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Hazard Definitions values of system volts and amps will depend on the
These terms are used to bring attention to presence of hazards level of battery discharge, in other words, the greater
of various risk levels or to important information concerning the battery discharge level the lower the system volts
product life. and higher the system amps will be. The volt and amp
Indicates presence of hazards readings will change and system volts reading will
CAUTION that will or can cause minor increase up to regulator set point and the system
personal injury or property damage if ignored. amps will decrease to low level (depending on other
Indicates special instructions loads) as the batteries recover and become fully
NOTICE on installation, operation or charged.
maintenance that are important but not related to
personal injury hazards. • Low Amps: A minimum or lowest charging system
amp value required to maintain battery state of
charge, obtained when testing the charging system
Table of Contents with a fully charged battery and no other loads
Section 1: Wiring Diagram ...................................... 2 applied. This value will vary with battery type.
Section 2: Basic Troubleshooting ............................ 3
• Medium Amps: A system amps value which can
Section 3: Advanced Troubleshooting ..................... 4
cause the battery temperature to rise above the
adequate charging temperature within 4-8 hours
Battery Conditions of charge time. To prevent battery damage the
Until temperatures of electrical charge amps should be reduced when battery
NOTICE system components stabilize, these temperature rises. Check battery manufacturer’s
conditions may be observed during cold start voltage tests. recommendations for proper charge amps rates.
• Maintenance/low maintenance battery: • High Amps: A system amps value which can cause
— Immediately after engine starts, system volts the battery temperature to rise above adequate
are lower than regulator setpoint with medium charging temperature within 2-3 hours. To prevent
amps. battery damage the charge amps should be
— 3-5 minutes into charge cycle, higher system reduced when the battery temperature rises.
volts and reduced amps. Check battery manufacturer’s recommendations
— 5-10 minutes into charge cycle, system volts for proper charge amp rates.
are at, or nearly at, regulator setpoint, and
amps are reduced to a minimum. • Battery Voltage: Steady-state voltage value as
— Low maintenance battery has same charac- measured with battery in open circuit with no
teristics with slightly longer recharge times. battery load. This value relates to battery-state of
charge.
• Maintenance-free battery:
— Immediately after engine start, system volts are • Charge Voltage: A voltage value obtained when
lower than regulator setpoint with low amps. the charging system is operating. This value will
— 15-30 minutes into charge cycle, still low volts be higher than battery voltage and must never
and low amps. exceed the regulator voltage set point.
— 15-30 minutes into charge cycle, volts increase • B+ Voltage: A voltage value obtained when mea-
several tenths. Amps increase gradually, then suring voltage at battery positive terminal or
quickly to medium to high amps. alternator B+ terminal.
— 20-35 minutes into charge cycle, volts increase
to setpoint and amps decrease. • Surface Charge: A higher than normal battery
voltage occurring when the battery is removed
• High-cycle maintenance-free battery: from a battery charger. The surface charge must
— These batteries respond better than standard be removed to determine true battery voltage and
maintenance-free. Charge acceptance of these state of charge.
batteries may display characteristics similar to
maintenance batteries. • Significant Magnetism: A change in the strength
or intensity of a magnetic field present in the
alternator rotor shaft when the field coil is ener-
Charge Volt and Amp Values gized. The magnetic field strength when the field
The volt and amp levels are a function of the battery- coil is energized should feel stronger than when
state of charge. If batteries are in a state of discharge, the field is not energized.
as after extended cranking time to start the engine,
the system volts, when measured after the engine is • Voltage Droop or Sag: A normal condition which
started will be lower than the regulator set point and occurs when the load demand on the alternator is
the system amps will be high. This is a normal greater than rated alternator output at given rotor
condition for the charging system. The measured shaft RPM.
Page 1
TG0002B
Section 1: Wiring Diagram C. E. Niehoff & Co.
BRUSHLESS ALTERNATORS
R Terminal
D+ Terminal
B+ Terminal
G G
G
B Ground Bolt
R Terminal
D+ Terminal
B+ Terminal
G
G G
B Ground Bolt
Page 2
TG0002B
C. E. Niehoff & Co.
BRUSHLESS ALTERNATORS Section 2: Basic Troubleshooting
5. Operate vehicle
Observe charge voltage.
If charge voltage is above
CAUTION 33 volts, immediately
shut down system. Electrical system damage may occur if
C. Preliminary Check-out charging system is allowed to operate at high voltage. Go to
Check condition of items in Table 1 and correct if Table 1 at left.
necessary.
If voltage is at or below regulator setpoint, let
TABLE 1 System Conditions charging system operate for several minutes to
normalize operating temperature.
SYMPTOM ACTION
6. Observe charge volts and amps
Low Voltage Output Check: loose drive belt; low Charge voltage should increase and charge amps
battery state of charge. should decrease. If charge voltage does not
Check: current load on increase within ten minutes, continue to next
system is greater than step.
alternator can produce.
Check: defective wiring or 7. Battery is considered fully charged if charge
poor ground path; low voltage is at regulator setpoint and charge amps
regulator setpoint. remain at lowest value for 10 minutes.
Check: defective alternator 8. If charging system is not performing properly,
and/or regulator. go to Chart 1, page 4.
High Voltage Output Check: wrong regulator.
Check: high regulator set-
point.
Check: defective regulator.
Check: alternator.
No Voltage Output Check: broken drive belt.
Check: battery voltage at
alternator output terminal.
Check: defective alternator
and/or regulator.
Check: self-energizing alter-
nator lost residual magne-
tism. Go to Chart 1, page 4.
Page 3
TG0002B
Section 3: Advanced Troubleshooting C. E. Niehoff & Co.
BRUSHLESS ALTERNATORS
START HERE
è Chart 1 – No Output – Test for Residual Magnetism
G
G
Go to Chart 2.
Momentarily (1 sec.) jumper D+ terminal on regulator to B+
terminal on alternator. Touch shaft with steel tool to detect any
magnetism. Is shaft magnetized?
Yes No
G G
Operate alternator. Does voltage output exist? Go to Chart 2.
Yes No
G G
System operating normally. Go to Chart 2.
Unplug alternator-to-regulator harness. Plug CEN Regulator Bypass Adapter A10-129 into harness plug. Clip
red lead to B+ terminal on alternator. Touch black lead to ground on alternator case. (If Adapter is not available,
connect jumper wires from pin B on harness to alternator B+ terminal and from pin C on harness to ground.)
Spark will occur at ground. Touch steel tool to shaft to detect any magnetism. Is shaft magnetized?
Yes No
G G
Disconnect Adapter or jumper wires. Disconnect Adapter or jumper wires. Alter-
Go to Chart 3. nator is defective.
Check for battery voltage across Pins A and E on plug end of harness. Does voltage exist?
Yes No
G
G
Alternator is defective.
Disconnect battery cable to B+ terminal on alternator. Connect red lead of
DMM to Pin B on plug end of harness. Connect black lead to B+ terminal PIN CONNECTIONS
on alternator. Does continuity exist? Pin A B
Pin B Field +
Yes No Pin C Field
Pin D AC
Alternator G Pin E B+
G
Yes No
G G Figure 3
Regulator is defective. Alternator is defective. Alternator-to-Regulator
Harness Plug
If you have questions about your alternator or any of these test procedures, or if you need to locate a Factory Authorized Service Distributor, please contact us at: