Kenworth T660 overvoltage only on startup

Discussion in 'Heavy Duty Diesel Truck Mechanics Forum' started by Sophia68, Jan 29, 2024.

  1. Sophia68

    Sophia68 Bobtail Member

    12
    9
    Feb 26, 2023
    Colorado
    0
    Have the STRANGEST problem:
    When I start my truck in the morning the volts go to 15.3 to 15.5 , voltage light comes on, then return to 14.8 after I start driving, light goes out and usually doesn't come back on unless I stop at a red light. Sometimes I will see a voltage fluctuation: up then back down.
    Battery load tested all batteries, all in green.
    Replaced 3 copper lugs that had some corrosion.
    All connections to alternator are tight. Pos and neg battery wires were recently cleaned and sprayed with battery terminal corrosion inhibitor.

    I read some where I should check for gunk that might have gotten between cables going to the starter.
    Checked alternator with truck running: shows its putting out 14.5 volts.

    What else can I look at?

    Thanks.
     
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  3. AModelCat

    AModelCat Road Train Member

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    Jul 7, 2015
    Canuckistan
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    What is the actual voltage at the alternator and batteries? That gauge on the dash probably isn't even an actual voltmeter and just reads whatever the ECM tells it to.
     
  4. uncleal13

    uncleal13 Road Train Member

    3,797
    6,297
    Apr 9, 2009
    Humboldt, Sk
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    The regulator in the alternator could be failing, it’ll probably stay on high voltage one day. Then it will cook your batteries.
    Some alternators have a voltage sensor line that is fused, maybe check the fuse panel for one. Cascadia’s have such a fuse.
     
  5. Sophia68

    Sophia68 Bobtail Member

    12
    9
    Feb 26, 2023
    Colorado
    0
    14.5 coming from the alternator posts
     
  6. JB7

    JB7 Heavy Load Member

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    1,647
    Dec 13, 2022
    Laurel, MD
    0
    Only checking with a meter does not tell much. Alternator should be tested with one of the newer type testers, batteries too. I would also want to know what voltage the ECM is reading at start up when the problem occurs by connecting to a laptop with software. May be a gauge problem. As uncleal13 stated there may be a regulator problem. Some systems the alternator is controlled by a module (ECM, PCM), with or without an internal electronic regulator. Were the batteries completely disconnected when they were tested?
     
  7. Sophia68

    Sophia68 Bobtail Member

    12
    9
    Feb 26, 2023
    Colorado
    0
    Thanks for all the kind responses. I took the alternator off, took off the rear cover and found an armature that goes to the voltage regulator had broken. It was nearly broken completely off but touching intermittently, hence the voltage fluctuations.
    Installed new alternator and back to 14.8 V

    Back on the road...
     
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