500 Series Troubleshooting Guide

for N1509 and N1511 Alternators

Hazard Definitions

These terms are used to bring attention to presence of hazards of

various risk levels or to important information concerning product
life.
Indicates presence of hazards
CAUTION
that will or can cause minor personal
injury or property damage if ignored.
Indicates special instructions
NOTICE
on installation, operation or maintenance that are important but not related to
personal injury hazards.

will be lower than the regulator setpoint and the system

amps will be high. This is a normal condition for the
charging system. The measured values of system volts
and amps will depend on the level of battery discharge.
In other words, the greater the battery discharge level,
the lower the system volts and higher the system amps
will be. The volt and amp readings will change, system
volts reading will increase up to regulator setpoint and
the system amps will decrease to low level (depending
on other loads) as the batteries recover and become fully
charged.

Low Amps: A minimum or lowest charging system

amp value required to maintain battery state of
charge, obtained when testing the charging system
with a fully charged battery and no other loads
applied. This value will vary with battery type.

Medium Amps: A system amps value which can

cause the battery temperature to rise above the
adequate charging temperature within 4-8 hours of
charge time. To prevent battery damage, the charge
amps should be reduced when battery temperature
rises. Check battery manufacturers recommendations for proper rates of charge amps.

High Amps: A system amps value which can cause

the battery temperature to rise above adequate charging temperature within 2-3 hours. To prevent battery
damage the charge amps should be reduced when
the battery temperature rises. Check battery manufacturers recommendations for proper rates
of charge amps.

Battery Voltage: Steady-state voltage value as measured with battery in open circuit with no battery
load. This value relates to battery state of charge.

Maintenance-free battery:
Immediately after engine start, system volts
are lower than regulator setpoint with low
charging amps.
15-30 minutes into charge cycle, still low volts
and low amps.
15-30 minutes into charge cycle, volts increase
several tenths. Amps increase gradually, then
quickly to medium to high amps.
20-35 minutes into charge cycle, volts increase
to setpoint and amps decrease.

Charge Voltage: A voltage value obtained when the

charging system is operating. This value will be
higher than battery voltage and must never exceed
the regulator voltage setpoint.

B+ Voltage: A voltage value obtained when measuring voltage at battery positive terminal or alternator
B+ terminal.

Surface Charge: A higher than normal battery voltage occurring when the battery is removed from a
battery charger. The surface charge must be removed
to determine true battery voltage and state of charge.

High-cycle maintenance-free battery:

These batteries respond better than standard
maintenance-free. Charge acceptance of these
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 energized. The
magnetic field strength when the field coil is energized should feel stronger than when the field is not
energized.

Voltage Droop or Sag: A normal condition which

occurs when the load demand on the alternator is
greater than rated alternator output at given rotor
shaft RPM.

Table of Contents

Section 1: Wiring Diagram........................................2

Section 2: Basic Troubleshooting .............................3
Section 3: Advanced Troubleshooting ................ 4 8

Battery Conditions

Until temperatures of electrical

system components stabilize, these
conditions may be observed during cold start voltage tests.

NOTICE

Maintenance/low maintenance battery:

Immediately after engine starts, system volts
are lower than regulator setpoint with medium
amps.
3-5 minutes into charge cycle, higher system
volts and reduced amps.
5-10 minutes into charge cycle, system volts
are at, or nearly at, regulator setpoint, and
amps are reduced to a minimum.
Low maintenance battery has same characteristics with slightly longer recharge times.

Charge Volt and Amp Values

The volt and amp levels are a function of the battery

state of charge. If batteries are in a state of discharge,
as after extended cranking time to start the engine, the
system volts, when measured after the engine is started

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Page 1

Section 1: Wiring Diagram

28 V System
LED Indicator
E terminal
T

AC terminal
T T

AC 14V 28V

maintains alternator output voltage at regulated

settings as vehicle electrical loads are switched
on and off.

maintains equal voltage across battery terminals

of series-connected batteries.

28 V B+
terminal
14 V B+
terminal

B Terminal

N3207 regulator used with some units:

N1509 and N1511 100 A (28 /14 V) dual voltage

alternators are internally rectified. All windings and
current-transmitting components are non-moving,
so there are no brushes or slip rings to wear out.
Energize switch (commonly an oil pressure switch)
activates regulator. Field coil is then energized. Upper
voltage (28 V) is rectified with standard diodes. Lower
voltage (14V) circuit output current is controlled by
SCRs in the drive end housing. Alternator output current is self-limiting and will not exceed rated capacity
of alternator.

14 V System
LED Indicator

CEN N1509 and N1511 Dual Voltage

Alternator Description and Operation

Figure 1 N1509 Alternator and N3207 Regulator Terminals

N2003 load and battery control device (LBCD) used

with these units provides dual-voltage reverse polarity
protection and independant control of battery-charging current.

Figure 1 N1511 Alternator and N3207 Regulator Terminals

Figure 2 N1509 and N1511 Alternators with Regulator

Page 2

TG0014D

Section 2: Basic Troubleshooting

A. Tools and Equipment for Job

D . Basic Troubleshooting

Digital Multimeter (DMM)

1.

Inspect charging system components

Check connections at ground cables, positive
cables, and regulator harness. Repair or replace
any damaged component before troubleshooting.

2.

Inspect load and battery control device

connections
Connections must be in proper sequence and
clean and tight. See Figure 5, page 7.

3.

Inspect connections of vehicle batteries

Connections must be clean and tight.

4.

Determine battery type, voltage and state

of charge
Batteries must be all the same type for system
operation. If batteries are discharged, recharge
or replace batteries as necessary. Electrical
system cannot be properly tested unless batteries are charged 95% or higher. See page 1 for
details.

5.

Connect meters to alternator

Connect red lead of DMM to alternator 28 V B+
terminal and black lead to alternator B terminal. Clamp inductive ammeter on 28 V B+
cable.

6.

Operate vehicle
Observe charge voltage.

Ammeter (digital, inductive)

Jumper wires
If no tools are available, monitor LED code.

B. Identification Record

List the following for proper troubleshooting:

Alternator model number ______________________

Regulator model number ______________________

Setpoint listed on regulator ____________________

LBCD model number __________________________

C. Preliminary Check-out

Check symptoms in Table 1 and correct if necessary.

TABLE 1 System Conditions
SYMPTOM

Low Voltage Output

High Voltage Output

No Voltage Output

No 14 V Output

TG0014D

If charge voltage is above

33 volts for 28 V system
or 16 V for 14 V system, immediately shut down system.
Electrical system damage may occur if charging system
is allowed to operate at excessive voltage. Go to
Table 1 at left.

ACTION
Check: loose drive belt; low battery state of charge.
Check: current load on system
is greater than alternator
can produce.
Check: defective wiring or poor
ground path; low regulator
setpoint.
Check: defective alternator
and/or regulator.
Check: wrong regulator.
Check: high regulator setpoint.
Check: defective regulator.
Check: alternator.
Check: presence of energize
signal.
Check: battery voltage at alternator output terminal.
Check: defective alternator
and/or regulator.
Go to Flashing Amber in
Table 2, page 6.

CAUTION

If voltage is at or below regulator setpoint, let

charging system operate for several minutes to
normalize operating temperature.
7.

Observe charge volts and amps in each circuit

Charge voltage should increase and charge amps
should decrease. If charge voltage does not increase within ten minutes, continue to next step.

8.

Batteries are considered fully charged if charge

voltage is at regulator setpoint and charge amps
remain at lowest value for 10 minutes.

9.

If charging system is not performing properly,

go to Chart 1, page 5.

Page 3

Section 3: Advanced Troubleshooting

N3207 Regulator

DESCRIPTION AND OPERATION

N3207 Regulator with OVCO is attached directly to
the outside of alternator. Regulator setpoint has
negative temperature compensation. At 75F, the
setting is 28.2 V for 28 V system and 14.1 V for
14 V system.
Main diagnostic feature of N3207 regulator consists
of two tricolored (red, amber, green) LEDs located on
the side of the regulator. One LED indicates 28 V
system performance, the other LED indicates 14 V
system performance. The two LEDs work independently of each other. See Table 2 for diagnostic
features and LED explanations.
OVCO (overvoltage cutout) will trip at any of the
following conditions:

14 V side trips at voltage higher than regulator setpoint that exists longer than 3 seconds of
reading voltage above 16 V. OVCO feature detects
overvoltage and reacts by signaling relay in F
alternator circuit to open. This turns off alternator
(14 V LED is steady RED light). OVCO circuit will
reset by either:
Restarting engine (regulator regains control of
alternator output voltage) OR
System falling below 11 V. OVCO will automatically reset.

28 V side trips at voltage higher than regulator setpoint that exists longer than 2 seconds of
reading voltage above 32 V. OVCO feature detects
overvoltage and reacts by signaling relay in F
alternator circuit to open. This turns off alternator
(28 V LED is steady RED light). OVCO circuit will
reset by either:
Restarting engine (regulator regains control of
alternator output voltage) OR
System falling below 22 V. OVCO will automatically reset.

TROUBLESHOOTING
Shut down vehicle and restart engine. If alternator
functions normally after restart, a no output condition was normal response of voltage regulator to
overvoltage condition. Inspect condition of electrical
system, including loose battery cables, both positive
and negative. If battery disconnects from system, it
could cause overvoltage condition in electrical system,
causing OVCO circuit to trip.
If you have reset alternator once, and electrical system
returns to normal charge voltage condition, there may
have been a one time, overvoltage spike that caused
OVCO circuit to trip.
If OVCO circuit repeats cutout a second time in short
succession and shuts off alternator F circuit, try
third restart. If OVCO circuit repeats cutout a third
time, check color of LED while engine is running.
28 V RED LED - go to Chart 3, page 6.
14 V RED LED - go to Chart 4, page 6.

TABLE 2 N3207 Regulator LED Diagnostics

LED COLOR

STATUS

OFF

Regulator is not energized. Measure E terminal voltage. If voltage above 21 V, regulator is defective.

FLASHING
Green

Respective system voltage is at regulated setting and operating under control.

Amber

Respective system voltage is below regulated setting. Alternator is not producing power or circuit is
overloaded. See Chart 1 on page 5 for 28 V systems, Chart 2 for 14 V systems.

Red

Respective system voltage is above regulated setting. This may occur intermittently with voltage
transients or with system faults.

STEADY
Red

Page 4

Alternator is shut down and is not producing power for either voltage. 28 V side trips after
2 seconds of reading voltage above 32 V. 14 V side trips after 3 seconds of reading voltage above
16 V. Regulator remains in this mode until reset by restarting engine or if system voltage drops
below 22 V or 11 V, respectively. See Chart 3 on page 6 for 28V systems, Chart 4 for 14 V systems.

TG0014D

Section 3: Advanced Troubleshooting

(CONTD)

Chart 1 28 V LED Flashing AMBER No 28V Alternator Output Test Charging Circuit

STATIC TEST MASTER SWITCH ON, KEY ON, ENGINE OFF

Test for battery voltage at alternator 28 V B+ terminal. Does battery voltage exist?
Yes

No

Repair vehicle wiring as necessary. Continue test.

Jumper 28 V B+ terminal on alternator to E terminal on regulator. Wait 10 seconds. Run engine. Does
alternator charge and is 28 V LED flashing GREEN?
No

Yes

Turn off engine, leave key on. Remove jumper wire. Go to E

terminal on regulator. Test for battery voltage going into E
terminal from battery. Does battery voltage exist?
Yes
No

Repair vehicle circuit to E terminal. Vehicle charging circuit test is complete.

Turn off engine, leave key on. Connect

jumper wire from pin A in harness plug to
B terminal on alternator. Spark will occur.
Touch steel tool to shaft to detect significant
magnetism. is shaft magnetized?
Yes

No

Alternator is
defective.

Run engine and re-test charging circuit for operation.

Test for battery voltage at pin D in harness

plug. Does battery voltage exist?
Yes

No

Alternator is
defective.

Connect DMM red lead to pin C on

harness plug. Connect black leak to alternator B terminal. Does continuity exist?
Yes

No

Alternator is
defective.
PIN CONNECTIONS
Pin A
F
Pin B
SCR Gate
Pin C
B
Pin D
28 V B+
Pin E
14V B+
Pin F
AC

Figure 3 Alternator-to-Regulator Harness Plug

Set DMM to diode test. Connect DMM red

lead to pin F on harness plug. Connect
black leak to alternator B+ terminal.
Reverse leads. Meter should read OL in
one direction, and voltage drop in the other
direction. Do tests prove out?
Yes

Regulator is
defective.

TG0014D

No

Alternator is
defective.

Page 5

Section 3: Advanced Troubleshooting

(CONTD)

Chart 2 14 V LED Flashing AMBER No 14 V Alternator Output Test Circuit

Yes

Run engine. Is 28 V LED on regulator flashing GREEN?

No

Go to Chart 1.

T
Yes

With engine off, is battery voltage present at alternator 14 V B+ terminal?

No

Repair vehicle wiring

as necessary. Continue test.

Connect DMM red lead to pin E on alternator-to-regulator harness plug.

Connect black lead to pin C on same plug. Does battery voltage exist?
Yes
No

Alternator is defective.

T
Substitute a known good regulator. Run engine. Is regulator setpoint voltage present and is 14 V LED flashing GREEN?

Yes

No

T
Alternator is defective.

Original regulator was defective.

Chart 3 28 V LED Steady RED No Alternator Output Test OVCO Circuit

Remove 28 V and 14 V positive battery cables AT BATTERY PACK before proceeding.

Unplug alternator-to-regulator harness from regulator. Connect red lead from DMM to socket A in plug.
Connect black lead to socket D in plug. Does resistance read 2.2 0.2 ohms?
No

Yes

T
Alternator is defective.

T
Set DMM to manual ohms scale. Connect red lead from DMM to socket A in plug. Connect black lead to B
terminal. Does meter read OL (out of limits)? Then connect red lead to socket D and black lead to B terminal. Does meter read OL (out of limits)?
Yes
No

Alternator is defective.

Reconnect cables. Replace existing regulator with known

good regulator. Run engine. Does OVCO trip?
Yes

No

Alternator is defective.

Original regulator is defective.

Chart 4 14 V LED Steady RED No Alternator Output Test OVCO Circuit

Run engine. Is 28 V LED on regulator flashing GREEN?
Yes

No

Replace regulator with known good regulator. Run engine. Does OVCO trip?
Yes

Alternator is defective.

Page 6

Go to Chart 3.

No

Original regulator is defective.

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Section 3: Advanced Troubleshooting

N2003 Load & Battery Control Device
DESCRIPTION AND OPERATION

Main diagnostic feature of the LBCD is an LED

display located on the side of the device. The LBCD
monitors alternator output and vehicle electrical
system and regulated voltage. If system voltage falls
below 20.5 volts, N2003 will disconnect batteries
and supply trickle charge. See Table 3 for diagnostic
features and LED display explanations.

Pin

TABLE 4 N2003 Harness Plug

Pin Functions
Function

Battery Ground

Chg. System Indicator Ground Signal

Battery Disconnect Ground Signal

AC In from Regulator AC Terminal

Battery Voltage Sense/Trickle Charge

TABLE 3 N2003 Load & Battery Control Device Diagnostics

CHARGING
SYSTEM LED
STATUS

N2003 LED
COLOR

ON

Unlit (Clear)

Alternator not charging.

ON

Solid Amber

Alternator RPM below 1500 rpm.

OFF

Solid Green

System operating properly. Batteries are

connected to system. Alternator charging.

OFF

Solid Red

N2003 STATUS

Batteries are disconnected from system and

battery voltage is less than 24.5 V. Alternator
28 V B+ output terminal is at regulated voltage.

Figure 4 N2003
Control Harness Receptacle

12 V Battery
12 V Load
T

24 V Load
T

24 V Battery
T
T

LED

Figure 5 N2003 Load & Battery Control Device

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Page 7

Section 3: Advanced Troubleshooting

(CONTD)

Chart 5 28V Only N2003 Sequence of Operation

DYNAMIC TEST MASTER SWITCH ON, KEY ON, ENGINE ON

Start

T
Steady AMBER

T
T

Read RPM

T
Is RPM greater than 1500?
No

Yes

Charging system indicator

LED is OFF.
Wait ten seconds.

T
Read System Voltage

T
Is System Voltage less than 20.5 V?
Yes

No

T
Steady RED

T
Steady RED

Batteries are disconnected.

Are batteries disconnected?

Read Alternator Voltage

T
Is Alternator Voltage less than 24 V?
No

Yes

Steady GREEN.
System is operating
properly.

Trickle charge
OFF.

Trickle charge
ON.

Yes

No

Connect batteries and

then go back to
Read System Voltage
above

LBCD is defective. Replace.

Read Battery Voltage

T
Is Battery Voltage more than 24.5 V
for one time and one time only?
Yes

No

T
Batteries are reconnected.
Steady GREEN.
System is operating properly.
If you have questions about your alternator or any of these test procedures, or if you need to locate a Factory Authorized Service Dealer, please contact us at:

Page 8

C. E. Niehoff & Co. 2021 Lee Street Evanston, IL 60202 USA

TEL: 800.643.4633 USA and Canada TEL: 847.866.6030 outside USA and Canada FAX: 847.492.1242
E-mail us at [email protected] OR visit our Web site at www.CENiehoff.com

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