'83 D150 overcharge

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If touching both terminals resulted in an open, then the alternator can not work. We know the alternator does work. Make sure you have good contact, and if need be rotate the pulley asliughtly. The carbon brushes add resistance but not 200 ohms worth.

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Then check each to ground. if they still show open, then they are not grounding internally.
 
What would cause it to be open?
Read this and you can see what's inside the magic box that could be broken.

However since the alternator was producing power, I suspect the measuring was faulty
 
Put it on 200 setting as low as it goes. Touched both terminals reads this. Same thing with each terminal to the ground on the alternator the truck body or case of alt.

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Does not look like the meter is working. That is a stupid display I guess they are trying to say "I" as in "Infinity" or "open." But it looks like it is saying 1 something ohms. Anyhow the meter may be defective or one probe open. Try the other resistance settings.

Make CERTAIN your probes are held hard together. If that does not work, remove either probe from the meter, and take the remaining connected on and touch it into the vacant connector. Then remove that probe from the meter and try the other lead

The main thing we are trying to find out, is whether the rotor or either brush holder is shorted to the case. Again, you should have continuity BETWEEN the two brush terminals, but open from either to the case.
 
Just want to state that the alt is new rebuilt and this problem existed with previous alt aswell
 
When I put the meter together it reads 0.1 ohms when I put it on alternator field terminals and no continuity. Sorry about the cheap meter.
 
Tested out another VR with the meter. Reads 1.6 ohms at 20k setting. So I think the meter works.
 
Tested out another VR with the meter. Reads 1.6 ohms at 20k setting. So I think the meter works.
Why are you measuring a VR?

First establish how the meter works.
If touching the probes together is zero, then no touching 1 . that should be infinity.
Next if you want to test a known or somewhat known, measure the resistance of each resistor.

Now go back to the alternator. Is either terminal shorting to the housing? Does the meter reads infinity?
Then check for continuity between the the two terminals.
 
Based on this I'd start with the 2000 Ohm range and see what it shows.
Maybe the 200 ohm range is dead.
GAR_TL_077.pdf
When testing the dual ballast resistors, one should be around 5 ohms and the other 0.5 ohms. But at some point the 0.5 ohms was changed. Your shop manual will say what it should be in '85.
 
First establish how the meter works.
If touching the probes together is zero, then no touching 1 . that should be infinity.
This is exactly what happens.

Now go back to the alternator. Is either terminal shorting to the housing? Does the meter reads infinity?
Then check for continuity between the the two terminals.

With all tests meter reads infinity. No continuity between terminals.
 
When testing the dual ballast resistors, one should be around 5 ohms and the other 0.5 ohms. But at some point the 0.5 ohms was changed. Your shop manual will say what it should be in '85.
Which probes go where for this test? Key on or off?
 
If I put one on battery negative and one on ballast resistors one reads 017 one reads 018 I think that you may be right that the meter is junk. Any suggestions on a replacement?
 

Thought I'd start it up and test again. When ignition going now there is no charge at battery. Just reads 12.4v which is same as engine off.
 
If I put one on battery negative and one on ballast resistors one reads 017 one reads 018 I think that you may be right that the meter is junk. Any suggestions on a replacement?
Don't be doing random stuff like this. Meters may not be protected, and you NEVER do resistance tests on circuits which MAY have power applied.
 
Try this. Take your alternator, "rig" a couple of wire leads, either with alligator clips or the push on flag/ spade terminals and connect them to the field terminals. hold one to a good ground, like the block, and touch the other to battery POS. In subdued lighting, you should see a spark. Sometimes you can even HEAR the spark, if your hearing is good.

There is no possible way that alternator can charge at ALL if the field is open. It is a simple electromagnetic coil (electromagnet) connected between the two field / brush terminals.
 
Don't be doing random stuff like this. Meters may not be protected, and you NEVER do resistance tests on circuits which MAY have power applied.
After doing proper between two points on ballast resistor reads 1.5 on 200 ohms

Try this. Take your alternator, "rig" a couple of wire leads, either with alligator clips or the push on flag/ spade terminals and connect them to the field terminals. hold one to a good ground, like the block, and touch the other to battery POS. In subdued lighting, you should see a spark. Sometimes you can even HEAR the spark, if your hearing is good.
Definitely no spark.
 
Weird. I would pull the brushes. An alternator cannot charge without power/ current in the field
 
I feel pulling the brushes may be beyond my skill/tool set. I'm currently using a remanufactured ACDelco alternator.
 
Pulled the brushes and one fell apart. I'll get back here after the ones I ordered arrive. Thanks for all the help and patience.
 
Weird. I would pull the brushes. An alternator cannot charge without power/ current in the field

So I turned the truck on today with the alternator with open field (currently one brush broken) and began to overcharge the battery up to 16+ volts. Unplugged the VR and the same. It only went back to 12.8 v when I unplugged the red wire from the field terminal in the alternator. Is this normal?
 
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