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If there is little or no magnetic pull at the pulley shaft or at the rear bearing, initiate the following test:
With the key off and the engine off, remove the large harness plug from the regulator.

Insert the end of a short length of electrical wire to the RED connector slot of 

the regulator harness and the other end of the wire to the BLUE connector slot. 

This bypasses the regulator and tests the alternator and the harness.
Using your steel screwdriver, inspect for a magnetic field as described above.
With your voltmeter, check for voltage on the blue wire at the alternator. If volt-

age does not exist, the harness may be at fault. If voltage does exist at the 

harness, but no magnetism is present, the alternator is likely to be malfunc-

tioning.
If a magnetic field is present. Both harness and alternator brushes and rotor 

appear to be working properly. If no magnetic field is present, proceed with the 

next test.

Testing the actual output of the alternator is known as “Full Field Testing”. This can 

be accomplished by jumping a positive 12VDC current to the field terminal at the 

rear of the alternator. This test eliminates both the regulator and the harness, mak-

ing it easier to isolate your investigation to the alternator.
CAUTION: Ensure that all voltage sensitive equipment is turned off prior to starting the engine. Voltage is unregulated 

during this test and could damage sensitive electronics. DO NOT let the engine run any longer than necessary to detect 

charging. If the system is not charging, remove the alternator and have it inspected by a qualified alternator shop, or call 

Balmar for warranty evaluation.
To test the alternator:

Clip a jumper wire to the positive post of the alternator, or on the battery side of the isolator (if an isolator is in use). 

Use a SHIELDED alligator clip for post attachment. Unintentional contact between the alligator clip and the alternator 

case could result in damage to your electrical system.
Disconnect the field/stator plug from the rear of the alternator and attach the other end of the jumper wire to the al-

ternator’s Field terminal (F). Attach a female spade connector to the field end of the wire for a solid connection. CAU-

TION: Do not allow the wire to contact the case while it is attached to the positive post. The case is grounded and 

severe damage could occur.
The regulator is now bypassed. When the ignition is engaged and the motor is started, the voltage should rise and 

charging current should be present.
The motor should be run long enough to determine that charging voltage is present. Unregulated voltage can rise 

quickly. Do not allow extended unregulated charging to occur without carefully monitoring voltage levels. If the alterna-

tor fails to generate voltage during field testing, a malfunction of the alternator is likely. Contact your local alternator 

repair shop or Balmar’s technical service staff for recommendations.

Conclusion

If your readings differ substantially from the “Expected Readings” listed in the troubleshooting charts, the regulator may 

be malfunctioning, or there may be a continuity problem. Contact our technical support staff at (360) 435-6100. If you 

determine that repair service is necessary for either your alternator or regulator, please gather the following information 

before contacting our service technicians: Make and model of alternator. Model of voltage regulator and date of mfg. (date 

punched on rear side label of regulator). Voltage readings on red, brown and blue wire at regulator with engine off, key on. 

Voltage readings on red, brown and blue wire at regulator with engine running at a fast ideal 1400 rpm.

NOTES:

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- 15 -

Summary of Contents for MAX CHARGE MC-612-DUAL

Page 1: ...ternators are being used to charge the same large battery bank The MC 612 DUAL provides two field output connectors two power input connectors and two system ground connections making it pos sible to...

Page 2: ...rom inverters transmitters and other sources of RF noise convenient access and readability of the display The regulator wiring harness is 54 inches long providing a three to four foot radius for mount...

Page 3: ...BATTERY Temperature Sensor MC TS A Sensor lug connects to negative battery post enabling regula tor to monitor and respond to battery temperature condition USE CARE TO ENSURE POSITIVE AND NEGATIVE WI...

Page 4: ...switch or to the wire in the existing engine wiring loom that delivers switched voltage from the ignition switch In some cases an oil pressure switch may be used to activate the regulator In either ca...

Page 5: ...e 1 4 spade terminal from the terminal 12 pin Crimp the spade terminal to the sense wire and reconnect the spade to the 12 terminal pin Data TX and RX Terminals 13 and 14 Are currently for factory use...

Page 6: ...gramming features Included with the regulator is a small screwdriver that doubles as the regulator s programming tool A small magnet embedded in the tip of the screwdriver s handle allows the user to...

Page 7: ...ds the bulk charge time by an additional six minutes and compares real time to target values This will re occur until all values are met 5 Ramps down to Absorption voltage 6 Absorption Charge Regulato...

Page 8: ...code Indicates temperature setpoint for ambient alternator and battery temperatures Followed by degrees celsius Indicates in millivolts the voltage value used to control voltage compensation for batt...

Page 9: ...AgL Optima OPS as well as a factory default program UFP and a program for systems with voltage sensitive halogen equipment HAL Programming can be accomplished whenever the regulator is activated Syste...

Page 10: ...16 and 17 Programming For Secondary Alternator OR Regulator Temperature Sensor The regulator allows the user to select between the use or a second battery temperature sensor or a second alternator tem...

Page 11: ...ues for that mode will begin to scroll in the opposite direction Continue to HOLD until the desired value is displayed 4 REMOVE the magnet from the RED dot The mode indicator will be displayed again f...

Page 12: ...indicated Field Threshold Bulk To Absorption Controls the criteria the regulator uses to determine how hard the alternator has to be working to stay in calculated bulk charging mode Factory set at 67...

Page 13: ...at s capable of providing a signal to a user supplied and installed audible or visual alert to indicate the following while the regulator is in operation Small Engine Mode is activated Regulator is at...

Page 14: ...tery Sense wire and there is zero or an unexpected voltage reading at the BLUE wire contact our technical support staff at 360 435 6100 or e mail us at balmar balmar net If all voltages at the regulat...

Page 15: ...tery side of the isolator if an isolator is in use Use a SHIELDED alligator clip for post attachment Unintentional contact between the alligator clip and the alternator case could result in damage to...

Page 16: ...eplacement In order to expedite warranty claims more efficiently BALMAR asks that prior to returning a defective product for repair you call their customer service department for a warranty return aut...

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