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

12. 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 FLD lead from existing
regulator to IGN terminal on new regulator, 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 FLD lead
from existing regulator to IGN terminal on A2-346
regulator 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. 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 tach-
ometer 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 blackwire 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
terminal from red wire to 28 V battery positive
post.
d) If using J1939 connector on harness, connect as
indicated by vehicle manufacturer.
13. Alternator electrical connections:
a. Replace battery positive cable if damaged or worn.
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. Replace ground cable if damaged or worn. Connect
ground cable from vehicle to alternator B– terminal.
Torque B– terminal on alternator to 15 Nm/11 lb. ft.
14. 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.
8. 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. Secure alternator to alternator mounting bracket.
Mounting bolts should extend 17.8/22.7 mm (0.7/0.88 in.)
into alternator mounting rail. Use four 1/2-13, grade 5
or higher mounting bolts with lock washers (existing
hardware may be suitable). Torque mounting bolts to
88 Nm/65 lb. ft.
c. Some alternator installations may require a vibration
dampening 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
specification for engine gear case bolt torque.
9. Replace alternator drive belt if damaged or worn. Install
alternator drive belt and secure belt tension bracket
assembly. Loop alternator drive belt over pulleys and
align belt with polyvee grooves.
Make sure pulley ratio will not overspeed
alternator.
10. 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 failure. Too high belt
tension increases bearing fatigue, resulting in
bearing failure.
11. Modify electrical connections to disable existing regulator:
• 50-RD regulator – see Figure 2. Disconnect POS lead at
POS terminal on regulator and reconnect to FLD terminal
on regulator. Torque #10-32 screw to 2.3 Nm/20 lb. in.
CAUTION
Figure 3 – 50-VR Regulator Modification (see NOTE above)
Reroute this lead
from IGN to FLD
IGN
BAT GND
FLD
CAUTION
Figure 2 – 50-RD Regulator Modification
Reroute this lead
from POS to FLD
POS FLD NEG
WARNING
• 50-VR regulator without Deutsch connector – see Figure 3.
Disconnect IGN lead at IGN terminal on regulator and
reconnect to FLD terminal on regulator. Torque screw to
1.4–1.7 Nm/12–15 lb. in.
NOTE: For 50-VR regulators with Deutsch connector,
unplug the Deutsch wiring harness from the 50-VR
regulator and plug it into a CEN A9-940 wiring adaptor.
No other wiring modification to 50-VR regulator is
required. Support wiring harness as needed.
CAUTION
II65G Page 2 of 2
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]