LMTV Alternator replacement 24 volt

[Keith Knight]

Keeping on the simple side didn’t you have to do other things to keep the dash indicator lights working properly?
Would love to see diagrams and part numbers of how you solved it.

 

[MatthewWBailey]

You’re killing me with abbreviations without stating what they are! LOL!!!

AIH = air inlet heater
PDP = power distribution panel
IMHO = in my humble opinion
EE = Electrical Engineer
LBCD = Lateral Border of Cardiac Dullness
FWIW = for what it's worth
Alt = Alternator
COTS = commercial off the shelf

I know you already know these I'm just being redundant. Rick is way better at acronyms than I.

 

[MatthewWBailey]

Keeping on the simple side didn’t you have to do other things to keep the dash indicator lights working properly?
Would love to see diagrams and part numbers of how you solved it.

Yes but only 1 wire. The "charging system" light control comes from the LBCD terminal B (FMTV
diagram page 23). I repurposed that 1853 wire with Ron's help to the i terminal of the new Alt. It needed a diode that's all since it's a sink, or low side control. Red wire in pics below.

the S terminal is a remote sense which I ran all the way back to the Batt with a sealed fuse at the 24v post. The Alt measures post voltage instead of the line voltage when charging. And now, I'm using the old "energize" wire off the old neihoff regulator to run a tach. 568A now goes to the R terminal and to the tach in the dash.

I used the diode shown below.
I edited the FMTV schematic but forgot to
Change 100 to 110

 

[Ronmar]

So with all the accolades we're giving Neihoff at this point, perhaps there's a better question: Is it (100A) overloaded in a stock A1? Seems like the adjectives of "robust" and "rarely fail" and "no data" are ignored when it's considered overloaded. So is it overloaded? Yes or no? (Don't forget that hard pulsing 90A AIH draw)


my professional opinion (FWIW) is that this pulsing 90A AIH is an ALT wrecker or at least a Regulator wrecker. I'd have to test 2 units side by side to prove it thou.

if you are only drawing 24v out of it, it would be no more overloaded than any other 24v alt. The Neihoff‘s Achilles heel rears its ugly head when you start pulling 14v out of it. The alt is rated 100A combined load, and since the 14 is pulled from the first half of the windings, it can only deliver ~60A max at 12v. An incandescent light load is ~25A, if you have the lights on and are pulling that, the alt can only deliver ~75A @24. The truck needs perhaps 15+ of that, you are now at 60 or less available. A 240A wet cell needs that if its discharged, and if they are really flat we are talking hours at max load to recharge.

At straight 24, you have 100A. Well thats 12.5 A for the lights, another 15 for the truck loads, that leaves you 70A. The batts are looking for 60A(25% AH), so <90% load. A much more favorable situation if you have several hours of charging ahead. Not an issue if you keep the batteries topped(float charger or run a lot of hours)

Of course AGM batts blow this situation up with their 45% of AH current draw(108A for a 240AH bank). Thats was probably a big factor in the 260A alt changeup.

now pick a vehicle, any vehicle. The daily in your driveway perhaps. Total loads, total battery demand(25 or45% of batt AH capacity based on batt type) and compare it against the alternator rating. I would be surprised if you find a worst case combination much above 50-60% of the alternators rating, and the batts will most likely NOT require hours to recharge.

As for loads like the AIH, still not thinking this is terrible. Again only fairly brief periods, and surely not as bad as say a winch Their voltage drawdown when on basically cuts off feed to the battery. The alt and batt are a team, so as the alt goes to full output and voltage drops, the battery steps in and makes up the rest, then the alt replaces it when the AIH cuts off. if your batts are kept up, not much of an issue IMO, and not thinking it is an alt killer. Lots of vehicles use them…

 

[DeMilitarized]

So with all the accolades we're giving Neihoff at this point, perhaps there's a better question: Is it (100A) overloaded in a stock A1? Seems like the adjectives of "robust" and "rarely fail" and "no data" are ignored when it's considered overloaded. So is it overloaded? Yes or no? (Don't forget that hard pulsing 90A AIH draw)

For the record, I DO have a failed 100a Neihoff alternator at the local rebuild shop. Already dropped $800 on a failed regulator 2k miles ago with only 9k on the truck at the time. He tested it on his bench setup and it's putting out 50A max on his tester. So he's tearing into it. I'll know more once he's done. So apparently I'm the only person in the known universe that's ever had a bad Neihoff alt?, I should be shamed drawn and quartered. lol. Tyler screwed me again? I'm betting that's it.

On the LBCD, I see 2 big capacitors and 2 diodes. The diodes can go in the PDP. The patent app discuses "ripple reduction during battery-less operation". If you eliminate "battery less operation" you don't need this mystical black box which imho as an EE does nothing but bust my balls. I gave mine away, with cash and bitcoin to a needy family along with the power relay. I shorted my manual disco terminals with bus bars for security but they're easily removable for maintenance. I'll post that another place. So I'm never in battery less mode

Further food for thought, convince me that at $800+ per regulator and god knows what for the alt itself ($1200), why isn't this thing able to produce 200% and never fail regardless of load duty? If I gave you $2000, could you buy a better more capable unit in the commercial market? With ALL the 12v load removed on mine with 2batts I'm pulling 115A during initial startup for several minutes. Is that an overload on a N1511?

my professional opinion (FWIW) is that this pulsing 90A AIH is an ALT wrecker or at least a Regulator wrecker. I'd have to test 2 units side by side to prove it thou.

I have a stock lmtv alt that failed you could buy for parts if interested.