 and put this in its place. More information has been added.

General 203 Issue 1

Alternator Testing and Diagnostic Procedure January 2007

This bulletin applies to all 12 or 24 volt alternators that have an internal fan (A1).

A
Alternators that have an internal fan (A1) and are returned for warranty claims have been found to have no
faults. Incorrect diagnosis of faults has been attributed to:
Loose alternator connections
An inadequate ground path for the alternator to the battery
Poor battery condition
Incorrect pass or fail criteria for the alternator output.
For more information on the pass or fail criteria for the alternator output, refer to step 8 of test procedure, The
Alternator is not Charging or the Tachometer is not Operating or the Tachometer has an Intermittant Fault.
The following alternator testing and diagnosis procedure should be followed before a suspect alternator is
replaced.

Notes:
Stop the engine.
Before electrical connections are serviced, ensure that the battery is isolated from the circuit. There are
two methods for isolating the battery from the circuit. Disconnect the battery from the terminal or use the
battery isolation switch. Failure to isolate the battery from the circuit may cause the alternator diode and
regulator pack to fail.
If an alternator failure has occured, this may be due to an incorrect application or incorrect service
procedures. If any of these reasons are suspected to have occured, the validity of the warranty claim should
be questioned.

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Service Bulletin - General 203 Issue 1 January 2007

Inspection of the Alternator

Check the condition of alternator drive belt. Refer to the relevant Operation and Maintenance Manual,
Alternator and Fan Belts - Inspect for the correct procedure.
Check the condition of the battery. Refer to the relevant Operation and Maintenance Manual, Battery
Electrolyte Level - Check for the correct procedure.
Check the condition of the battery terminals. Check the condition of the connections in the charging circuit.
Ensure that there are no loose or corroded connections. Any loose or corroded connections should be cleaned
or replaced and tightened securely.
The alternator requires a good earth path from the alternator housing to the battery earth. If the alternator
bracket is painted then the bracket should be removed. Any paint on the bracket must be removed from the
mounting surfaces between the alternator and mounting bracket and the mounting bracket to the cylinder
block.
If the alternator is contaminated with dust or dirt then a compressed air line should be used to blow dirt from
alternator vents.
Warning! Personal injury can result from air pressure. Personal injury can result without following proper
procedure. When using pressure air, wear a protective face shield and protective clothing. Maximum air
pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.
If the points that are described in the inspection of the alternator section do not rectify the fault refer to the test
procedures section for the specific fault.
Note: When performing any diagnostic checks a good ground must be used to prevent incorrect diagnosis.
When finding ground it is recommended using either an area of the alternator body or application chassis that
is free from corrosion or paint.

Test Procedures
The following test procedures will assist you in fault finding on the alternator.

The Alternator is not Charging or the Tachometer is not Operating or the Tachometer
has an Intermittant Fault
1 Stop the engine.
2 Disconnect the battery before removing any connections from the B+ terminal (B1).
3 Identify the B+ terminal (B1) on the rear of the alternator.
Note: Dependant on the alternator types the back cover and terminals will vary in appearance. However, the
B+ terminal assembly and rectification procedure is common with all alternator types.

B
4 Remove the cables from the B+ terminal to reveal the lower B+ terminal securing nut (C1).

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C D
Note: Ensure that the lower nut (D1) is fitted correctly. If the lower B+ nut (D1) and collar (D2) assembly is not
secure the alternator may fail to charge, charge intermittently or the tachometer output may fail or fail
intermittently.
5 Tighten the nut (C1) to a torque of 4-5 Nm (35-44 lb in).
6 Fit the connections. Tighten the connections to the the following torques:
B+ terminal 7 Nm (62 lb in)
D+ terminal 3.7 Nm (33 lb in)
W terminal 3.7 Nm (33 lb in).
7 Reconnect the battery. Refer to Operation and Maintenance Manual, Battery - Replace.
8 Run the engine. Check that the alternator is charging and that the tachometer is reading correctly. The
alternator should charge between 13 and 15 volts for a 12 volt system and 26 to 30 volts for a 24 volt system,
when measured between the B+ terminal and the alternator body. If the voltage does not meet this
specification then the unit should be changed.

The Warning Lamp does not Illuminate

The warning lamp for the charging system should illuminate when the ignition switch is in the ON position and
the engine is not in operation.
Note: Do not run the engine.
1 Check the warning light bulb. If necessary, replace the warning light bulb.
2 Use a multimeter to check and record the battery voltage.
3 Check and record the voltage between the B+ terminal and ground. The measured voltage should equal that
of the battery voltage. If the measured voltage does not meet the battery voltage and the procedures for
checking electrical connections have been completed, then the alternator should be replaced.
4 Turn the ignition switch to the ON position. Measure and record the voltage between the D+ terminal (C2)
and ground. If the recorded voltage is greater than 2 volts then the alternator should be replaced.
Note: This voltage will be greater when the engine is running.

The Warning Light Remains On When The Engines is Running

1 Start the engine. Run the engine at a fast idle.
2 Measure and record the voltage between the B+ terminal and ground.
3 Measure and record the voltage between the D+ terminal and ground.
4 The measured voltage at the B+ terminal and D+ terminal should be 13 to 15 volts for a 12 volt system and
26 to 30 volts for a 24 volt system. If the measured voltages meet this specification, proceed to step 5. If the
measured voltages do not meet this specification and the procedures for checking the alternator belt, battery
condition and electrical connections have been completed, then the alternator should be replaced.
5 The engine speed should be increased to a high idle and an electrical load should be turned on such as
lights or heater fan.

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Service Bulletin - General 203 Issue 1 January 2007

6 Measure and record the voltage between the B+ terminal and ground.
7 Measure and record the voltage between the D+ terminal and ground.
8 The measured voltage for the B+ and D+ terminal should be 13 to 15 volts for a 12 volt system and 26 to 30
volts for a 24 volt system. If the measured voltages do not meet this specification and the procedures for
checking the alternator belt, battery condition and electrical connections have been completed, then the
alternator should be replaced.

Potential Alternator Diode Failure

All alternators (Perkins part numbers 2871A301, 2871A302, 2871A303, 2871A304, 2871A305, 2871A701 and
2871A702) may fail due to internal diode failure. Diode failure may occur when the alternator is subjected to
excessive reverse voltage or over voltage.
Reverse voltage and over voltage in applications has been identified as being due to:
Incorrect jump starting of engine
Incorrect battery isolation when welding on the engine
Disconnection of the charging circuit when the engine is running (e.g. by battery isolation switch)
Incorrect installation of battery connections
Loose charging circuit connections resulting in intermittent connection and excessive reverse voltage
transients
Inadequate or intermittent ground path from the alternator to battery resulting in intermittent connection
and excessive reverse voltage transients.
Ensure the following procedures are adhered to prevent alternator diode failure:
Ensure that jumper leads are connected correctly. Refer to Operation and Maintenance Manual, Starting With
Jump Start Cables for the correct procedure.
Ensure that the correct welding procedures are adhered to. Refer to Operation and Maintenance Manual,
Welding On Engines With Electronic Controls for the correct procedures.

Procedure to Disconnect the Charging Circuit

Do not stop the engine using the battery isolation switch

Ensure the engine has stopped before the battery is disconnected
Before servicing any electrical connections ensure that the battery is isolated from the circuit using the
battery isolation switch or disconnection from the battery terminal
Ensure charging circuit connections are maintained. The alternator requires a good earth path from the
alternator housing to the battery earth.

Return of Failed Component

If any of the test procedures indicate that the alternator has failed then the alternator should be replaced. Care
should be taken when disassembling the alternator and pulley to ensure neither component is damaged. To fit
an alternator, refer to Disassembly and Assembly, Alternator - Install for the correct procedures, service tools
and torques.
Note: Any alternator returned under warranty that features a damaged cooling fan, electrical internals
disassembled or with corroded or arching on the terminals, due to incorrect customer cable installation, will be
rejected as a warranty claim. Defective alternators returned to Peterborough under the Parts Return Process,
should be packed to ensure no transit damage (the end cover is vulnerable).
The submitted warranty claim, should also detail the test results and figures of the diagnoses procedure.

End

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Service Bulletin - General 203 Issue 1 January 2007

Issued by Perkins Engines Company Ltd, Peterborough PE1 5NA, England. Proprietary information of Perkins Engines Company Ltd
2007, all rights reserved. The information is correct at the time of print. This bulletin is for technical information only and cannot be used
as a basis for any claim including but not limited to warranty.

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