N1602 Alternator

C.E. Niehoff & Co. Troubleshooting Guide

R

Contents Voltage testing:

Section A: Description and Operation.................................. 2 • Set meter to proper scale and type (AC or DC).

Section B: Basic Troubleshooting......................................... 5 • Be sure to zero the meter scale or identify the meter
burden by touching meter leads together. Meter burden
Section C: Advanced Troubleshooting................................. 6 must be subtracted from final reading obtained.
Battery Charging Conditions • Be sure the meter leads touch source area only.
Prevent short circuit damage to test leads or source by
The following conditions may be observed during cold-start not allowing meter leads to touch other pins or exposed
voltage tests until temperatures of electrical system compo- wires in test area.
nents stabilize. The time it takes to reach optimum voltage • Be sure to use CEN tools designed especially for trou-
and amps will vary with engine speed, load, and ambient bleshooting CEN alternators when available.
temperature.
Resistance (ohm) testing:
Maintenance/Low Maintenance Lead-Acid Battery:
• Set meter to proper scale.
Traditional lead acid batteries require lowest charge voltage
of all vehicle battery chemistries. Battery cells must be • Be sure to zero the meter scale or identify the meter
maintained by periodically topping off with distilled water as burden by touching meter leads together. Meter burden
required. must be subtracted from final reading obtained.
Maintenance-free Lead-Acid Battery: • Be sure meter leads touch source area only. Allowing
fingers or body parts to touch meter leads or source
Maintenance-free batteries are similar to Maintenance/Low during reading may alter reading.
Maintenance batteries, but may require slightly higher
charge voltage. • Be sure reading is taken when source is at 70ºF. Read-
ings taken at higher temperatures will increase the
Deep-cycle/Marine Maintenance-free Battery: reading. Conversely, readings taken at lower tempera-
Charge acceptance of these batteries may display charac- tures will decrease the reading.
teristics similar to maintenance-free batteries and may • Be sure to test directly at the source. Testing through
charge faster due to generally lower capacity relative to extended harnesses or cable extensions may increase
size. the reading.
AGM (Absorbed Glass Mat) Maintenance-free Battery: • "OL" as referenced in this document refers to open cir-
These dry-cell batteries respond better than standard main- cuit: "infinite" resistance, typically in very high kilo- or
tenance-free batteries. If battery state of charge (SOC) megaohm range depending on meter and settings.
drops to 75% or less, batteries should be recharged to 95% Diode testing:
or higher separately from engine charging system to avoid
damaging charging system components and to provide best • Diodes allow current to flow in one direction only. Typi-
overall performance. Charge acceptance of these batteries cal voltage drop in forward bias can range from 0.1-
may display characteristics similar to maintenance batteries, 0.85V. Meter should read OL in reverse bias. Check
but may require higher charge voltage and will draw significant meter user manual for meter-specific testing guidelines.
current (<100 amps) when under 50% SOC. Voltage drop testing:
Lithium Battery: • Measure voltage between B+ on alternator or power
Lithium batteries have unique charging characteristics that source and B- (ground) on alternator or source. Record
differ from lead acid. These batteries require charging sys- reading. Move to batteries or other power source and
tems configured specifically for lithium battery chemistries. measure again between B+ and B- terminals on battery
Contact CEN for more information on lithium battery charg- or other power source. The difference between the two
ing systems and components. readings represents voltage lost within circuit due to,
but not limited to, inadequate cable gauge or faulty con-
nections.
• Voltage drop measurements must be taken with all
electrical loads or source operating.
Dynamic/Live testing (Connecting power and ground to
component to test operation/function out of circuit):
• Connect jumper leads directly and securely to power
source contacts of component being tested.
Testing Guidelines • Make any connection to power and ground at power
supply or battery source terminals. Do not make con-
Professional service technicians rely on the following guide- nection at component source terminals, as that may
lines when testing electrical components. create an arc and damage component source terminals.

TG109 Page 1
Section A: Description and Operation
R

N1602 Alternator Alternator-to-Regulator

Harness Regulator
Description and Operation B+ Terminal B+ Terminal
B‒ Terminal
The CEN model N1602 is a negative ground, hinge B‒ Terminal
mount alternator rated at 28 volts, 400 amps. It can also
provide dual voltage (28 volts, 400 amps and 14 volts, 50
amps) with compatible CEN regulator. N1602 is self-recti-
fying and brushless, so all windings and current-carrying
components are stationary, so there are no brushes or
slip rings to wear out.

Charging system is energized when regulator IGN termi-

nal receives an ignition/energize signal from the vehicle,
usually via oil pressure switch or multiplex system (see
pages 3 and 4 for regulator features). The regulator moni-
Figure 1: N1602 Alternator
tors alternator shaft rotation and provides field current
only when it detects the alternator shaft rotating at a suit-
able speed.

After the regulator detects shaft rotation, it gradually

A
Socket A = F‒
applies field current, preventing an abrupt mechanical
B Socket B = AC
load on accessory drive system. Soft start may take up to
D Socket C = B‒
20 seconds after rotation and energize signals are C
Socket D = B+
sensed.

Figure 2: Alternator-to-Regulator Harness Plug Sockets

OPTIONAL
BATTERY TEMP &
VOLTAGE SENSE
(SMART REG ONLY)
24 V LOAD

B+ 14V TERMINAL
(DUAL VOLTAGE
REGS ONLY)
12 V LOAD

B+ 14V

J1939 CONNECTOR
(SMART REGS ONLY)

PHASE
CONNECTOR

Figure 3: N1602 Alternator Wiring Diagram

(See model-specific characteristics drawing for detailed notes and information)

Page 2 TG109
 Section A: Description and Operation (cont.)
R

Alternator-to- Dummy Receptacle

Regulator Harness for Alternator AC
Voltage Regulator for 28V Systems Receptacle harness
Description and Operation
Status LED
CEN voltage regulators can be mounted directly on
alternator or remotely with compatible extension harness1. J1939/Voltage/Temp
28 volt smart regulator features include: Sense Harness
Receptacle
• IGN terminal/pin (required): Vehicle must supply battery
voltage to IGN terminal to energize charging system.
See Figure 4. IGN
Terminal
• AC output (optional): Phase terminal/pin taps AC voltage AC
from alternator phase for use with relay or tachometer. Terminal
Output is typically half of the output voltage at a
frequency ratio of 10:1 of alternator speed. See Figure 4.
• Over-voltage cut out (OVCO): Regulator shuts off field Voltage
switching circuit if it senses 31 volts or higher for 3 Selection Switch
seconds or longer.
• Negative temperature compensation.
• Adjustable voltage set points. See Table 1 and Figure 4.
• J1939 communication via 10 pin connector. See Figure
5.
• Remote temperature compensation (optional): When
used with compatible CEN remote harness or sensor 2,
regulator will optimize voltage setting based on battery
chemistry and compartment temperature (See Table 1
below).
Figure 4: Typical Smart Regulator External Features
• Remote voltage compensation (optional): When used
with compatible CEN remote harness or sensor 2,
regulator will boost voltage to batteries up to one volt Table 1: Regulator Voltage
over set point as necessary to compensate for resistive Selection Switch Settings
output cable losses. Setting Battery Type
• Charging system status LED indicator. See Figure 4 and 1 Hawker/6TAGM only
Table 2.
2 6TMF only
3 Hawker/6TAGM & 6TMF
4 Other types

Table 2: 28 Volt Smart Regulator LED Indications

LED COLOR ALTERNATOR / REGU- REQUIRED ACTION
LATOR STATUS
GREEN Alternator and regulator No action required.
(Solid) operating normally.
Voltage is low. If voltage is at or below regulator setpoint, allow charging system to operate for
several minutes to normalize operating temperature. If charge voltage does not
AMBER increase within 10 minutes, see Basic Troubleshooting procedures on page 5.
(Flashing) No rotation detected. Power down and restart alternator. If LED remains flashing amber, perform trouble-
shooting procedures in Chart 1 on page 6.
RED OVCO condition Power down and restart alternator. If LED remains solid red, refer to OVCO trouble-
(Solid) detected. shooting procedure on page 5.

RED Voltage is high. Power down and restart alternator. If LED remains flashing red, refer to Basic
(Flashing) Troubleshooting procedure on page 5.

1. Contact CEN for regulator extension harness options. NOTE: LED off = No power/output
2. Contact CEN for sensor/harness options

TG109 Page 3
Section A: Description and Operation (cont.)
R

Voltage Regulator for Dual Voltage Systems J1939/Voltage/

Description and Operation Temp Sense
Harness Receptacle
(N3223 only)
CEN voltage regulators can be mounted directly on 4-Socket Alternator- 3-pin Alternator
alternator. Dual voltage regulator features include: to-Regulator AC Harness
Harness Receptacle Receptacle
• IGN terminal/pin (required): Vehicle must supply battery
voltage to IGN terminal to energize charging system.
See Figure 5.
• AC output (optional): Phase terminal/pin taps AC voltage
from alternator phase for use with relay or tachometer.
Output is typically half of the output voltage at a IGN
frequency ratio of 10:1 of alternator speed. See Figure 5. Terminal
• Over-voltage cut out (OVCO): Regulator shuts off field AC
switching circuit if it senses 31 volts or higher for 3 Terminal
seconds or longer.
• Negative temperature compensation.
• 14 volt output up to 50 amps. See Figure 5.
N3223 regulator also includes:
• J1939 communication via 10 pin connector. See Figure
5.
• Charging system status LED indicators for 14V and 28V
circuits. See Figure 5 and Table 3.

14V Output
Terminal Status
LEDs

Figure 5: Typical Smart Regulator External Features

Table 3: Dual Voltage Smart Regulator LED Indications

LED COLOR ALTERNATOR / REGULATOR STATUS REQUIRED ACTION
GREEN Alternator and regulator operating No action required.
(Solid) normally.
Voltage is low If voltage is at or below regulator setpoint, allow charging system
AMBER to operate for several minutes to normalize operating temperature.
(Solid) If charge voltage does not increase within 10 minutes, see Basic
Troubleshooting procedures on page 5.
AMBER No rotation detected. Power down and restart alternator. If LED remains flashing amber,
perform troubleshooting procedures in Chart 1 on page 6.
(Flashing)
RED OVCO condition detected. Power down and restart alternator. If LED remains solid red, refer
(Flashing) to OVCO troubleshooting procedure on page 5.

NOTE: LED off = No power/output.

Page 4 TG109
 Section B: Basic Troubleshooting
R

Required Tools and Equipment 4. Determine battery type, voltage, and state of charge.
Batteries must be all the same type. If batteries are
• Digital Multimeter (DMM)
discharged, recharge or replace batteries. Electrical
• Ammeter (digital, inductive) system cannot be properly tested unless batteries
• Jumper wires are charged 95% or higher. See page 1 for details.
5. Connect meters to alternator:
Identification Record
• Connect DMM red lead to alternator B+ terminal.
Enter the following information in the spaces provided for
identification records. • Connect
DMM black lead to alternator B– terminal.
 Alternator model number:_________________________ • Clamp inductive ammeter onto alternator B+
cable.
 Regulator model number:_________________________ 6. Operate vehicle and observe charge voltage.
Charge voltage should increase and charge amps
 Voltage set points listed on regulator: _______________ should decrease. Battery is considered fully charged
when charge voltage is at regulator set point and
charge amps remain at lowest value for 10 minutes.
Preliminary Check-out
7. If voltage is at or below regulator set point, allow
Check symptoms in Table 4 below and correct if necessary. charging system to operate for several minutes to
normalize operating temperature. If charge voltage
TABLE 4: Preliminary Charging System Check-Out does not increase within 10 minutes, go to Chart 1
CONDITION: CHECK FOR:
on page 6.

Low Voltage Output Low battery state of charge. CAUTION If voltage exceeds 32 V (or 16 V for 14
V circuit), shut down system
Load on system exceeds rated output
of alternator. immediately. Damage to electrical
system may occur if charging system
Faulty wiring or poor ground path. is allowed to operate above 32 V (or 16
Faulty alternator or regulator. V for 14 V circuit) for more than 3
Wrong pulley installed. seconds.
Wrong regulator installed.
Check for OVCO Condition
High Voltage Output Faulty regulator. 1. Shut down vehicle and restart engine. If alternator
Faulty alternator. functions normally after restart, a no output condition
was normal response of voltage regulator to high
No Voltage Output No energize signal at IGN terminal on voltage condition.
regulator. 2. Inspect vehicle electrical system, including loose
Faulty alternator B+ terminal battery cables. If battery disconnects from system, it
connection. could cause high voltage condition in electrical sys-
Faulty alternator or regulator. tem, causing OVCO circuit to trip.
3. If you have reset alternator once, and electrical sys-
tem returns to normal charge voltage condition,
Basic Troubleshooting there may have been a one time, high voltage spike,
causing OVCO circuit to trip.
1. Inspect charging system components for damage.
Check connections at B– cable, B+ cable, and regulator 4. If OVCO circuit repeats cutout a second time in short
harness. Check regulator terminal wiring from regulator succession and shuts off alternator, follow trouble-
to vehicle components. Repair or replace any damaged shooting procedures in chart 3 on page 8.
component before electrical troubleshooting.
2. Inspect vehicle battery connections. Connections must
be clean and tight.
3. Inspect belt for wear and condition.

TG109 Page 5
Section C: Advanced Troubleshooting
R

Chart 1: No 28 V Alternator Output – Test Charging Circuit

• TEST MEASUREMENTS ARE TAKEN ON HARNESS PLUG AT ALTERNATOR. TAKING MEASUREMENTS FROM AN
EXTENDED HARNESS PLUG MAY AFFECT RESULTS.
• FOR REMOTE-MOUNTED REGULATOR, CHECK CONDITION OF HARNESS FUSES BEFORE TROUBLESHOOTING.
• BEFORE STARTING DIAGNOSTIC SEQUENCE, VERIFY THE FOLLOWING AND REPAIR/REPLACE IF NOT TO SPEC:
−− BATTERIES FOR STATE-OF-CHARGE (25.0-28.0 V), CONDITION, AND SECURE CONNECTIONS.
−− MASTER BATTERY SWITCH FOR FUNCTION.
−− J1939 INTERCONNECT HARNESS FOR FUNCTION IF USED IN PARALLEL-OPERATION SYSTEM.

CAUTION MAKE SURE METER PROBES DO NOT TOUCH OTHER PINS/SOCKETS AND CAUSE AN ARC THAT MAY
DAMAGE PINS/SOCKETS AND HARNESS WIRING.

MASTER BATTERY SWITCH ON, KEY ON, ENGINE ON: Test for battery voltage from B+ terminal on alternator to
ground, then from IGN terminal on regulator to ground. Does battery voltage exist at both locations?
Yes No

Repair vehicle wiring as necessary. Run engine and

Turn engine off. Disconnect 4-socket alternator-to- re-test charging circuit. Is charging system perform-
regulator harness plug at regulator and perform the ing properly?
following tests on alternator harness connector.
No Yes

System is operative.

MASTER BATTERY SWITCH ON, KEY OFF, ENGINE OFF: Readings of all four tests must pass.
1. Battery voltage test: Set DMM to volts DC test. Connect DMM black lead to socket C. Connect DMM red lead to socket D.
Battery voltage should exist.
2. Field coil resistance test: Set DMM to ohms test. Connect DMM red lead to alternator B+ terminal. Connect DMM black
lead to socket A. DMM should measure nominal 1.0-1.5 ± 0.2 ohms. Field coil is faulty if reading is less than 0.5 ohms or
greater than 3 ohms.
3. Field coil isolation test: Set DMM to ohms test. Connect DMM black lead to alternator B‒ terminal. Connect DMM red lead
to socket A. DMM should measure OL.
4. Phase signal test: Set DMM to diode test. Connect DMM black lead to socket B. Connect red lead to alternator B+ terminal.
DMM should read OL in this direction. Reverse leads. DMM should read diode voltage drop in this direction.
Repeat test for socket B and alternator B– terminal. Tests should read diode voltage drop in one direction and OL in the
other direction.
Yes No

Regulator is faulty. Alternator is faulty.

A
Socket A = F‒
B Socket B = AC
D Socket C = B‒
C
Socket D = B+

Figure 6: 4-Socket Alternator-to-Regulator Harness Connections

Page 6 TG109
 Section C: Advanced Troubleshooting (cont.)
R

Chart 2: No 14 V Circuit Output

MASTER BATTERY SWITCH ON, KEY OFF, ENGINE OFF:

1. Set DMM to volts DC test.
2. Test for battery voltage from alternator B‒ terminal to regulator 14 V terminal.
3. Does battery voltage exist?

Yes No

Repair 14 V vehicle wiring as necessary. Run engine

and re-test charging circuit. Is charging system per-
forming properly?
No Yes

System is operative.

1. Disconnect 3-pin AC harness from regulator.

2. Set DMM to diode test. Connect DMM black lead to alternator B‒ terminal. Connect red lead
to alternator 3-pin harness pin A, then pin B, then pin C. DMM should read OL for all three
pins. Reverse DMM leads and repeat test sequence. DMM should read diode voltage drop
in this direction for all three pins.
3. Connect DMM black lead to alternator B+ terminal. Connect red lead to alternator 3-pin har-
ness pin A, then pin B, then pin C. DMM should read diode voltage drop for all three pins.
Reverse DMM leads and repeat test sequence. DMM should read OL in this direction for all
three pins.
Do all tests pass?
Yes No Alternator is faulty

Replace existing regulator with known good regulator. Run engine. Is charging system running
properly?

Yes No

Original regulator faulty Alternator is faulty

C A Pin A = Phase 1
Pin B = Phase 2
B Pin C = Phase 3

Figure 7: 3-Pin AC Harness Connections

TG109 Page 7
Section C: Advanced Troubleshooting (cont.)
R

Chart 3: Test OVCO Circuit

1. Turn engine off. Disconnect 4- socket alternator-to-regulator harness plug. Set DMM to
ohms test.
2. Connect DMM red lead to alternator B+ terminal.
3. Connect DMM black lead to harness socket A. Does resistance read 1.0-1.5 ± 0.2 ohms?

Yes No Alternator is faulty

1. Set DMM to ohms test.

2. Connect DMM black lead to alternator B‒ terminal.
3. Connect DMM red lead to harness socket A. Does resistance read OL?

Yes No Alternator is faulty

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

Yes No Original regulator faulty

Alternator is faulty

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
E-mail us at service@CENiehoff.com

Page 8 TG109