n1387 series troubleshooting guide for n1387-1...

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Page 1 TG0019A Table of Contents Section 1: Component Description .............................. 2 Section 1: Start-up/Shutdown Procedures ................... 2 Section 2: Wiring ......................................................... 3 Section 3: CAN/J1939 Diagnostics .............................. 4 Section 4: Basic Troubleshooting ................................ 5 Section 5: Advanced Troubleshooting ...................... 6-9 Section 6: Troubleshooting the EPM ................... 10-12 Battery Conditions Until temperatures of electrical system components stabilize, these conditions may be observed during cold start voltage tests. Maintenance or low maintenance battery: Immediately after engine starts, system volts are lower than regulator setpoint with medium amps. 3-5 Minutes into charge cycle, system volts are higher and amps are dropping. 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 characteris- tics with slightly longer recharge times. Maintenance-free battery: Immediately after engine start, system volts are lower than regulator setpoint with low charging amps. 15-30 minutes into charge cycle, volts and amps are still low. 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. NOTICE N1387 Series Troubleshooting Guide for N1387-1 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 setpoint and the system amps will be high. This is a normal condition 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, system volts reading will increase up to regulator setpoint 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 rates of charge amps. 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 rates of charge amps. 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 setpoint. B+ Voltage: A voltage value obtained when measur- ing 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 energized. The magnetic field strength when the field coil is ener- gized 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. WARNING Indicates the presence of hazards that can cause severe personal injury, death or substantial property damage if ignored. Indicates presence of hazards that will or can cause minor personal injury or property damage if ignored. Indicates special instructions on installation, operation or mainte- nance that are important but not related to personal injury hazards. CAUTION

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Page 1: N1387 Series Troubleshooting Guide for N1387-1 …ceniehoff.com/Documents/Ctrl_Hyperlink/TG0019A_uid12172009217332.pdfN1387 Series Troubleshooting Guide for N1387-1 Alternators Charge

Page 1TG0019A

Table of ContentsSection 1: Component Description .............................. 2Section 1: Start-up/Shutdown Procedures ................... 2Section 2: Wiring ......................................................... 3Section 3: CAN/J1939 Diagnostics .............................. 4Section 4: Basic Troubleshooting ................................ 5Section 5: Advanced Troubleshooting ......................6-9Section 6: Troubleshooting the EPM ................... 10-12

Battery ConditionsUntil temperatures of electricalsystem components stabilize, theseconditions may be observed duringcold start voltage tests.

• Maintenance or low maintenance battery:— Immediately after engine starts, system volts are

lower than regulator setpoint with medium amps.— 3-5 Minutes into charge cycle, system volts are

higher and amps are dropping.— 5-10 Minutes into charge cycle, system volts are

at, or nearly at, regulator setpoint and amps arereduced to a minimum.

— Low maintenance battery has same characteris-tics with slightly longer recharge times.

• Maintenance-free battery:— Immediately after engine start, system volts

are lower than regulator setpoint with lowcharging amps.

— 15-30 minutes into charge cycle, volts and ampsare still low.

— 15-30 minutes into charge cycle, volts increaseseveral tenths. Amps increase gradually, thenquickly, to medium to high amps.

— 20-35 minutes into charge cycle, volts increaseto setpoint and amps decrease.

• High-cycle maintenance-free battery:— These batteries respond better than standard

maintenance-free. Charge acceptance of thesebatteries may display characteristics similar tomaintenance batteries.

NOTICE

Hazard DefinitionsThese terms are used to bring attention to presence of hazardsof various risk levels or to important information concerningproduct life.

NOTICE

N1387 Series Troubleshooting Guidefor N1387-1 Alternators

Charge Volt and Amp ValuesThe volt and amp levels are a function of the batterystate of charge. If batteries are in a state of discharge,as after extended cranking time to start the engine, thesystem volts, when measured after the engine is started

will be lower than the regulator setpoint and the systemamps will be high. This is a normal condition for thecharging system. The measured values of system voltsand 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 ampswill be. The volt and amp readings will change, systemvolts reading will increase up to regulator setpoint andthe system amps will decrease to low level (dependingon other loads) as the batteries recover and becomefully charged.

• Low Amps: A minimum or lowest charging systemamp value required to maintain battery state ofcharge, obtained when testing the charging systemwith a fully charged battery and no other loadsapplied. This value will vary with battery type.

• Medium Amps: A system amps value which cancause the battery temperature to rise above theadequate charging temperature within 4-8 hours ofcharge time. To prevent battery damage, the chargeamps should be reduced when battery temperaturerises. Check battery manufacturer’s recommenda-tions for proper rates of charge amps.

• High Amps: A system amps value which can causethe battery temperature to rise above adequatecharging temperature within 2-3 hours. To preventbattery damage, the charge amps should be reducedwhen the battery temperature rises. Check batterymanufacturer’s recommendations for proper ratesof charge amps.

• Battery Voltage: Steady-state voltage value asmeasured with battery in open circuit with nobattery load. This value relates to battery state ofcharge.

• Charge Voltage: A voltage value obtained when thecharging system is operating. This value will behigher than battery voltage and must never exceedthe regulator voltage setpoint.

• B+ Voltage: A voltage value obtained when measur-ing voltage at battery positive terminal or alternatorB+ terminal.

• Surface Charge: A higher than normal batteryvoltage occurring when the battery is removed froma battery charger. The surface charge must beremoved to determine true battery voltage and stateof charge.

• Significant Magnetism: A change in the strength orintensity of a magnetic field present in the alternatorrotor shaft when the field coil is energized. Themagnetic field strength when the field coil is ener-gized should feel stronger than when the field is notenergized.

• Voltage Droop or Sag: A normal condition whichoccurs when the load demand on the alternator isgreater than rated alternator output at given rotorshaft RPM.

WARNINGIndicates the presence of hazardsthat can cause severe personal

injury, death or substantial property damage if ignored.Indicates presence of hazards thatwill or can cause minor personal

injury or property damage if ignored.Indicates special instructions oninstallation, operation or mainte-

nance that are important but not related to personal injuryhazards.

CAUTION

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Section 1: Component Description and Operation

CEN N1387-1 Dual Voltage Alternator Descrip-tion and OperationN1387-1 28 V 210 A alternator with optional 28 V/14V (50 A maximum on 14 V) is internally rectified. Allwindings and current-transmitting components arenon-moving, so there are no brushes or slip rings towear out.

After engine is running, N3225 regulator receivesenergize signal. Regulator monitors alternatorrotation and provides field current only when itdetects alernator shaft rotating at suitable speed.

After regulator detects alternator rotation, it gradu-ally applies field current, preventing an abruptmechanical load on accessory drive system. The softstart may take up to 20 seconds.

N3225 regulator used with these units also

• is negative temperature compensated. Setpointsare 28.0 ± 0.2 V and 14.0 ± 0.2 V at 75° F.

• provides overvoltage cutout (OVCO). Regulatorwill trip OVCO when system voltage rises above32 V in a 28 V system (16 V in a 14 V system) forlonger than 2 seconds. OVCO feature detects highvoltage and reacts by signaling relay in F– alterna-tor circuit to open, turning off alternator. Restart-ing engine resets OVCO circuit. If vehicle is run inOVCO mode OVCO will automatically reset whensystem voltage drops to 22 V (11 V on 14 V side).Regulator regains control of alternator belowoutput voltage.

• maintains alternator output voltage at regulatedsettings as vehicle electrical loads are switchedon and off.

• can be used in single or dual voltage with thisalternator.

— Allows single-voltage operation (28 V only).14 V is not available as a single voltage appli-cation.

— Provides optional 28 V/14 V output only fromthe regulator when phase cable from alterna-tor is connected to regulator.

• works with the EPM to provide dual voltageoutput during batteryless operation. Whenoperating in batteryless mode, the system willhave higher ripple. LEDs might change colormore rapidly depending on loads.

EPM Electric Power Manager used with these units

• is rated for continuous current at 200 A on 28 Vside. The 14 V side is rated for continuouscurrent at 100 A.

• manually connects batteries after battery-connectbutton on vehicle is pressed.

• automatically disconnects batteries from vehicleloads 3 minutes after engine shuts down.

• provides 28 V auxillary output power for up tofour 20 A channels and 14 V auxillary outputpower for one 20 A channel, protected by aninternal, resettable, electronic circuit breaker.

• keeps batteries connected to system when emer-gency flashers are used.

Normal Start-Up Procedure1. Press the vehicle battery-connect button to connect

batteries.

2. Turn START-RUN switch to RUN.

3. Wait until glow plug light goes off.

4. Turn START-RUN switch to START and crankengine.

5. Return switch to RUN when engine starts.

6. If engine fails to crank, turn START-RUN switch toOFF, repeat steps 1-5 above.

7. If engine still fails to start, the EPM could bedamaged.

Emergency Start-Up Procedure

1. Connect slave vehicle Nato connector to vehicle.

2. Follow steps 2-5 above.

3. Disconnect slave NATO connector after engine isrunning.

Shutdown Procedure1. Place gear shift in park or neutral and set parking

brake.

2. Turn start-run switch to OFF to stop engine.

3. Batteries will be disconnected from vehicle in 3min. unless emergency flashers are on, thenbatteries will stay connected until flashers areturned off or battery is discharged.

This procedure will bypass EPM andbatteries in system. Use thisprocedure ONLY when vehicle mustbe removed immediately fromlocation in an EMERGENCY.

a. Remove cables from “Load” side of EPM andtemporarily attach to “Battery” side of EPM.

b. Follow steps 2-5 above.

Do not leave vehicle cablingconnected as described in steps 7a-b. Diagnostic and repair must beperformed as soon as possible.

WARNING

WARNING

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Figure 2 — N1387-1 Alternator with N3225 Regulator

Figure 1 — N1387-1 Alternator and N3225 Regulator Terminals

Section 2: Wiring

N3225REGULATOR

14 V B+ terminal

28 V B+terminal

14 V

ACIGN

AC terminalIGN terminal

14 V28V

RegulatordiagnosticLEDs

B–terminal

J1939CONN

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Section 3: CAN/J1939 Diagnostics

CAN/J1939 InterfaceDESCRIPTION AND OPERATIONThe EPM and the CEN N3225 digital regulator are compatible with theSAE J1939 communications standard for vehicle networking.

CEN uses MIL-STD connector MS3112E12-10P to interface between theEPM/N3225 and the DPA adapter used to monitor the broadcastmessages on the CAN bus line. The readouts of these messages areshown in Table 2 for the EPM and Table 3 for the regulator.

Pin Identification

TABLE 1 – J1939 ConnectorCircuit Identification

A

B

C

D

E

F

G

H

J

K

CAN High

CAN Low

CAN Shield

Ground

Restricted use

Restricted use

Restricted use

unused

unused

+28V power

Figure 4 – EPM Electric Power Manager

J1939ConnectorUnder Cap

EPMConnectorto N3225Regulator

EPM Readout Expected ReadingTABLE 2 – EPM/J1939 Readout Diagnostics (With Engine Running)

Load Voltage 28 V System

Load Voltage 14 V System

Alternator Speed

Battery Voltage 28 V System

Battery Voltage 14 V System

EPM Temperature

Charging and DischargingCurrent of 28 V Battery

Batt Charging 28 V LED

Batt Charging 14 V LED

Main Switches On

Cranking Detected

Emergency Flasher Detected

Figure 3 – J1939Connector Pins

27–29 V

13.5–14.5 V

1200 to 6000 RPM

27–29 V

13.5–14.5 V

–50ºF (–46ºC) to200ºF (93ºC)

10 A (varies accordingto battery condition)

OK

OK

OK

OK

OK

Action If Expected Reading Not Achieved

See Chart 1, page 7.

See Chart 2, page 8.

Check drive belt and charging system connection.

See Chart 1, page 7.

See Chart 2, page 8.

Check connections to EPM.

Observe current charges with battery and ignition on and then off.

See Chart 1, page 7.

See Chart 2, page 8.

Verify “Battery Connect” indicator is lit AMBER.

See Chart 5, page 11.

Check bulbs on flashers or ICC to battery.

Regulator Readout Expected ReadingTABLE 3 – N3225 Regulator/J1939 Readout Diagnostics

Alternator Output Voltage 28 V System

Alternator Output Voltage 14 V System

Alternator Speed

Alternator Temperature

Battery Voltage 28 V System

Battery Voltage 14 V System

Alternator Output Capacity

Charging System Status

27–29 V

13.5–14.5 V

1200 to 6000 RPM

Less than 260º F/127ºC

27–29 V

13.5–14.5 V

0–100%

OK

Action If Expected Reading Not Achieved

See Chart 1, page 7.

See Chart 2, page 8.

Check drive belt and chg system connection.

Decrease load on alternator. See Chart 4, page 9.

See Chart 1, page 7.

See Chart 2, page 8.

Varies with load.

See Chart 1, page 7, or Chart 2, page 8.

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C. Basic Troubleshooting1. Inspect charging system components

Check connections at ground cables, positivecables, and regulator harness. Repair or replaceany damaged component before troubleshooting.

2. Inspect EPM connectionsConnections must be in proper sequence andclean and tight. See Figure 9, page 10.

3. Inspect connections of vehicle batteriesConnections must be clean and tight.

4. Determine battery type, voltage, and stateof chargeBatteries must be all the same type for systemoperation. If batteries are discharged, rechargeor replace batteries as necessary. Electricalsystem cannot be properly tested unless batter-ies are charged 95% or higher. See page 1 fordetails.

5. Connect meters to alternatorConnect red lead of DMM to alternator 28 V B+terminal and black lead to alternator B– termi-nal. Clamp inductive ammeter on 28 V B+cable.

6. Operate vehicleFollow start-up procedure on Page 2. Observecharge voltage.

If charge voltage is above33 volts for 28 V system

or 16 V for 14 V system, immediately shut down system.Electrical system damage may occur if charging systemis allowed to operate at excessive voltage. Go to page 9.

If voltage is at or below regulator setpoint, letcharging system operate for several minutes tonormalize operating temperature.

7. Observe charge volts and amps in each circuitCharge voltage should increase and charge ampsshould decrease. If charge voltage does not in-crease within ten minutes, continue to next step.

8. Batteries are considered fully charged if chargevoltage is at regulator setpoint and charge ampsremain at lowest value for 10 minutes.

9. If charging system is not performing properly,go to Chart 1, page 7.

A. Tools and Equipment for Job• Digital Multimeter (DMM)

• Ammeter (digital, inductive)

• Jumper wires

If no tools are available, monitor LED code.

B. Identification RecordList the following for proper troubleshooting:

Alternator model number ____________________

Regulator model number _____________________

Setpoint listed on regulator ___________________

EPM model number __________________________

Section 4: Basic Troubleshooting

CAUTION

SYMPTOM ACTION

TABLE 4 – System Conditions

Check: loose drive belt; lowbattery state of charge.

Check: current load on systemis greater than alternatorcan produce.

Check: defective wiring or poorground path.

Check: defective alternatorand/or regulator.

Check: defective regulator.Check: alternator.Check: presence of energize

signal to IGN terminal onregulator.

Check: battery voltage at alter-nator output terminal.

Check: defective alternatorand/or regulator.

Check:defective regulator.Check:cable from 14 V regulator

terminal to battery.

Low Voltage Output

High Voltage Output

No Voltage Output

No 14 V Output

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N3225 RegulatorDESCRIPTION AND OPERATION

N3225 Regulator with OVCO is attached directly tothe outside of the alternator. Regulator setpoint hasnegative temperature compensation. At 75ºF, thesetting is 28.2 V for 28 V system and 14.1 V for 14 Vsystem.

Main diagnostic feature of N3225 regulator consistsof two bicolored (amber, green) LEDs located on theside of the regulator. One LED indicates 28 V systemperformance, the other LED indicates 14 V systemperformance. The two LEDs work independently ofeach other. See Table 5 for diagnostic features andLED explanations.

OVCO (overvoltage cutout) will trip at any of thefollowing conditions:

• 14 V side trips at voltage higher than regulatorsetpoint that exists longer than 2 seconds ofreading voltage above 16 V. OVCO feature detectsovervoltage and reacts by signaling relay in F–alternator circuit to open. This turns off alterna-tor (14 V LED is flashing AMBER /28 V LED isoff). OVCO circuit will reset by restarting engine(regulator regains control ofalternator outputvoltage and resets OVCO).

• 28 V side trips at voltage higher than regulatorsetpoint that exists longer than 2 seconds ofreading voltage above 32 V. OVCO feature detectsovervoltage and reacts by signaling relay in F–

alternator circuit to open. This turns off alterna-tor (28 V LED is flashing AMBER / 14 V LED isoff). OVCO circuit will reset by restarting engine(regulator regains control of alternator outputvoltage and resets OVCO).

TROUBLESHOOTING

Shut down vehicle and restart engine per start-upprocedure on page 2. If alternator functions normallyafter restart, a “no output condition” was normalresponse of voltage regulator to overvoltage condi-tion. Inspect condition of electrical system.

If you have reset alternator once, and electricalsystem returns to normal charge voltage condition,there may have been a one time, overvoltage spikethat caused OVCO circuit to trip.

If OVCO circuit repeats cutout a second time in shortsuccession and shuts off alternator F– circuit, trythird restart. If OVCO circuit repeats cutout a thirdtime, check color of LEDs while engine is running.

28 V LED flashing AMBER / 14 V LED off—go toChart 4, page 9.

14 V LED flashing AMBER /28 V LED off—go toChart 3, page 9.

Section 5: Advanced Troubleshooting

N3225 LEDs COLOR N3225 STATUSTABLE 5 – N3225 Regulator LEDs Diagnostics

Regulator is not energized. Measure IGN terminal voltage.If voltage is above 21 V, regulator is defective.

Off (Clear)

Respective system voltage is below regulated setting or isprocessing soft start (20-second delay).

Steady AMBER

Respective system voltage is reading high voltage.Flashing AMBER(either 28 V or 14 V)

GREEN Normal operation (respective system voltage is at regulated setting)

Alternator is shut down and is not producing power for eithervoltage. 28 V side trips after 2 seconds of reading voltageabove 32 V. 14 V side trips after 2 seconds of reading voltageabove 16 V. Regulator remains in this mode until reset byrestarting engine or if system voltage drops below 22 V or 11V, respectively. See Chart 3 on page 9 of TroubleshootingGuide for 28V systems, Chart 4 for 14 V systems.

AMBER(either 28 V or 14 Vwith the other LEDoff)

GREEN(both flashing once every 5 sec.)

Regulator is energized, but waiting for AC signal from alternator.

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Section 5: Advanced Troubleshooting(CONT’D)

Shut off engine. With key off, engine off: Test for battery voltage at alternator 28 V B+terminal. Does battery voltage exist?

Yes No

Check and repair EPM wiring and battery cables as necessary.Continue test.

Chart 1 – 28 V LED Steady AMBER – No 28V Alternator Output – Test Charging Circuit

With DMM, check resistance across field coil. Connect red lead of DMM to socket A in alternator-to-regulatorharness plug. Connect black lead to B+ terminal on alternator. Does meter show 2.0 ± 0.2 ohms?

Yes No

Yes

Test phase signal into regulator (AC). Set meter to diode tester:

Connect red lead of DMM to socket C of regulator harness and blacklead to socket B. Meter should show voltage drop value.

Then reverse meter lead connections. Meter should show OL (blocking).

No

Yes No

Regulator responded to overvoltage condition. Go to Chart 4on page 9 to troubleshoot OVCO.

Figure 5 – Alternator-to-Regulator4-Socket Harness Plug

SOCKET CONNECTIONSA F–B Phase Signal ACC B–D 28 V B+

With key on, engine running: Test for battery voltage between IGN terminal on regulator and alternatorB– terminal. Does 28 V battery voltage exist?

Yes No

With key off, engine off: Remove alternator-to-regulator 4-pin harness from regulator. Test for batteryvoltage across sockets D and C in harness plug. Does 28 V battery voltage exist?

Alternator is defective.

Alternator is defective.

Alternator is defective.Regulator is defective.

Yes

Connect jumper wire from socket A in regulator harness plug to B– terminal on alternator.Spark will occur. Touch steel tool to shaft to detect significant magnetism. Is shaft magnetized?

No

Repair vehicle ignition circuit wiring as necessary.

Yes No

CAUTION Troubleshooting sequences must be performed during 3-minute delay after battery-connect button onvehicle is pressed. If main LED on EPM is not flashing GREEN, press button to reactivate system. LED onEPM must be flashing GREEN while performing tests.

Start engine. Wait 20 seconds. Is 28 V LED steady GREEN on regulator?

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Section 5: Advanced Troubleshooting(CONT’D)

Chart 2 – 14 V LED Solid AMBER – No 14 V Alternator Output – Test Circuit

Figure 7 – Phase Connection 3-Pin Harness Plug

PIN CONNECTIONSA Phase P1B Phase P2C Phase P3

With key off, engine off: Test for battery voltage of 14 V output terminal on regulator.Does +14 V battery voltage exist?

Yes No

Yes

Set DMM to diode tester. Connect red lead of DMM to socket C of regula-tor harness plug and black lead to each phase pin in phase harnessplug. Meter should show voltage drop value.

Then reverse meter lead connections. Meter should show OL (blocking).

No

Alternator is defective.Regulator is defective.

Figure 6 – Alternator-to-Regulator 4-Socket HarnessPlug

SOCKET CONNECTIONSA F–B Phase Signal ACC B–D 28 V B+

CAUTION Troubleshooting sequences must be performed during 3-minute delay after battery-connect button onvehicle is pressed. If main LED on EPM is not flashing GREEN, press switch to reactivate system. LED onEPM must be flashing GREEN while performing tests.

Check and repair EPM wiring and battery cables as necessary.Continue test.

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(CONT’D)Section 5: Advanced Troubleshooting

Yes No

Alternator is defective.

Unplug alternator-to-regulator 4-socket harness from regulator. Connect red lead from DMM to pin A inplug. Connect black lead to pin D in plug. Does resistance read 2.0 ± 0.2 ohms?

Chart 4 – 28 V LED Flashing AMBER/ 14V LED Off – No Alternator Output – Test OVCO Circuit

Yes No

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

Alternator is defective. Original regulatoris defective.

Chart 3 – 14 V LED Flashing AMBER/ 28V LED Off – No Alternator Output – Test OVCO Circuit

Yes No

With red lead from DMM connected to pin A in plug, connect black lead to B– terminal. Doesresistance read OL (out of limits)?

Alternator is defective.

Figure 8 – Alternator-to-Regulator 4-Socket Harness Plug

SOCKET CONNECTIONSA F–B Phase Signal ACC B–D 28 V B+

Yes No

Original regulatoris defective.

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

Alternatoris defective.

Yes No

Alternator is defective.

Unplug alternator-to-regulator 4-socket harness from regulator. At receptacle on regulator, connect red leadfrom DMM to pin C. Connect black lead to B– terminal. Does resistance read OL (out of limits)?

CAUTION Troubleshooting sequences must be performed during 3-minute delay after push-button switch on vehicle ispressed. If main LED on EPM is not flashing GREEN, press switch to reactivate system. LED on EPM must beflashing GREEN while performing tests.

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Pin Function

TABLE 7 – EPM Harness PlugSocket Functions

A

B

C

D

Battery Ground

Alternator Phase In Signal

Energize (Active Low) Signal

Ignition Signal

Figure 10 – EPM System Schematic

EPM Electric Power ManagerDESCRIPTION AND OPERATION

Main diagnostic feature of the EPM is a bicolored(amber, green) LED located on the side of the device.The EPM manually connects and automaticallydisconnects batteries after 3 minutes unless emer-gency flashers are on.

EPM also allows batteryless operation until vehicle isshut off.

Section 6: Troubleshooting the EPM

Figure 9 – EPM Electric Power Manager

J1939ConnectorUnder Cap(see p. 4 fordetails)

EPM LED

EPMConnector

AUXCircuitsConnector

Aux. LoadDiagnosticLEDs

EPM LED COLOR EPM STATUS

TABLE 6 – EPM LED Diagnostics

EPM is not energized or EPM isdefective.

Off (Clear)

Flashing GREEN

Steady GREEN

EPM has connected the batteriesduring start-up and has preventedautomatic disconnection for 3minutes after vehicle shuts downwhen only vehicle battery-connectbutton is pressed.

Normal operation (batteries areconnected to the system andengine is running)

PinFunction

(Max. 30 A)

TABLE 8 – AUX Circuit and LED Functions

A

B

C

D

E

14 V

28 V

28 V

28 V

28 V

EPM

EPM

EPM

N3225

N1387-1

LED ColorNormally On

If LEDOFF:

GREEN

GREEN

GREEN

GREEN

GREEN

A short or overcurrentmay have occurred.Check AUX load wiringand reset EPM bypressing Low BatteryIndicator.

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Section 6: Troubleshooting the EPM

CAUTION Troubleshooting sequences must be performed during 3-minute delay after battery-connect button onvehicle is pressed. If main LED on EPM is not flashing GREEN, press switch to reactivate system. LED onEPM must be flashing GREEN while performing tests.

Chart 5 – Engine Will Not Crank at Start-Up

Yes No

Check and repairvehicle battery-connect button andwiring as necessary.Re-test.

Disconnect 4-socket harness at EPM. Whilepressing vehicle battery-connect button, checkfor continuity between socket C on EPM harnessplug and ground. Does continuity exist?

Yes No

Turn START-RUN switch to OFF. Press vehicle battery-connect button. Check LED on EPM.Is LED flashing GREEN?

Before Troubleshooting, Check Batteries for Proper Charge Voltage. See Page 1.

Yes No

EPM isdefective.

Check for continuity across 28 V and 14 Vterminals on EPM. Does continuity exist?

Check and repairstarter and starterwiring as necessary.

Re-test.

EPM isdefective.

Chart 6 – No Power to Aux. Loads –One or More LEDs are OFF

Yes No

Disconnect Aux. Load harness from EPM. Turn start-run switch to OFF.Press vehicle battery-connect button. Is LED on EPM flashing GREEN?

Before Troubleshooting, Check Batteries for Proper Charge Voltage. See Page 1.

Yes No

EPM isdefective.

Are all five Aux diagnostic LEDs lit on EPM?

Check and repairload and load wiringas necessary.

Re-test.

EPM isdefective.

(CONT’D)

Page 12: N1387 Series Troubleshooting Guide for N1387-1 …ceniehoff.com/Documents/Ctrl_Hyperlink/TG0019A_uid12172009217332.pdfN1387 Series Troubleshooting Guide for N1387-1 Alternators Charge

Page 12 TG0019A

(CONT’D)Section 6: Troubleshooting the EPM

Batteries are connected

Vehicle battery-connect buttonis pressed.

3-Minute counter in EPM starts.

Chart 7 – 28V Only – EPM Sequence of Operation

Flashing GREEN

START-RUN Switch operated to start vehicle

Batteries will stay connected as long as vehicle is runningor emergency flashers are on

Normal operation

Shut down vehicle

Flashing GREEN

3-Minute Delay

3-Minute Delay Ends and EPM disconnects batteries

AUX LEDs Steady GREEN

AUX Current available

If emergency flashers are theonly load required, enginedoes not need to be started tokeep batteries connected. Afterflashers are switched on, EPMwill keep power to loads untilbatteries are discharged.

EPM and AUX Diagnostic LEDs OFF.

AUX Channels still available.

3-Minute delay in EPM ends

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 USATEL: 800.643.4633 USA and Canada • TEL: 847.866.6030 outside USA and Canada • FAX: 847.492.1242