C.E. Niehoff & Co. C803D/C840D Alternator OEM Installation - Manual (Page 2)

2. Install alternator:
a. Carefully place alternator on alternator mounting
bracket.
Use caution when lifting alternator to
prevent possible minor personal injury.
Use hoist along with alternator lifting
ring located on top of alternator.
b. Rail mounting requires four 1/2-13 UNC-2A, SAE grade
5 or higher, mounting bolts with lock washers. Mount-
ing bolts should extend 17.8/22.7 mm (0.7/.88 in.) into
alternator mounting rail. Torque mounting bolts to
88 Nm/65 lb. ft.
c. Some alternators are furnished with a vibration damp-
ening bracket (CEN part no. A4-104). Attach one end of
bracket to drive end housing and other end to engine.
See Figure 1. See engine manufacturer's torque specifi-
cation for engine gear case bolt torque.
3. Units are shipped with pulley, disc spring washer, and
nut installed. Install alternator drive belt and secure belt
tension bracket assembly. Loop alternator drive belt over
pulleys and align belt with polyvee grooves.
4. Belt tension guidelines shown below are a starting point
for manual and automatic belt tensioners.
• K-section pulley: 10 grooves minimum, 12 grooves
preferred.
• Belt wrap: 180 degree nominal. Less wrap requires
a pulley with more grooves and more belt tension.
• Belt tension: 80 lbs to 120 lbs nominal. More pulley
grooves permit lower belt tension. For further questions,
please contact drive belt manufacturer.
Both too low and too high belt tension
causes premature bearing failure. Too low
belt tension causes belt slip, pulley heating,
bearing heating, and ultimately bearing fail-
ure. Too high belt tension increases bearing
fatigue, resulting in bearing failure.
5. Regulator electrical connections (see Figure 2):
a. Make sure alternator-to-regulator harness plug is
secure in regulator receptacle.
b. A2-330/A2-336: Connect IGN terminal to ignition
source through oil pressure switch, using proper ring
terminal. Torque terminal nut to 4.5 Nm/40 lb. in.
A2-346: Regulator can function with or without
vehicle ignition. When necessary, connect IGN terminal
on A2-346 regulator to vehicle ignition to provide bat-
tery voltage when engine is running. Circuit should be
off (no voltage present) when vehicle ignition is off or
II64G Page 2 of 2
engine is not running. Use proper ring terminal and
torque M5 terminal nut to 4.5 Nm/40 lb in.
c. P terminal can tap AC voltage, typically half the charge
voltage. When required, connect P terminal to tachom-
eter or relay. Use proper ring terminal. Torque terminal
nut to 4.5 Nm/40 lb. in.
d. D+ terminal can provide 28 VDC sense voltage to
multiplex controller. Maximum current from D+ can
be no more than 5 amps. When required, connect D+
terminal to controller through a relay. The relay coil
must be diode protected and rated for proper voltage.
Use proper ring terminal. Torque terminal nut to
4.5 Nm/40 lb. in.
e. A2-346 only: If not using A9-4036 temperature-
voltage sense/J1939 harness, keep cap on regulator.
If using A9-4036 temperature-voltage sense/J1939
harness:
1) Remove cap from regulator and plug harness
connector into 10-pin connector.
2) Harness length is 182 inches, enough to reach
battery compartment in most vehicles. Unused
harness length should be coiled up. Use cable ties
every 12-14 inches to securely support harness
between regulator and battery compartment.
If harness length must be shortened:
a) Black wire:
— Cut black wire off 6" above terminal, save terminal.
— Cut remaining black wire to length.
— Crimp and solder terminal and 6" wire or
reconnect with insulated butt splice and seal
with heat.
b) Red wire—cut to desired length and use terminal
to connect.
c) Attach terminal from black wire in A9-4036
harness to 28 V battery negative post. Attach ter-
minal from red wire to 28 V battery positive post.
d) If using J1939 connector on harness, connect
as indicated by vehicle manufacturer.
6. Alternator electrical connections:
a. Connect battery positive cable from vehicle to alternator
B+ terminal. Torque B+ terminal on alternator to
30 Nm/22 lb. ft. Torque cable clamp hardware to 14 Nm/
120 lb. in.
B+ cable must be supported by cable
clamp within 12 in. of B+ output terminal
to avoid premature failure of B+ output
terminal. CEN recommends using cable
clamp attached to alternator anti-drive
end housing for support.
b. Connect ground cable from vehicle to alternator B–
terminal. Torque B– terminal on alternator to 15 Nm/
11 lb. ft.
7. Attach fresh air duct to duct opening on anti-drive end
housing. Duct specifications include:
• 100mm/4 in. diameter duct no more than 2.5 m/8 ft.
long must be used.
• A maximum of two 90º bends is allowed.
• Installation must not obstruct airflow.
• Do not allow moisture, such as rain, road spray, water
used during vehicle cleaning, to be ingested by duct.
CAUTION
WARNING
Figure 2 - Regulator Connections
P terminal
D+ terminal IGN terminal
LED
CAUTION
A2-330/
A2-336
P terminal
D+ terminal IGN terminal
LED A2-346
Regulator receptacle
Regulator receptacle
temperature-voltage sense/
J1939 harness
If you have questions about your alternator or any of these instructions, or if you need to locate a Factory Authorized Service 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 • FAX: 847.492.1242
E-mail us at [email protected]