C.E. Niehoff & Co. C130, C131, C132 User Manual

C.E. Niehoff & Co.

See Pages 2, 3, and 4 for Technical Speciﬁ cations

This symbol is used to indicate presence

WARNING

of hazards that can cause severe personal injury, death or substantial property damage.

This symbol is used to indicate presence

CAUTION

of hazards that can cause minor personal injury or property damage.

This alternator contains no serviceable

WARNING

parts except pulley, fan, and regulator. Manufacturer’s hazardous location certification is void if repaired except for the pulley, fan, and regulator which may be replaced with factory parts.

Explosion hazard—substitution of compo-

WARNING

nents may impair suitability for Class I, Division 2.

Risque d’explosion—la substitution de

ADVERTISSEMENT

composants peut rendre ce matériel inacceptable pour les emplacements de Classe I, Division 2.

Explosion hazard—do not replace any

WARNING

component unless power has been switched off or the area is known to be non-hazardous.

Risque d’explosion—couper le courant

ADVERTISSEMENT

ou s’assurer que l’emplacement est désigné non dangereux avant de replacer le composants.

Explosion hazard—do not disconnect

WARNING

equipment unless power has been switched off or area is known to be non-hazardous.

Risque d’explosion—avant de décon-

ADVERTISSEMENT

necter l’equipement, couper le courant ou s’assurer que l’emplacement est désigné non dangereux.

Installation Instructions

Improper installation of alternator in an

WARNING

explosive environment can cause severe personal injury, death, or substantial property damage. Alternator must be installed by a qualified person trained in the installation of alternators in explosive atmospheres. For CSA and UL classifica tions and atmospheric conditions, see page 2 of these instructions.

1. Mount alternator on a suitable bracket and secure with hardware per alternator drawing on page 2 of these instructions.

SM40A

C130, C131, and C132 Alternators

Combo Guide

2. Remove anti-drive end (ADE) cover from the alternator.

3. One of the following two alternator circuits described below is required to operate alternator.

a. If alternator is to be self-energized, be sure

the link is connected between B+ stud and IGN terminal (as shipped). This alternator relies on residual magnetism to operate. Observe all applicable safety procedures when performing the following operation: If neces sary, restore lost magnetism by connecting test light between B+ stud and R terminal for 1-3 seconds while alternator shaft IS NOT TUR NING and battery is connected to illumi nate test light. Check for magnetic field at pulley. If magnetized, remove test light, start alternator, and test.

b. If the alternator is to be energized through

ignition key, connect energizing signal lead directly to IGN terminal and remove link between B+ stud and IGN terminal. Torque IGN terminal bolt to 2 Nm/18 lb. in. This alternator relies on residual magnetism to operate. Ensure battery voltage is present at IGN terminal. Observe all applicable safety procedures when performing the following operation: If necessary, restore lost magnetism by connecting test light between B+ stud and R terminal for 1-3 seconds while alternator shaft IS NOT TURNING and battery is con nected to illuminate test light. Check for magnetic field at pulley. If magnetized, remove test light, start alternator, and test.

4. Connect B+ cable to B+ stud on alternator. See wire chart on page 3 for correct cable size and length. Torque terminal nut to 9 Nm/80 lb. in.

5. Connect R lead to R terminal on alternator if required for vehicle operation (optional connection). Torque R terminal bolt to 2 Nm/18 lb. in.

6. Connect B– cable to B– terminal stud on alternator (B– is an isolated ground). B– cable gauge should be same as gauge of battery positive cable. Torque terminal nut to 9 Nm/80 lb. in.

Supply wires suitable for rated

Utiliser des câbles d’alimentation

7. Perform a final inspection on the installation.

8. Re-install anti-drive end cover on alternator. Posi-

9. Install suitable alternator drive belt.

10. Start engine. Confirm operation of charging

CAUTION

load at 90°C ambient shall not exceed 200°C.

ATTENTION

appropriée pour 200ºC.

tion louvers consistent with deflection of rain or fluids during normal operating conditions. Fasten with screws and washers in four places. Use a

suitable adhesive such as Loctite® 222. Follow manufacturer’s instructions. Torque screws to 3.4 Nm/30 lb. in.

system meets specification.

Page 1

Installation Instructions (CONT’D)

Page 2

SM40A

Installation Instructions (CONT’D)

(OPTIONAL)

on page 1

Step 6 on page 1

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Page 3

Installation Instructions (CONT’D)

0

10

20

30

40

50

60

70

0 1000 2000 3000 4000 5000 6000 7000 8000

RPM

OUTPUT/ A

0

1

2

3

4

5

6

7

TORQUE/Nm

OUTPUT/ A TORQ UE/ Nm

ALTERNATOR CHARACTERISTICS FOR 28 VOLTS/ 60 AMPS:

APPLICABLE MODELS: C130, C132

OUTPUT CURVE: OUTPUT AMPERES VERSUS ALTER NATOR SHAFT SPEED IN RPM AT 28.0 VOLTS.

TORQUE CURVE: DRIVE TORQUE IN Nm VERSUS ALTERNATOR SHAFT SPEED IN RPM REQUIRED TO

PRODUCE OUTPUT CURVE.

ALL MEASUREMENTS DEPICTED ON PERFORMANCE CURVES ARE TAKEN AT 22ºC/72ºF AMBIENT

TEMPERATURE (UNLESS OTHERWISE SPECIFIED) AND A STABILIZED MACHINE TEMPERATURE AT MA XIMUM OUTPUT WITH VOLTAGE CONSTANT AS SPECIFIED.

ABBREVIATIONS:

RPM REVOLUTIONS PER MINUTE

Nm NEWTON-METER

Conversion: 1 Nm = 8.85 Pound Inch (LBIN)

Page 4

SM40A

Installation Instructions (CONT’D)

ALTERNATOR CHARACTERISTICS FOR 14 VOLTS/ 70 AMP: APPLICABLE MODELS: C131

OUTPUT CURVE: OUTPUT AMPERES VERSUS ALTERNATOR SHAFT SPEED IN RPM AT 13.8

VOLTS.

TORQUE CURVE: DRIVE TORQUE IN Nm VERSUS ALTERNATOR SHAFT SPEED IN RPM REQUIRED TO PRODUCE OUTPUT CURVE.

SM40A

ALL MEASURMENTS DEPICTED ON PERFORMANCE CURVES ARE TAKEN AT 104°F (40°C) AMBIENT TEMPERATURE (UNLESS OTHERWISE SPECIFIED) AND A STABILIZED MACHINE TEMPERATURE AT MAXIMUM OUTPUT WITH VOLTAGE CONSTANT AS SPECIFIED.

ABBREVATIONS: RPM REVOLUTIONS PER MINUTE Nm NEWTON-METER

Conversion: 1 Nm = 8.85 Pound Inch (LBIN)

Page 5

Parts Replacement Instructions

Pulley Replacement

Remove existing pulley (see Figure 1):

1. Remove pulley nut and washer.

2. Remove and discard pulley.

Install new pulley (see Figure 1):

1. Install new pulley and fasten with pulley nut and washer.

2. Keep pulley, fan, and shaft from spinning while torquing pulley nut to 68 Nm/50 lb. ft.

Drive End (DE) Fan Replacement

Remove existing DE fan (see Figure 1):

1. Remove pulley nut and washer.

2. Remove pulley.

3. Remove woodruff key and discard fan.

Install new DE fan (see Figure 1):

1. Place new fan on shaft.

2. Install woodruff key.

3. Install pulley and fasten with pulley nut and washer.

4. Keep pulley, fan, and shaft from spinning while torquing pulley nut to 68 Nm/50 lb. ft.

Anti-drive End (ADE) Cover Replacement

Remove ADE Cover on Alternator (see Figure 1):

1. Remove hardware and discard ADE cover plate.

Install New ADE Cover on Alternator (see Figure

1):

1. Install new ADE cover plate. Position louvers consistent with def lection of rain or fluids during normal operating conditions.

2. Fasten in four places with screws and washers. Use a

suitable adhesive such as Loctite® 222. Follow manufacturer’s instructions. Torque screws to 3.4 Nm/30 lb. in.

Fan

Woodruff Key

Alternator

Pulley

Regulator

F

E

ADE Cover

Page 6

Figure 1 – Parts Replacement

SM40A

Parts Replacement Instructions (CONT’D)

Anti-drive End (ADE) Regulator Replacement

Remove ADE Regulator on Alternator (see Figures 1 and 2):

1. Remove hardware and ADE cover plate.

2. Remove and discard hardware attaching regulator to plate.

3. Unplug alternator-to-regulator harness from regulator.

4. Discard regulator.

Regulator

Install New ADE Cover on Alternator (see Figures 1 and 2):

1. Plug alternator-to-regulator harness securely into new regulator.

2. Install new regulator on plate using new screws from kit. Use a suitable adhesive such as Loctite® 222. Follow manufacturer’s instructions. Torque screws to

2.8 Nm/25 lb. in.

3. Re-install ADE cover plate. Position louvers consis-

tent with def lection of rain or fluids during normal operating conditions.

4. Fasten in four places with screws and washers. Use a

suitable adhesive such as Loctite® 222. Follow manufacturer’s instructions. Torque screws to 3.4 Nm/ 30 lb. in.

Alternator-to-regulator harness plug

SM40A

E

D

C B

A

Figure 2 –Regulator Replacement

Page 7

Troubleshooting

Tools and Equipment for Bench Testing

• Testing Electrical Components, page 12.

• Digital Multimeter (DMM)

• Ammeter (digital, inductive)

• Test bench with 5–10 hp motor able to drive alternator to 8000 rpm. Mount alternator per test bench manufacturer’s instructions. Make sure test bench batteries are charged at 95% or higher.

Bench Tests

• Voltage at regulator setpoint ±0.2 V is considered “normal.”

• Alternator rated output (listed on nameplate) ±10% is determined at 5000 rpm at 72ºF.

• Run alternator for 15 minutes to stabilize readings.

• Alternator/regulator should be connected to test bench per schematic diagram on page 3.

test bench, make sure batteries

CAUTION

are connected per schematic diagram on page 3.

Alternator/regulator will not

BENCH TEST 1: NO-LOAD TEST

With battery connected and nominal electrical load set as shown in Table 1, run alternator at 2000-2500 rpm shaft speed.

• If alternator passes No-Load Test, go to Full Load

• If alternator fails No-Load Test, go to Static Tests.

BENCH TEST 2: FULL LOAD TEST

With battery connected and electrical load set as shown in Table 2, run alternator at 5000-8000 rpm shaft speed.

• If alternator passes Full Load Test, alternator is

• If alternator fails Full Load Test, go to Static Tests.

NOTICE

function without being properly connected to power source.

Test.

TAB LE 1 No-Load Test

ALT. AMPS VOLTS

C130 C132

C131 5 - 40 14±0.2

functioning properly.

TABLE 2 Full Load Test

ALT. AMPS VOLTS

C130 C132

C131 70 14±0.2

When connecting alternator to

28V

5-40 28±0.2

28V

60 28±0.2

Alternators should not be powered

WARNING

during static tests. Connections required during testing can cause shorts and damage alternator.

Static tests should conﬁ rm

NOTICE

on-vehicle and on-bench tests.

Tools and Equipment for Static Testing

• Testing Electrical Components, page 12.

• Digital Multimeter (DMM)

• Ammeter (digital, inductive)

• Regulator tester

Regulator Test

• Regulator tester tests all regulator functions.

• If regulator tester is used, follow regulator tester manufacturer’s instructions.

• If regulator tester is not available, regulator can only be tested for a shorted field-switching transistor. Follow Regulator Test below.

REGULATOR TEST: CHECK FOR SHORTED FIELDSWITCHING TRANSISTOR

1. Set DMM to diode test scale.

2. See Figure 3. Connect one meter lead to pin C in regulator receptacle and connect other lead to pin A in regulator receptacle. Observe meter reading. Reverse leads and observe meter reading. If DMM reads zero in either direction, field-switching transistor is shorted. Replace regulator. If regulator failure is indicated, field coil failure must also be suspected.

CONNECTIONS

A B–



B IGN



C F–



D Phase (R)



E B+



Figure 3 Regulator Harness Connections

Regulator Receptacle

Alternator-to-Regulator

Harness Plug

Page 8

SM40A

Troubleshooting (CONT’D)

Internal Circuit Tests

• Internal Circuit Tests will show the condition of internal circuits through the alternator via alternatorto-regulator harness.

• Some disassembly will be necessary to access the components. Do not disassemble the alternator beyond what the tests require.

• Before performing Internal Circuit Tests, check for visible signs of damaged components.

• The expected reading/result listed for each test must be obtained. Replace any component that fails the test.

TABLE 3 Pin-to-Pin Tests (See Figure 4)

TEST

NO.

1

2*

3

4

5

6

7

8

9

10

11

12

13

* Applies only when f ield coil is att ached to rectifier/housing assembly.

METER SCALE

& SYMBOL

Ohms Ω

Diode Test

Ohms Ω

Diode Test

Ohms Ω

METER (+) LEAD

CONNECTION

Socket A

Socket E

Socket C

Socket D

Alt. B+ Terminal

Socket D

Alt. B– Terminal

Socket E

Socket A

Alt. B+ Terminal

Alt. B– Terminal

R Terminal

Failure to perform the complete series of Internal Circuit Tests can result in improper diagnosis of alternator condition.

METER (–) LEAD

CONNECTION

Alternator Case

Socket C

Alt. B– Terminal

Alternator Case

Alt. B– Terminal

Alternator Case

Alt. B+ Terminal

Socket D

Alt. B– Terminal

Socket D

Alt. B+ Terminal

Alt. B– Terminal

Alt. B+ Terminal

Alternator Case

NOTICE

CAUTION

TESTED CIRCUIT

Isolated ground

Field coil resistance

Field coil insulation

Phase winding and diode

Regulator power circuit

Regulator ground circuit

All diodes in parallel

Stator insulation

Service technicians should understand and follow all information in the service manual when servicing the product.

EXPECTED

READING

OL (infinity)

4.8±0.2 ohms

OL (infinity)

<0.7 volts (flow)

OL (blocking)

<0.7 volts (flow)

0 ohms

OL (blocking)

<0.8 volts (flow)

OL (infinity)

CONNECTIONS

A B–



B IGN



C F–



D Phase (R)



E B+



Alternator-to-Regulator Harness Connector

SM40A

Figure 4 Alternator Connections

B+

IGN

R

DE C

AB

B−

Page 9

Exploded Parts View

Pulley

C130/C131/C132 Parts View

Fan

C130/C131/C132

Woodruff Key

Page 10

Regulator

F

E

Alternator

ADE Cover

Contact CEN Service Dealer, CEN Warehouse Dealer, or CEN Service Department for current exploded view and par ts list

SM40A

ALTERNATOR

MODEL

C130/C130-1/

C130-4/C13 0 - 5

VOLTS

24

AMPS

60

WATTS

1680

C130/C131/C132

Model

A2-139

Steps

N/A

Speciﬁ cations and Data

REGULATOR

Settings

28.0

Temp. Comp.(4)

Flat

10.17/22.4

ALT.

WEIGHT

kg/lb

C130-3

C131/C131-1/

C131-2

C131-3

C132 /C132 -1

1. Measurements are taken at the listed ambient

temperature and a stabilized machine temperature at maximum output with voltage constant as specified.

2. The alternator has an isolated ground.

3. Temperature compensation—see definition below.

Flat temperature compensation: Regulator controls voltage range in a near-constant state during the vehicle operating conditions. CEN flat-temperature compensated regulators have preset voltage setpoints.

24

14

28

NOTES

60

70

60

1680

980

1680

A2-161

A2-152

A2-162

A2-139

N/A

27.6

14. 2

13.8

28.0

Flat

10.17/22.4

Setpoint: Voltage value to which regulator is set. Voltage value is established by battery type and vehicle duty cycle. Setpoint value is fixed (flat compensation).

SM40A

Page 11

Testing Electrical Components

Testing Guidelines

Professional service technicians rely on these guidelines when testing electrical components.

Voltage testin g:

• Set meter to proper scale and type (AC or DC).

• Be sure to zero the meter scale or identify the meter burden by touching meter leads together. Meter burden must be subtracted from final reading obtained.

• Be sure the meter leads touch source area only. Prevent short circuit damage to test leads or source by not allowing meter leads to touch other pins or exposed wires in test area.

Resistance (ohm) testing:

• Set meter to proper scale.

• Be sure to zero the meter scale or identify the meter burden by touching meter leads together. Meter burden must be subtracted from final reading obtained.

• Be sure the meter leads touch source area only. Prevent altering the reading by not allowing fingers or body parts to touch meter leads or source during reading.

• Be sure reading is taken when source is at 70ºF. Readings taken at higher temperatures will increase the reading. Conversely, readings taken at lower temperatures will decrease the reading.

• Be sure to test directly at the source, testing through extended harnesses or cable extensions may increase the reading.

Voltage drop testing:

• Measure voltage between B+ on alternator or source and B- (ground) on alternator or source. Record obtained reading. Move to batteries or other source and measure again between B+ and B- terminals on battery or other source. Difference between the two readings represents voltage lost within the circuit due to but not limited to inade quate cable gage or faulty connections.

• Voltage drop measurements must be taken with all electrical loads or source operating.

Dynamic/Live testing:

• Definition: Connecting power and ground to a component to test operation/function out of circuit.

• Be sure to directly and securely jumper leads to source terminals of the component being tested.

• Be sure to touch the contact end of jumper leads only to the power supply or battery terminals. Touching a contact end to component terminals may create an arc and damage component terminals.

If you have quest ions about your a lternator or a ny of these test procedures, or i f you need to locate a Factory Authorized Ser vice Dealer, 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 •

E-mail us:

Visit our Web site:

Page 12

FAX: 847.492.1242 •

service@ CENiehoff.com

www.CENiehoff.com

SM40A

C.E. Niehoff & Co. C130, C131, C132 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual