C.E. Niehoff & Co. C651/C654 Troubleshooting Guides - Manual

Page 1
TG0010C
Table of Contents
Section 1: Wiring Diagram ....................................... 2
Section 2: Basic Troubleshooting ............................ 3
Section 3: Advanced Troubleshooting ................. 4 – 7
Battery Conditions
Until temperatures of electrical
system components stabilize, these
conditions may be observed during cold start voltage tests.
• Maintenance/low maintenance battery:
— Immediately after engine starts, system volts
are lower than regulator setpoint with medium
amps.
— 3-5 minutes into charge cycle, higher system
volts and reduced amps.
— 5-10 minutes into charge cycle, system volts
are at, or nearly at, regulator setpoint, and
amps are reduced to a minimum.
— Low maintenance battery has same charac-
teristics with slightly longer recharge times.
• Maintenance-free battery:
— Immediately after engine start, system volts are
lower than regulator setpoint with low amps.
— 15-30 minutes into charge cycle, still low volts
and low amps.
— 15-30 minutes into charge cycle, volts increase
several tenths. Amps increase gradually, then
quickly to medium to high amps.
— 20-35 minutes into charge cycle, volts increase
to setpoint and amps decrease.
• High-cycle maintenance-free battery:
— These batteries respond better than standard
maintenance-free. Charge acceptance of these
batteries may display characteristics similar to
maintenance batteries.
NOTICE
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 hazards
that will or can cause minor
personal injury or property damage if ignored.
Indicates special instructions
on installation, operation or
maintenance that are important but not related to
personal injury hazards.
CAUTION
NOTICE
600 Series Troubleshooting Guide
for C651 and C654 Alternators
Charge Volt and Amp Values
The volt and amp levels are a function of the battery-
state of charge. If batteries are in a state of discharge,
as after extended cranking time to start the engine,
the system volts, when measured after the engine is
started will be lower than the regulator set point and
the system amps will be high. This is a normal condi-
tion for the charging system. The measured values of
system volts and amps will depend on the level of
battery discharge, in other words, the greater the
battery discharge level the lower the system volts and
higher the system amps will be. The volt and amp
readings will change and system volts reading will
increase up to regulator set point and the system
amps will decrease to low level (depending on other
loads) as the batteries recover and become fully
charged.
• Low Amps: A minimum or lowest charging system
amp value required to maintain battery state of
charge, obtained when testing the charging system
with a fully charged battery and no other loads
applied. This value will vary with battery type.
• Medium Amps: A system amps value which can
cause the battery temperature to rise above the
adequate charging temperature within 4-8 hours of
charge time. To prevent battery damage the charge
amps should be reduced when battery temperature
rises. Check battery manufacturer’s recommenda-
tions for proper charge amps rates.
• High Amps: A system amps value which can cause
the battery temperature to rise above adequate
charging temperature within 2-3 hours. To prevent
battery damage the charge amps should be
reduced when the battery temperature rises.
Check battery manufacturer’s recommendations
for proper charge amp rates.
• Battery Voltage: Steady-state voltage value as
measured with battery in open circuit with no
battery load. This value relates to battery-state of
charge.
• Charge Voltage: A voltage value obtained when the
charging system is operating. This value will be
higher than battery voltage and must never exceed
the regulator voltage set point.
• B+ Voltage: A voltage value obtained when mea-
suring voltage at battery positive terminal or
alternator B+ terminal.
• Surface Charge: A higher than normal battery
voltage occurring when the battery is removed from
a battery charger. The surface charge must be
removed to determine true battery voltage and
state of charge.
• Significant Magnetism: A change in the strength
or intensity of a magnetic field present in the
alternator rotor shaft when the field coil is ener-
gized. The magnetic field strength when the field
coil is energized should feel stronger than when
the field is not energized.
• Voltage Droop or Sag: A normal condition which
occurs when the load demand on the alternator is
greater than rated alternator output at given rotor
shaft RPM.