In May of 2020 I bought a 90-01-4513 alternator to replace a Delco Remy 36SI. This alternator is a factory refurbished model and is rated at 160A. It has A 14gauge remote sense wire with a 5A fuse located 6 inches from four 990CCA AGM Deep cycle batteries in an '06 Western Star. The alternator charges all day at 2 and 13 AMPs and maintains a voltage about 13.5V. I have a large stereo 1000W but a 20 farad capacitor feeds both amps and consistently maintains 14V that it sips from the system. When the truck is initially started it will put out 50+ amps for a short period of time to replenish the batteries. I have a 5000W pure sine inverter with two pair of large cables, 200A fuses and a casing ground wire and once a day I cook a meal with the truck running at high idle. The voltage never drops below 12V and the alternator will peak at 90A and this will continue for anywhere from 30-60 minutes. I did this routinely with the Delco Remy but after two months the Wilson suddenly stopped charging. I replaced it under warranty through O'Reilly's and low and behold within the same time period the 2nd one also failed. This is a 160A rated alternator and I just cannot accept that this product isn't capable of this. A benchmark certificate came with each of them showing twice that, 183A tested after rebuild. How can they be failing? All I really overworking them. I've sent the scenario to Wilson to gather their response. In the meantime I still have my Delco Remy 36SI and believe I will diagnose and replace the failed components and have it ready this time. I better get cooking as it would seem I only have two months. Of course, there's still 7.5 months left on my warranty.
Alternator stops charging after 2 months
Discussion in 'Heavy Duty Diesel Truck Mechanics Forum' started by Lockport, Sep 19, 2020.
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Does the alternator get hot to the touch? I've driven "alternator eaters" and it usually was a bad ground.
truckdriver31 Thanks this. -
201 Thanks this.
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A sick battery or 2 will cause alternator to burn up as well.
truckdriver31 Thanks this. -
There's also one ground cable at the batteries that has considerable frayed and broken strands, so I'll be replacing the lug on that cable as well. -
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At the threshold of larger cables - that last post should say.
Seems to be 120°f after 13h drive (CA legal)
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