Changed alternator and still no charge

[shannondeese]

I have gone through the trouble shooting steps so many times I can't see straight anymore. So I'm here to ask for some help. I have a Deuce that has a charging issue. I am getting 23 VDC at the exciter wire. 23VDC at the batteries. But 0 VDC at the alternator out put terminal. I have changed to a known good alternator and still have the same problem. The trouble shooting manual says to now change wire 2. Which is fine if I knew where wire 2 goes. It disappears into the wiring harness right under the alternator. Any and all help would be appreciated. Thanks.

 

[donnerwetter58]

The alternator output (wire 2) should have battery voltage on it as it goes to battery +. Wire 2 goes from the alternator to the starter solenoid where it is connected to the same stud as the battery + cable.
Sounds like good advice from the TM as wire 2 has to be open to read 0 V.

 

[doghead]

This may help.

 

[shannondeese]

That's what I needed. Thanks. I am going to build a new #2 wire.

 

[shannondeese]

Today I cut the wrap off of the wiring harness running down the passenger side of the frame. The harness that has the #2 wire running from the alternator to the starter. I found a spot that was open to the air behind the exhaust flex coupling. I patched the area with liquid tape, rewrapped the harness and put it all back in the clamps. Now my truck charges like it is supposed too. Thanks for the help.

 

[steelandcanvas]

Was the wire shorting against the frame, or was it open?

 

[shannondeese]

It was open and I am assuming shorting against the clamp behind the exhaust. I couldn't see it because of the exhaust flex pipe. Once I removed that it was easy to find. But of course I had already pull the harness covering off by that point. I don't know if it was actually grounding out because it didn't look burned but the insulation was torn and exposing the wires to the air.

 

[JamesSummerville]

Electrical is easy until you get boards and brains, it is always a grounded wire cut wire or the insane like on this boat I worked on, put on a new power plant worked fine, on the boat nothing. 30 mins to hook up to the boat it didn't work. To make a long story short a perfect ice cream scoop of the control wire pack was cut out. Let me explain the perfect circle cut. Not sure what it is about.

 

[donnerwetter58]

I have a feeling you will be experiencing this problem again.
Wire 2 most likely has a broken conductor within the insulation that was moved back into contact when you were moving the harness around to unwrap it.
If the wire shorted you would see the evidence.

 

[steelandcanvas]

I have a feeling you will be experiencing this problem again.
Wire 2 most likely he has a broken conductor within the insulation that was moved back into contact when you were moving the harness around to unwrap it.
If the wire shorted you would see the evidence.

I agree, I think he should have cut the wire, installed a butt splice, and shrink tube over the splice. Finish wrapping everything back up with a GOOD quality electrical tape such as Scotch 33. His fix may come back to haunt him, as there are some broken conductors in that wire.