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05-27-2023, 09:38 PM
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#1
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Junior Member
Newmar Owners Club
Join Date: May 2023
Posts: 12
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2003 Kountry Star not charging from the Alternator
I am the new owner of a 2003 Kountry Star 3904 DP with a 3126 Cat and an Allison tranny. When I purchased it, I was aware there was a charging problem since the battery light was on on the dash and the test with a multi meter indicated no charge occurring at either of the sets of batteries. I got what I feel to be a good deal on it so I am willing to make some repairs that most likely will be self performed.
I spoke to the original owner (the seller was a flipper) and it was mentioned that a shade tree mechanic had wired the batteries incorrectly, I assume in series instead of series parallel they were wired in series sending 24VDC to the system.
The TCM was replaced by a Freightliner shop because the transmission wasn't shifting right according the original owner.
The coach drives fine when the batteries have a good charge and and so far all of the other items seem to function properly on generator power.
I have found the converter to be be bad (IOTA DLS-55). In my research I cannot find a good wiring diagram for the chassis electrical system. I am hoping there is a fuse that may be blown in the Alternator system so I don't have to R/R the alternator. Some diagrams indicate a 50 amp breaker.
I am in the beginnings of trouble shooting and it appears the relays are ok, but haven't been able to test the BIRD since I have nothing from the converter or the Alternator yet.
The questions are :
(1)-What is recommended for a new converter? Stick with the IOTA or go with something like a Powermax?
(2)-Does anyone have experience with the charging system from the Alternator to the batteries or decent wiring diagram?
Thanks for any input!
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05-28-2023, 12:48 AM
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#2
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Senior Member
Join Date: Jul 2014
Posts: 34,245
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Most alternators don't have fuses because it would need to be larger then the alternators output and if it blows, the alternator could burn out.
The main wire from the alternator may run right to the starter motors positive battery terminal.
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05-28-2023, 03:05 PM
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#3
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Senior Member
Tiffin Owners Club
Join Date: Jun 2017
Location: Odessa, FL
Posts: 264
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Post on Freightliner Forum
You might want to re-post on this site. There is a guy name Skip who can probably dig them up for you.
https://www.irv2.com/forums/f26/
__________________
2023 Tiffin Allegro Bus 45OPP
2019 Birkshire 34QS - Traded
2020 Jeep Cherokee Trailhawk with BlueOx/AF1
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05-28-2023, 07:13 PM
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#4
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Senior Member
Join Date: Apr 2011
Location: Powell River, B.C.
Posts: 30,382
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Quote:
Originally Posted by shepardmike
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No need Mike I found the post here . lol
43JOOP, your going to have to get , eyes on the alternator and get the brand info . I believe it'll be Leece-Neville. The alternator requires an ignition signal power feed to activate it .
The alternator output power cable and ground are attached to the starter at the main cables from the chassis battery .
From the chassis battery to the coach batteries is all Newmar through a BIRD system , probably in the power cable bay on the back wall.
Here's what I have for 2003 Freightliner XC chassis wiring schematics .
If the system was fed 24 volts ; just about anything could be wrong . 
And because the alternator is wired direct to the starter cables the 24 volts would have hit the alternator AS SOON as the batteries were hooked up.
__________________
99DSDP 3884, Freightliner, XC, CAT 3126B, 300 HP /ALLISON 3060
2000 Caravan toad, Remco & Blue Ox.
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05-28-2023, 07:19 PM
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#5
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Senior Member
Join Date: Apr 2011
Location: Powell River, B.C.
Posts: 30,382
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BTW;  and the Newmar family .
55 amp converter ; seems a little low for coach your size you may want to step up to a 70 amp . Particularly if you have four coach batteries .
__________________
99DSDP 3884, Freightliner, XC, CAT 3126B, 300 HP /ALLISON 3060
2000 Caravan toad, Remco & Blue Ox.
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05-28-2023, 09:10 PM
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#6
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Junior Member
Newmar Owners Club
Join Date: May 2023
Posts: 12
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Thanks for the input from all.
Skip426 thank you for the Chassis wiring diagrams and fingers crossed I will not be chasing a Gremlin.
I will let you folks know what I find once I get a chance to dig into more later this week.
Thanks again.
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05-28-2023, 09:33 PM
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#7
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Senior Member
Join Date: Apr 2011
Location: Powell River, B.C.
Posts: 30,382
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If you follow the alternator activation wire ( 71A PK ) back to the dash you'll find a 30 amp fuse #11 , but that fuse feeds a number of important items , so I doubt it's blown .
Hate to say it but with no alternator out put I'd suspect the internal regulator or diodes .
Is your coach a side rad or rear rad chassis ?
__________________
99DSDP 3884, Freightliner, XC, CAT 3126B, 300 HP /ALLISON 3060
2000 Caravan toad, Remco & Blue Ox.
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05-28-2023, 09:39 PM
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#8
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Junior Member
Newmar Owners Club
Join Date: May 2023
Posts: 12
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Quote:
Originally Posted by Skip426
If you follow the alternator activation wire ( 71A PK ) back to the dash you'll find a 30 amp fuse #11 , but that fuse feeds a number of important items , so I doubt it's blown .
Hate to say it but with no alternator out put I'd suspect the internal regulator or diodes .
Is your coach a side rad or rear rad chassis ?
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Its a rear RAD chassis.
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05-28-2023, 09:58 PM
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#9
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Senior Member
Join Date: Apr 2011
Location: Powell River, B.C.
Posts: 30,382
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Quote:
Originally Posted by 43JOOP
Its a rear RAD chassis.
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Ouch !
I got off lucky side rad chassis with no bedroom slide , when my alternator needed bearings , it was off the engine in 15 mins .
The Leece-Neville alternator is widely used in marine and RV so any number of places should be able to rebuild it .
__________________
99DSDP 3884, Freightliner, XC, CAT 3126B, 300 HP /ALLISON 3060
2000 Caravan toad, Remco & Blue Ox.
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05-28-2023, 10:03 PM
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#10
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Junior Member
Newmar Owners Club
Join Date: May 2023
Posts: 12
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Quote:
Originally Posted by Skip426
Ouch !
I got off lucky side rad chassis with no bedroom slide , when my alternator needed bearings , it was off the engine in 15 mins .
The Leece-Neville alternator is widely used in marine and RV so any number of places should be able to rebuild it .
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I guess I am lucky that it has a Bedroom slide. I am not looking forward to laying on my stomach to work on it but oh well, not any worse than the gasser repairs in the past! 
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05-28-2023, 10:21 PM
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#11
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Senior Member
Join Date: Dec 2019
Location: Canyon Lake, Texas
Posts: 2,932
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I just had my 200A Leese-Neville rebuilt. $590 with tax. They quoted $300-600 depending on what it needed.
__________________
2002 American Tradition 40'
Cummins 8.3, Banks 431hp, 1260 tq
Canyon Lake, TX
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05-29-2023, 05:52 AM
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#12
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Junior Member
Newmar Owners Club
Join Date: May 2023
Posts: 12
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Quote:
Originally Posted by Rob_M
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 thanks for the input!
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06-01-2023, 07:56 AM
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#13
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Junior Member
Newmar Owners Club
Join Date: May 2023
Posts: 12
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Update
Installed a new 75amp converter and the system is now charging and operating properly from the shore cord.
Dug into the alternator and found the hot wires disconnected from the alternator. Upon further inspection and testing found no output from the alternator.
During the troubleshooting process noticed the brushes where not connected to the regulator. possible the soldered connections over heated when the batteries where mis-wired.
Removed the alternator which sucks on the rear radiator chassis 
Next step to replace the alternator and fingers crossed that will be it.
All the other major items Fridge, generator, AC's are working properly.
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06-01-2023, 08:55 AM
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#14
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Senior Member
Join Date: Dec 2019
Location: Canyon Lake, Texas
Posts: 2,932
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Quote:
Originally Posted by 43JOOP
Installed a new 75amp converter and the system is now charging and operating properly from the shore cord.
Dug into the alternator and found the hot wires disconnected from the alternator. Upon further inspection and testing found no output from the alternator.
During the troubleshooting process noticed the brushes where not connected to the regulator. possible the soldered connections over heated when the batteries where mis-wired.
Removed the alternator which sucks on the rear radiator chassis
Next step to replace the alternator and fingers crossed that will be it.
All the other major items Fridge, generator, AC's are working properly. |
See post #40 in this thread for a new alternator source. Cheaper than what I spent on a rebuild of mine.
Stranded (again) in La Grange
https://www.irv2.com/forums/f115/stranded-again-in-la-grange-613244.html
__________________
2002 American Tradition 40'
Cummins 8.3, Banks 431hp, 1260 tq
Canyon Lake, TX
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