C.E. Niehoff & Co. C803D Troubleshooting Guides
C.E. Niehoff & Co.
Before troubleshooting any CEN products, the service technician should:
WARNING
• read, understand, and agree to follow all information contained in this troubleshooting guide.
• understand the operational characteristics of the electrical charging system components to be tested.
• be profi cient at the use of tools and test equipment used in troubleshooting CEN products.
Troubleshooting Guide
C803D Alternator
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 hazard(s) that
WARNING
can cause severe personal injury,
death, or substantial property
damage if ignored.
Indicates presence of hazards that
CAUTION
will or can cause minor personal
injury or property damage.
Table of Contents
Section A: Description and Operation .......................... 2
Section B: Schematic Diagram .................................... 3
Section C: On-Vehicle Troubleshooting ..................... 4-5
Tools and Equipment
• Digital Multimeter (DMM)
• Ammeter (digital, inductive)
• Jumper wires
• CEN 6-pin Inline Harness Test Tool A10-114
Figure 1—CEN 6-pin Inline Harness Test Tool A10-114
Testing Guidelines
Professional service technicians rely on the following
guidelines when testing electrical components.
Voltage testing:
• 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.
• Be sure to use CEN tools designed especially for
troubleshooting CEN alternators when available.
See page 1 for more information.
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 inadequate 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.
1. Be sure to connect jumper leads directly and securely
to source contacts of the component being tested.
2. Be sure to make any connection to power and ground
at the power supply or battery source terminals. Do
not make connection at component source terminals
as that may create an arc and damage component
source terminals.
TG32D
Page 1
Section A: Description/Operation
CEN C803D Alternator/Regulator Description and Operation
C803D 28 V, 500 A alternator is internally rectified. All windings and current-transmitting components are non-moving,
so there are no brushes or slip rings to wear out. C803D alternator is furnished with an open duct in the anti-drive end
cover plate, which accommodates a 4” duct.
This alternator is externally energized when the battery master switch on the vehicle is turned on and provides power
to the regulator through the IGN circuit (A2-346 regulator can also operate without vehicle connection to IGN, and
instead provide power by sensing rotation through the regulator’s AC circuit). Field coil is then energized. AC is rectified
into DC output through diodes in anti-drive end rectifier housing and supplied to the battery from the alternator B+
terminal. See Figure 7 on page 3. Alternator output current is self-limiting and will not exceed rated capacity of alternator. Regulator maintains alternator output voltage at pre-determined regulated setting (see below for setpoints) as vehicle
electrical loads are switched on and off.
A2-330, A2-336, and A2-361 regulators furnished with some units include:
• External IGN terminal for energize connection.
• (A2-330 & A2-336 only) P terminal that can provide optional AC voltage tap. P terminal signal frequency (Hz) x 10 =
alternator shaft rpm.
• (A2-330 & A2-336 only) D+ terminal that can provide DC voltage signal to vehicle electrical system, confirming alter-
nator operation.
• Overvoltage cutout (OVCO) function. See page 4.
• (A2-330 & A2-336 only) Tricolored LED. See page 4.
• (A2-330 only) Current-limiting function.
• Regulator fixed (flat temperature compensation) setpoints shown in Table 1 are selected based on battery type. Battery
type selection and battery maintenance/function are the sole responsibilities of the customer.
Table 1— A2-330, A2-336, & A2-361 Regulator Setpoint Switch Position
Voltage Setpoints (±0.2 V) Battery Type
Position 1 27.5 V Maintenance
Position 2 28.0 V Maintenance
Position 3 28.5 V Maintenance-free
Position 4 29.0 V Maintenance-free
Note on Group 31 batteries: If boiling or excessive gassing occurs with high voltage
setpoint (position 3), change to medium voltage setpoint (position 2).
Figure 2—Voltage Setpoints
A2-346 and A2-363 regulators furnished with some units include:
• (A2-346 only) Optional external IGN terminal for energize connection. This regulator can function with or without
vehicle ignition. When necessary, IGN terminal on regulator is connected to vehicle ignition to provide battery voltage
when engine is running. Circuit should be off (no voltage present) when vehicle ignition is off or engine is not running.
• (A2-346 only) P terminal that can provide optional AC voltage tap. P terminal signal frequency (Hz) x 10 = alternator shaft
rpm.
• (A2-346 only) D+ terminal that can provide DC voltage signal to vehicle electrical system, confirming alternator
operation.
• (A2-363 only) No external terminals, only a special 3-pin vehicle harness connector providing one pin for optional AC
voltage tap (PHASE OUT), one pin for DC voltage signal to vehicle electrical system confirming alternator operation
(D+), and one pin for the energize connection (ENG).
• Overvoltage cutout (OVCO). See page 4.
• Tricolored LED. See page 4.
• Battery type selection and battery maintenance/function are the sole responsibilities of the customer.
• J1939 connector to be used with optional A9-4036 harness.
— When A9-4036 temperature/voltage sense harness is not connected, regulator will operate in fixed voltage setting
determined by the select switch position on the bottom of the regulator. See Column 2 in Table 2.
— When A9-4036 temperature/voltage sense harness is connected, regulator will automatically optimize the charge
voltage for battery type based on temperature. Also, vehicle manufacturer-requested functions of 1939 interface
are available through connector. See Column 3 in Table 2.
Table 2— A2-346 & A2-363 Regulator Voltage/Battery Switch Position
Switch Position
Position 1 27.5 V Maintenance (D Category)
Position 2 28.0 V Maintenance-free (Group 31)
Position 3 28.5 V AGM
Position 4 29.0 V
A9-4036 Harness Not Connected
(Voltage Select)
A9-4036 Harness Connected
(Battery Select)
DO NOT US E POS ITION # 4
Figure 3—Voltage/Battery Switch
Page 2
TG32D
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