C. E. Niehoff & Co.

C. E. Niehoff & Co.

BRUSHLESS ALTERNATORS
C612/C617/C621 Alternators
BRUSHLESS ALTERNATORS
Troubleshooting Guide

Hazard Definitions — 15-30 minutes into charge cycle, volts

rise several tenths, amps increase grad-
These terms are used to bring attention to presence of
ually, then increase quickly to medium
hazards of various risk levels or to important information
to high amps.
concerning product life.
— 20-35 minutes into charge cycle, volts
rise to setpoint and amps lower.
Indicates presence of hazards
CAUTION that will or can cause minor • High-cycle maintenance-free battery:
personal injury or property damage if ignored. — These batteries respond better than stand-
ard maintenance-free. Charge acceptance
Indicates special instructions of these batteries may display characteris-
NOTICE on installation, operation or tics similar to maintenance batteries.
maintenance that are important but not related to
personal injury hazards.

Charge Volt and Amp Values

Volt and amp levels are functions of battery state
Table of Contents of charge. If batteries are charged 95% or higher
when engine is cranked, charge voltage will be
Section 1: Wiring ..............................................2 near regulator setpoint and amps will taper
Section 2: Basic Troubleshooting ......................3 quickly from medium to low.
Section 3: Advanced Troubleshooting ...............4
• Low amps: Necessary amps that a battery will
take continuously over a period of time with-
out damage, when battery is installed and
Battery Conditions constantly cycling.

Until electrical system compo- • Medium amps: Some multiple of low amp
NOTICE nent temperatures stabilize, value. This rate will cause battery tempera-
these conditions may be observed during cold start ture to rise over 4 to 8 hours.
voltage tests. • High amps: High amp rates over short time
• Maintenance battery: (2 to 3 hours) can severely overheat battery
— Immediately after engine start, system and cause thermal runaway.
volts are lower than regulator setpoint
with medium amps. • Charge voltage: Voltage delivered to battery
— 3-5 minutes into charge cycle, higher when alternator and regulator are properly
system volts and reduced amps. operating. Regulator setpoint and charge
— 5-10 minutes into charge cycle, system voltage are the same value. Charge voltage
volts are at, or nearly at, regulator and amp rates vary for each battery, based on
setpoint, and amps are reduced to a battery technology, size and state of charge.
minimum. • Battery voltage: Steady-state voltage of
• Low maintenance battery: battery/open circuit. Value relates directly to
— Same as above with slightly longer state of charge.
recharge times. • B+ voltage: Battery positive voltage – not a
• Maintenance-free battery: specific value.
— Immediately after engine start, system • Surface charge: Higher-than-normal terminal
volts are lower than regulator setpoint voltage present on the battery when it comes
with low amps. off a charger or after extended time in opera-
— 15-30 minutes into charge cycle, still tion. Surface charge must be removed to
low volts and low amps. determine true battery voltage.

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 Section 1: Wiring C. E. Niehoff & Co.
BRUSHLESS ALTERNATORS

R Terminal

D+ Terminal
B+ Terminal

G G
G

B– Ground Bolt

Figure 1 — C612/C617 Alternator with A2-141 Regulator

R Terminal
D+ Terminal
B+ Terminal

G
G G

B– Ground Bolt

Figure 2 — C621 Alternator with A2-141 Regulator

CEN Alternator Description CEN Alternator Operation

C612, C617 and C621 alternators are self- Residual magnetic field induces small voltage in
energizing and self-rectifying with internal diode stator and energizes field coil. Field coil continues
trios. All windings and current-transmitting receiving incremental voltage until full voltage is
components are non-moving, so there are no achieved. AC is rectified into DC output through
brushes or slip rings. diodes. Regulator controls voltage output.

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 C. E. Niehoff & Co.
BRUSHLESS ALTERNATORS Section 2: Basic Troubleshooting

Tools and Equipment for Job: C. Basic Troubleshooting

• Digital Multimeter (DMM) 1. Inspect charging system components
• Ammeter (digital, inductive) for damage
Check connections at ground cable, B+ cable
• CEN Special Tool A10-129 and regulator harness. Repair or replace any
damaged component before electrical trouble-
shooting.
A. Identification Record 2. Inspect vehicle battery connections
List the following for proper troubleshooting: Connections must be clean and tight.

o Alternator model number __________________ 3. Determine battery voltage and state of

charge
o Regulator model number ___________________ If batteries are discharged, recharge or
replace batteries as necessary. Electrical
system cannot be properly tested unless
o Setpoints listed on regulator _______________
batteries are at 95% or higher state of charge.
4. Connect meters to alternator
B. Preliminary Check-out Connect red lead of DMM to alternator B+
terminal and black lead to alternator B–
Check condition of items in Chart 1 and correct
ground bolt. Clamp inductive ammeter on
if necessary.
battery ground cable.
5. Operate vehicle
CHART 1 – SYSTEM CONDITIONS
Observe charge voltage.
Symptom Problem
If charge voltage is above
Low Voltage Check: loose drive belt; low CAUTION 33 volts, immediately shut
Output battery state of charge.
Check: current load on down system. Electrical system damage may occur if
system is greater than alter- charging system is allowed to operate at high voltage.
nator can produce. Go to Chart 1 at left.
Check: defective wiring or poor If voltage is at or below regulator setpoint,
ground path; low regulator let charging system operate for several
set point. minutes to normalize operating temperature.
Check: defective alternator
6. Observe charge volts and amps
and/or regulator.
Charge voltage should increase and charge
High Voltage Check: wrong regulator.
amps should decrease. If charge voltage does
Output Check: high regulator set point. not increase within ten minutes, continue to
Check: defective regulator. next step.
Check: alternator.
7. Battery is considered fully charged if charge
No Voltage Check: broken drive belt.
voltage is at regulator setpoint and charge
Output Check: battery voltage at alter-
amps remain at lowest value for 10 minutes.
nator output terminal.
Check: defective alternator or 8. If charging system is not performing prop-
regulator. erly, go to “Section 3: Advanced Trouble-
Check: self-energizing alterna- shooting,” page 4.
tor lost residual magnetism.
Go to “Section 3: Advanced
Troubleshooting,” page 4.

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Section 3: Advanced Troubleshooting C. E. Niehoff & Co.
BRUSHLESS ALTERNATORS

START HERE
è Chart 1 – No Output – Test for Residual Magnetism

Self-energized alternator may have lost magnetism. Touch steel

tool to shaft to detect any magnetism. Is shaft magnetized?
Yes No

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.

Chart 2 – No Output – Test for Magnetism

Unplug alternator-to-regulator harness. Plug Special Tool A10-129 into harness plug.
Clip red lead to B+ terminal on alternator. Touch black lead to ground on alternator case.
Spark will occur. Touch steel tool to shaft to detect any magnetism. Is shaft magnetized?
Yes No

G G
Disconnect Tool. Go to Chart 3. Disconnect Tool. Alternator is defective.

Chart 3 – No Output – Test Alternator-To-Regulator Harness

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 PIN CONNECTIONS
B+ terminal 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

is defective. Connect red lead of DMM to ground on alternator case.

Connect black lead to Pin B on plug end of harness. Does
continuity exist?
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:

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
Page 4 E-mail us at [email protected]
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