C.E. Niehoff & Co. C616, A8-205, A2-136 Installation

C. E. Niehoff & Co

BRUSHLESS ALTERNATORS

C616 Alternator

with Regulator

and External Rectifier

Installation Instructions

CAUTION

This symbol is used to indicate presence of hazards that can cause minor property damage.

C616 Alternator

1. Mounting lug width on alternator complies with SAE J180 (May 1987) standards.

2. Units are shipped with shaft collar, hardened washer and locknut. Remove and discard shaft collar. Install pulley and furnished hardened washer. Torque locknut to 163 Nm/ 120 lb. ft.

3. Use hardened washers between aluminum surfaces and bolt heads and nuts. Torque mounting bolts to 88 Nm/65 lb. ft.

CAUTION

Slip bushing in lower rear mounting lug must be securely tightened against mounting bracket on engine. Failure to do so can result in broken mounting lugs or broken upper mounting bracket.

0.625-18 Locknut and hardened washer— torque to 163 Nm/120 lb.ft.

12mm/0.50 in. Mounting bolt

Hardened washers

12mm/0.50 Locknut –

torque to 88 Nm/65 lb. ft.

12mm/0.50 in.

Mounting bolt

(full length)

Hardened

washer

Alternator mounting

bracket on engine

Slip bushing must be tightened against bracket — see “CAUTION” at left

Bracket

on engine

Figure 1 - C616 Alternator Inst allation

12mm/0.50

Locknut –

torque to

88 Nm/65 lb. ft.

Hardened

washer

A8-205 External Rectifier and A4-501 Bracket

1. Mounting location of rectifier and bracket should provide proper cooling and protect rectifier from direct water, road debris, or chemicals.

2. Using the standard A9-463 wiring harness, rectifier can be mounted up to 6 feet away from alternator.

3. Use hardened washers between aluminum surfaces and bolt heads and nuts. Bracket mounting bolts must have minimum .50 in. thread engagement. See Figure 2 for torque values.

4. Use a suitable adhesive such as Loctite or equivalent on screws. Follow manufacturer’s instructions.

222

Flat

washer

Lockwasher

.3750-16 UNC-2B Mounting bolt

grade 5 or better–

torque to 27 Nm/20 lb.ft.

Figure 2 - Rectifier and Bracket Installation

54 Nm/40 lb.ft.

Flat washer

11mm/0.44 in.

Mounting bolt -

grade 5 or better

Locknut

(4 places) –

torque to

Lockwasher

II0099APage 1 of 2

A2-136 Regulator

1. Mounting location of regulator must provide protection from water, road debris, or chemicals.

Regulator can be located up to 18 inches away from the rectifier. If extension harness CEN A9-448 is added, the regulator can be moved an additional 43 in. away.

2. See Figure 3 for torque values.

#10-32 x .62 flange lock screw (4 places) -

torque to 8.5 Nm/75 lb. in.

Figure 3 - Regulator Installation

Wiring Connections

1. Alternator phase cable:

a. Remove and save terminal cover screws and

terminal cover.

b. Connect phase cable into terminal block on top

of alternator either through anti-drive end (as shown in Figure 4) or through drive end:

1) Run phase cable through cable bracket mounted in one of two locations (LOC. A or LOC. B). See Figure 4.

Phase terminal bolts (3 places) –

torque to 9 Nm/80 lb. in.

Terminal cover screws –

torque to 3.9 Nm/35 lb. in.

Screws –

torque to 6.7 Nm/60 lb. in.

Cable bracket

Phase

cable

LOC. A

Field

inline

connection

Cable bracket

LOC. B

2) Use torque values shown to fasten cables to terminal block.

3) Coat terminals with Dow Corning® 1-2577 Low VOC RTV coating or equivalent. Do not use coating containing acetic acid (vinegar smell) on electrical components.

c. Replace terminal cover on terminal block. If

phase cable was routed through the anti-drive end, the terminal cover must be rotated 180º before re-installing. Use torque value shown to fasten screws in terminal cover.

2. Connect remaining harnesses between components as shown in Figure 4. Use torque values shown.

3. Choose wire gauge for B+ and B– cables capable of handling maximum alternator output with minimum voltage drop.

4. Connect E terminal on regulator to ignition source through oil pressure switch, using #10 ring terminal. Torque #10-24 terminal nut to 3.4 Nm/30 lb. in.

5. If required, connect R terminal to tachometer or relay, using 1/4 in. ring terminal. Torque terminal nut to 3.4 Nm/30 lb.in.

Sealing Wiring Connections

1. On ALL metallic electrical connections to rectifier (including B+ and B– connections), alternator, regulator, and their harness connectors, apply Dow Corning® 1-2577 Low VOC RTV coating or equivalent. Do not use coating containing acetic acid (vinegar smell) on electrical components.

2. At regulator harness connections, apply coating as described in step 1, then wrap connection in electrical tape from sleeve to sleeve.

Insulator

B+ terminal bolt –

Washer

torque to 30 Nm/22 lb. ft.

Lockwasher

Battery output cable terminal

B+ Terminal Connection

Phase terminal bolts (3 places) –

torque to 8 Nm/70 lb. in.

R and E

terminal nuts –

torque to

3.4 Nm/30 lb. in.

Field inline connection

B+

(see

inset above)

B– terminal bolt –

torque to 30 Nm/22 lb. ft.

Figure 4 - Electrical Connections

C. E. Niehoff & Co. • 2021 Lee Street • Evanston, IL 60202 Tech Services Hotline 800-643-4633

II0099APage 2 of 2