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What size is the battery cable?
I use #4 on all the car's i wire and have never had an issue using alts that big. I would assume you cable is around 15 to 18 feet long right ?
If you are using #2 ther should be almost no voltage loss from the post at the rear of the altenator and the connection point on the battery. Is it a solid pc of wire? meaning no cut and spliced sections?

What kind of car with what kind of grounds?
There might be an issue with the engine ground (alt ground) and the ground to the car / battery.
 
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