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From this link: (there are pictures at the link) http://www.steelsoldiers.com/cucv/56247-alternator-trouble.html Make sure your batteries are charged. Measure the battery voltage on each battery (positive to negative) and from the front battery negative to the back battery positive (write...

The exciter circuit passes through the lights. They should not go off until the alternators are producing electricity in a stock system. If they go off before the engine is running something is wrong.

The alternator lights come on when the key is turned on but then go off again before the truck is running?

Do both of the alternator lights come on when the key is on? Do they both go out when the truck is running? Does one come back on when the voltage drops ;ow?

Sounds like an alternator is not charging. It is also intermittent. It may be that when the alternator is tested it is good, when you put it back on the truck and run all the lights it is good. Come back a day later and run all the lights and the voltage drops low. The next time you get the...

Intermittent issues are tough, you have to be a the right place at the right time to catch them. Did you remove, clean and replace all the connections on 12V bus? How did you repair the 12V feed wire?

Is it the glow plug relay on the firewall chattering or the Gen 2 relay under the dash chattering? Either way it sounds like a bad (loose or corroded) connection. Warthog always says to test your fusible links by pulling on the real hard. They can open but still look okay from the outside...

So when you put a load on the electrical system (lights and wipers) then the truck voltage meter drops and a relay starts chattering (buzzing like a door buzzer)? Do the lights look dim when this happens? What voltage does each battery read when the truck meter is reading low?

Does this help?

Both. What reading do you get on each?

The glow plug relay should have two large terminals. One is the feed (in a stock system it is coming from the resistor on the firewall). The other has the orange wires that feed the glow plugs. When the truck is running and warm you should measure voltage on the feed wire but not the load...

I was looking at removing the large feed wire so that even if the relay is case grounded no power could get to the glow plugs. Do you have handheld volt meter? If so you can just measure on the glow plug side of the relay to if it is getting power to the glow plugs all of the time. If you...

The gar starts to surge and make noise? The glow plug relay? The glow plug relay is energized at all times when the key is on (pink/black wire). The glow plug controller grounds the light blue wire to energize the relay. Is there a problem where that relay is energized at all times? What...

I am still not following. What is surging? What is not working correctly?

Flipping out?

Unclesam colored the wiring diagrams that came out of the TMs which can be downloaded from this site. Warthog made these photos.

Does this help?