HEAVY DUTY BRUSHLESS ALTERNATOR SERVICE MANUAL 33
Contents
1. PART NO A 8 ion 1967343 SZ g PULLEY 14 1 2 13 FLANGED MOUNTING BOLT 102 s SAE GRADE 5 OR BETTER 1 2 13 FLANGED MOUNTING lt LOCKING NUT 103 j SAE GRADE 5 OR BETTER FLANGED A MOUNTING gt ALL PARTS ZINC OR PHOSPHATE COATED HARDENED STEEL NUT 103 ALTERNATOR OPTION WASHERS MAY BE SUBSTITUTED FOR FLANGES y BELT S 107 33 6246 Figure 43 Alternator Mounting Bolts 1 2 ALTERNATOR O MOUNTING LUGS H BOLT iO gt REMOVE OR DI NNECT 0 eee 6 ALTERNATOR MOUNTING 1 Negative cable at battery BRACKET 101 33 6248 NOTICE Always reinstall fasteners at original location If necessary to replace fasteners use only correct part number or equivalent See Fig 43 Figure 44 Installing Alternator on Engine TEST EQUIPMENT NEEDED e Ifcorrect part number 1s not available use only equal size and strength e Belt Tension Gage e Fasteners that are NOT to be reused will be noted in procedure NOTICE Before installing alternator to engine check e Fasteners requiring thread locking compound will mounting bracket 101 and adjustment bracket 104 be noted in procedure also stabilizer bracket 111 Fig 46 if used to ensure e Use specified torque values when shown they are not worn or cracked Make sure they will securely mount alternator to engine with proper Using or replacing fasteners in any other manner could hardware result in part or system damage a TIGHTEN2. 9 Oe rate Principle A 3 Final 1153556317 Dl saca ii 12 Troubleshooting Alternator Assembly 11 14 A All Charging Systems sess 4 DE Frame AA sss 14 B Systems with Indicator Light 5 Rectifier End Housing and Components 14 C Systems without Indicator Light 5 Final Alternator Assembly 18 D R Terminal Accessory Problems 6 Alternator Bench Test oococcccccncnnncnnnnnnnnnnnss 20 E NO OUMU cicikan Esha 6 Alternator Installation spare 21 F Rated Output CHECK 1 Alternator Specifications 2322222 25 S 26 33 6211 Figure 1 33 SI Alternator INTRODUCTION The 33 34 SI series alternator is a brushless heavy duty integral charging system with built in diode rectifier and voltage regulator producing DC current for battery electrical systems The 33 34 SI series is designed for use on large and mid range diesel and gasoline engines in over the road service as well as for off road agricultural and construction equipment The 34 ST is identical to the 33 SI except for the stabilizing lug 4th lug on top of the rectifier end frame and the ground screw 1s located on the right side of the rectifier end housing The stabilizing lug provides superior vibration resistance on certain applications The 33 34 SI alternato
3. 217 Screw Insulated Hex Head Regulator Short 218 Nut Hex Head 219 e Connector Bridge to Regulator Stud 220 Cover Terminal 221 Screw Hex Head Field Coil Attch 222 Plug Rectifier Housing 223 Screw and Lockwasher Assembly 224 Screw Ground 225 Cap Pin Terminal 226 Screw Insulated Hex head Rectifier Long Qty Ke BR BRR eRe w RRR PO NO 33 34 SI ALTERNATOR PAGE 27 1 33 6256 O Copyright DRI 1G 500 10 97 7 4 5 1 t i a 5 aes Ps Pe g a r 4 y Delco Remy International Inc 2902 Enterprise Drive Anderson IN 46013 For further information and specifications on these and other Delco Remy Products call 1 800 DRA 0222 Delco Remy is a registered trademark licensed by General Motors Corporation
4. NeicokRemy 1G 500 PRODUCT INFORMATION 1 98 BRUSHLESS ALTERNATOR SERVICE MANUAL 1998 Delco Remy International Inc All Rights Reserved SPECIFICATIONS MAXIMUM SPEED Continuous 10 000 rpm Intermittent 12 000 rpm ROTATION Clockwise Counterclockwise TEMPERATURE LIMITS 40 or 40 C Ambient 200 F or 93 C Ambient POLARITY Negative Ground Standard Insulated Models Available MOUNTING SAEJ180 Standard WEIGHT 33 SI 24 5 pounds 0 34 SI 25 4 pounds or 11 59 Built In Voltage Regulator Solid State Integrated Circuit Flat Temperature Compensated Low Parasitic Draw Low Turn On Speed Improved RFI Suppression Load Dump Protection Relay Terminal Output Terminal Indicator Light Terminal Integrated Circuit Regulator FEATURES 262 4 mm Brushless Construction Stationary Field Coil No Brushes or Slip Rings Corrosion Protection Special Environmental Protection Coating Applications Line Haul Diesel Trucks Large Commercial Diesel Engines Harsh Environments Heavy Belt Loads and Vibrations Stationary Field Coil Brushless Heavy Duty Roller Bearing ihi Fan Die Cast Aluminum Heavy Duty Ball Bearing 33 6208 33 34 SI ALTERNATOR PAGE 1 PRODUCT INFORMATION AND SERVICE MANUAL 33 34 SI HEAVY DUTY BRUSHLESS ALTERNATOR CONTENTS ic AAA E AEA i 1 Alternator Unit Reparan 9 ESAS e EEEE 2 Disassembly and Bench Checks
5. Place retainer plate 16 onto collar flanged side of retainer will face away from rotor toward bearing Using open tube that bears only on inner race of bearing press new DE bearing 5 onto rotor shaft until bearing is against collar INNER RACE BEARING BEARING ROTOR ASSEMBLY RETAINER COLLAR Figure 25 Rotor Assembly 3 Insert bearing 5 on rotor shaft into bearing well in drive end frame 4 See Fig 26 Bearing will be a snug fit but should slip in easily when properly aligned Lubricate outside of bearing very lightly with ball and roller bearing lubricant 1948791 if necessary to facilitate assembly Hold drive end assembly with long end of rotor shaft down so that bearing retainer plate 16 falls against housing then align retainer with screw holes See Fig 26 Start each of the four retainer attaching screws 214 then tighten screws gradually in sequence to pull retainer squarely against bearing DRIVE END FRAME 6 ROTOR RETAINER SCREWS 4 COLLAR 33 6234 Figure 26 Installing Rotor in Drive End Frame a TIGHTEN Bearing retainer attaching screws 214 to 5 N m 45 lb in 1 IMPORTANT To allow access for later installation of thru bolts 213 do not assemble fan and pulley to drive end assembly at this time ASSEMBLY OF RECTIFIER END HOUSING AND COMPONENTS INSTALL OR CONNECT Lightly lubricate outside surface of hinge bushing 17 Press hing
6. INSTALLATION PROCEDURE See Figure 44 All fasteners holding alternator mounting bracket 101 to Always follow engine manufacturer s instructions for engine manufacturers torque specifications installing alternator on engine The following procedure 1s typical and may not match all steps necessary for a specific application 33 34 SI ALTERNATOR ADJUST Rectifier end bushing 17 position in RE housing mounting lug to allow maximum distance between mounting lugs H NOTICE Belt tensioning and tightening of adjusting bracket and mounting bolts must be completed before stabilizing bracket is installed INSTALL OR CONNECT 1 33 SI or 34 SI mounting lugs H to alternator mounting bracket 101 2 One flanged mounting bolt 102 through the D E frame mounting lug H the alternator mounting bracket 101 and the R E frame mounting lug bushing 17 3 Flanged mounting nut 103 to flanged mounting bolt 102 finger tight NOTICE If either bolt or nut are not flanged a 1 8 thick hardened steel flat washer 105 See Figure 43 must be substituted for flanged applications 4 Flanged adjustment bolt 106 through flat washer 105 slot in adjustment bracket 104 and thread into hole in DE frame adjustment lug J finger tight 5 Alternator belt s 107 onto pulley 14 NOTICE If engine uses automatic belt tensioning idler see engine manufactures installation instruction 6 Idler 1f used NOTICE Do
7. Removing Rectifier End Bearing NOTICE Do not drive bearing out with hammer or other tool Use arbor press to push bearing from housing Wipe excess grease from bearing well then press bearing through to inside of housing PAGE 13 13 If bearing inner race 3 appears to be worn or rough remove from rotor shaft with a suitable puller 14 Toreplace rotor 10 or drive end bearing 5 See Fig 24 remove 4 bearing retainer attachment screws 214 from outside of housing 4 Lift rotor with bearing from housing then pull bearing off of rotor shaft If inside collar 215 appears rough or damaged pull collar from shaft NOTICE Do not drive mounting hinge bushing from lug on rectifier end housing with a hammer or other tool Use arbor press or vise to remove and replace bushing 15 To remove mounting hinge bushing 17 from lug on rectifier end housing 1 Press bushing from housing using arbor press with suitable tool 4 DRIVE END FRAME 5 DRIVE END BEARING 10 ROTOR ASSEMBLY 16 RETAINER 214 SCREWS 4 215 COLLAR Figure 24 Disassembly of Drive End Components PAGE 14 33 34 SI ALTERNATOR ALTERNATOR ASSEMBLY ASSEMBLY OF DE FRAME AND ROTOR INSTALL OR CONNECT 1 Press inner race for rectifier end bearing 3 onto short end of rotor shaft Stop when race is 3 7 mm 15 in above end of shaft See Fig 25 Press inside collar 215 onto rotor shaft until collar is against shoulder on rotor 10
8. into rectifier bridge 8 and into RE housing Finger tighten a TIGHTEN 21 Tworectifier ground screws 224 to 4 N m 35 Ib in See Fig 35 INSTALL OR CONNECT 22 R terminal connector strap 198 over rectifier stud closest to capacitor 12 Ifinstalling new R terminal follow instruction in package See Fig 35 AL SAR gt STATOR LEADS RECTIFIER BRIDGE CAPACITOR RELAY TERMINAL R TERMINAL CONNECTOR STRAP NUTS 3 RECTIFIER GROUND SCREW 2 33 6242 Figure 35 Installing R Terminal and Stator Leads 23 Three stator leads B over matching rectifier bridge S studs 24 Three nuts 218 on rectifier bridge studs Finger tighten 25 Secure fasteners shown in the following order See Fig 36 33 34 SI ALTERNATOR 218 NUT 224 SCREW 226 SCREW INSULATED LONG REGULATOR RECTIFIER BRIDGE SCREW INSULATED SHORT 33 6243 Figure 36 Fastener Torques a TIGHTEN 1 One regulator ground mounting screw 224 to 2 5 N m 23 Ib in 2 Two insulated regulator screws 217 to 2 0 N m 20 Ib in 3 Two rectifier bridge insulated screws 226 to 2 0 N m 20 Ib in 4 Three rectifier bridge nuts 218 to 2 5 N m 23 1b in 5 Regulator stud nut 218 to 2 0 N m 20 Ib in FINAL ALTERNATOR ASSEMBLY m CLEAN 26 Inner race of rectifier end bearing 3 on rotor shaft to prevent contamination of grease See Fig 37 Remove tape to expose
9. FIELD COIL ASSEMBLY 221 SCREW 4 Figure 29 Installing Field Coil RE HOUSING 222 PLUG BEARING INNER BEARING RACE ROTOR ASSEMBLY 33 6237 Figure 28 Installing Rectifier End Bearing Field coil and support attachment screws 217 to 6 2 N m 55 lb in INSTALL OR CONNECT NOTICE Handle stator with care to avoid bending windings or breaking varnish insulation on windings If windings are damaged before or during installation they may become shorted and cause reduced alternator output Stator must be installed before rectifier 9 Straighten stator leads B to ease installation Lubricate grommet C on stator leads lightly with petroleum jelly Welded junction connector on some stators must be positioned straight up from windings to prevent grounding to housing or rotor when alternator is assembled Straighten stator lead wires all the way to the windings and insert through well in housing into electronics compartment See Fig 30 Align thru bolt holes in stator 11 with those in RE housing 1 Push stator into housing far enough to hold it in place being sure grommet C on wires is inserted into well in housing at the same time Stator lead wires should be stiff enough to push grommet into WOOD BLOCKS FOR SEATING STATOR STATOR LEADS 3 GROMMET RECTIFIER END HOUSING STATOR 33 6231 Figure 30 Installing Stator 10 1 12 15 33 34 SI ALTERNATOR well as stat
10. INSTALL 31 Fan 13 onto rotor shaft with vanes toward body of alternator See Fig 40 CAPACITOR 216 G ALTERNATOR ASSEMBLY 15 COVER PLATE 216 SCREW 4 ALTERNATOR ASSEMBLY TORQUE WRENCH 33 6229 Figure 40 Installing Fan and Pulley PAGE 20 a2 33 34 NOTICE Several pulley styles are available from ACDelco for 7 8 shaft alternators including a blank that can be custom machined for unique applications Pulley 14 suitable for engine application Flat washer 212 and lock nut 211 onto shaft with locknut flat side next to washer Insert 5 16 hex wrench or driver into end of shaft Holding the shaft with a hex driver installed on a torque wrench makes an ideal way to check torque while tightening the nut Tighten pulley nut to 102 N m 75 lb ft ALTERNATOR BENCH TEST TEST EQUIPMENT NEEDED Alternator Test Stand 5000 rpm capability at least 5 HP Battery or Battery Set fully charged Variable Carbon Pile Load Test Ammeter current capability at least 15 amps higher than alternator rating Voltmeter Ohmmeter CLAMP ON AMMETER ALTERNATOR 33 34 SI ALTERNATOR The bench test procedure will verify alternator performance prior to installation on the vehicle This test checks the alternator output in the same manner as the Rated Output Check covered earlier If bench test equipment is not available install the alternator on the engine according to m
11. end of this manual or from Service Specification Bulletin If outside specifications replace field coil as described later in this manual DIODE TRIO Tocheck the diode trio 7 remove it from the electronics compartment by detaching the 3 nuts 218 stator leads B and attaching screw 217 Note that the insulating washer on the screw is assembled over the top of the diode trio connector Discard screw if insulation is fractured during removal RECTIFIER END HOUSING ASSEMBLY DIODE TRIO SCREW INSULATED SHORT NUTS 33 6224 Figure 14 Electrical Check of Diode Trio Use ohmmeter or diode check function on multimeter to check diode trio 7 See Fig 14 Place negative ohmmeter lead on the regulator strap and the positive lead to check continuity to each of the three rectifier bridge straps All three readings should indicate continuity Reverse the ohmmeter leads and perform checks again Reading should all indicate open circuits If all readings are proper diode trio is good If any reading is wrong replace diode trio 33 34 SI ALTERNATOR CAPACITOR Remove capacitor 12 by removing the remaining two attachment screws 224 and screw 226 sliding out capacitor A sharp tool may be used to break varnish seal 12 CAPACITOR Figure 15 Electrical Check of Capacitor Using continuity check mode diode check mode on digital meter check for a shorted capacitor by touching ohmmeter lea
12. not pry on alternator rectifier end housing 1 to adjust belt tension This may damage alternator Pry against the drive end frame 4 with suitable pry bar 108 NOTICE When alternator is used to attain belt tension see engine manufacturers tension specifications PAGE 23 TORQUE WRENCH PRY BAR 108 ADJUSTMENT BRACKET 104 ALTERNATOR BELT S 107 BLOCK ALTERNATOR 33 6249 Figure 45 Adjusting Belt Tension 7 Pry bar 108 between engine and drive end frame 4 of alternator Using pry bar 108 as a lever apply force to pry alternator and increase belt tension ADJUST Belt 107 tension using belt tension gage to specification and hold See Fig 45 a TIGHTEN Adjustment bracket 104 to engine or vehicle manufacturers specifications Flange adjustment bolt 106 and flanged mounting bolt 102 and nut 103 to 88 N m 65 1b ft MEASURE Belt 107 tension with belt tension gage to ensure the specification is maintained If not repeat steps 7 PAGE 24 MOUNTING BOLT 109 FLAT WASHER STABILIZER BRACKET 34 SI ONLY 1 RECTIFIER END HOUSING 33 6250 Figure 46 Connecting Stabilizing Bracket INSTALL OR CONNECT NOTICE Belt tensioning and tightening of adjusting bracket and mounting bolts must be completed before stabilizing bracket is installed Stabilizer mounting bolt 109 through flat washer 105 stabilizer bracket 111 RE housing stabilizer lug 1 fla
13. open for checks at various points Check and record voltage at battery terminal For multi battery systems check voltage of battery set connected as 1f in battery charging mode With all system electrical loads off start engine and run at moderate speed rpm Alternator speed should be near 5 000 rpm Recheck voltage at battery terminal Voltage should be higher than previous reading but below 15 5 volts on 12 volt system 31 volts on 24 volt system Ifreading 1s lower than previous reading Step 6 refer to section on No Output If reading is higher than 15 5 volts on 12 volt system 31 volts on 24 volt system refer to section on High Voltage Output PAGE 8 9 Turn carbon pile load on and adjust to obtain maximum alternator output on ammeter Record maximum output With alternator still running at maximum output check and record voltage drop in ground circuit between alternator housing and grounded battery terminal Then check voltage drop from output terminal to battery positive Turn carbon pile load off Maximum ampere output should be within 15 amps of output rating stamped on alternator identification plate or as listed in Specifications section of this manual Voltage drop should be 0 25 volts or less for each voltage drop test on 12 volt system 0 5 volts or less on 24 volt system If ground circuit voltage drop is over 0 25 volts on 12 volt system 0 5 volts on 24 volt system clean and ti
14. rectifier end bearing 27 Align mounting lugs and assemble two halves of alternator See Fig 37 inserting rectifier end bearing inner race on rotor shaft into bearing in rectifier end housing 1 Seat drive end housing 4 at this time Using arbor press and appropriate block to apply even pressure on end frames 33 34 SI ALTERNATOR RE HOUSING ASSEMBLY R E BEARING INNER RACE DRIVE END FRAME ASSEMBLY ROTOR ASSEMBLY THRU BOLTS 4 213 Figure 37 Assembly of Alternator Halves 28 Insert 4 thru bolts 213 through drive end housing 4 and stator 11 into threaded holes in rectifier end housing 1 Align housings and stator as needed to allow thru bolts to stand straight in holes and engage threads When all four thru bolts are inserted tighten them in round robin fashion a TIGHTEN Thru bolts 213 to 12 4 N m 110 Ib in 29 After assembly dip rectifier end frame of alternator about one and one quarter inch 1 4 deep into clear electric grade varnish or otherwise coat area of electronics to protect from corrosion See Fig 38 14 33 6244 Figure 38 Protective Varnish Dip PAGE 19 INSTALL NOTICE Make sure varnish is dry before proceeding 30 After varish is dry install rectifier end cover plate 15 with four attachment screws 216 Ifremoved replace capacitor DRA 198544 with one screw 216 See Fig 39 a TIGHTEN Attachment screws 216 to 3 N m 26 lb in
15. to regulator could result CLEAN Regulator mounting bosses in RE housing metal base plate and contactrings on regulator by wiping with dry cloth INSTALL OR CONNECT 14 Regulator 6 with terminal cover 220 assembled to RE housing 1 with regulator attaching screw 224 grounding See Fig 33 Finger tighten 15 One field coil lead terminal A over regulator 6 mounting hole closest to terminal Ensure leads do not touch edge of frame hole 16 Insulated screw 217 through lead terminal A and regulator 6 into rectifier end housing 1 Finger tighten FIELD COIL LEAD RE HOUSING REGULATOR CAPACITOR SCREW INSULATED SHORT NUT CONNECTOR SCREW TERMINAL COVER 33 6240 Figure 33 Installing Regulator Bridge to regulator stud connector 219 over threaded stud of regulator 6 with nut 218 Finger tighten Diode trio 7 on to 3 threaded studs on rectifier bridge 8 Insulated screw 217 through indicator strap 208 hole long leg of diode trio 7 and other field coil lead terminal A into regulator 6 unused hole and into R E housing See Fig 34 Finger tighten FIELD COIL LEAD TERMINAL R E HOUSING DIODE TRIO INDICATOR STRAP SCREW INSULATED SHORT SCREW INSULATED LONG esla Figure 34 Installing Diode Trio and Sense Connector PAGE 18 20 Screw 226 through other hole in bridge to regulator stud connector 219
16. 2 000 rpm and touch probe to insulated field ground terminal under the insulation at regulator not on screw head Be sure probe touches metal terminal through the protective coating TOUCH UNDER 1 THE INSULATION FIELD GROUND TERMINAL Figure 11 Regulator Quick Check 33 34 SI ALTERNATOR If ammeter shows 20 amps or more and drops to zero when probe is removed replace the regulator and test field coil for shorts or grounds If no output remove alternator and make bench checks ALTERNATOR UNIT REPAIR CAUTION Disconnect grounded cable at battery before removing or attaching battery cable at alternator output terminal Otherwise a tool shorted to the battery cable at the output terminal can quickly heat enough to cause a skin burn or damage the tool or cable NOTICE Always reinstall fasteners at original location If necessary to replace fasteners use only correct part number or equivalent e If correct part number is not available use only equal size and strength For alternator internal fasteners refer to Delco Remy Standard Hardware Fasteners section in Service Parts Catalog e Fasteners that are NOT to be reused will be noted in procedure e Fasteners requiring thread locking compound will be noted in procedure e Use specified torque values when shown RECTIFIER END HOUSING ASSEMBLY COVER PLATE SCREW 33 6222 Figure 12 Electronics Compartment PAGE 9 CAUTION Using or replac
17. EMBLY STATOR THRU BOLTS 4 1 WRENCH Sa 211 ALTERNATOR ASSEMBLY i N TORQUE 0 WRENCH WASHER Figure 19 Alternator Disassembly 10 Remove the 4 thru bolts 213 Carefully separate the drive end housing 4 from the stator 11 and rectifier STATOR LEADS end housing 1 taking care not to damage stator GROMMET windings See Fig 20 l SB STATOR NOTICE Rectifier bridge must be removed before removing stator See Paragraph 7 and Fig 18 To remove stator 11 from rectifier end housing 1 be sure all 3 stator leads are disconnected from diode bridge studs in electronics compartment Pry stator and housing apart 11 Toremove field coil and support 9 from rectifier end Figure 21 Removing Stator carefully Guide stator leads and grommet C through housing See Fig 22 remove 4 field coil and support well as stator is pulled from housing It may be necessary attaching screws 221 Lift coil and support from to push on grommet with a blunt instrument to unseat it housing while guiding field leads through hole from the housing See Fig 21 12 To remove rectifier end bearing 2 from RE housing 1 See Fig 23 use small screwdriver at slot to pry plug 222 from housing 33 34 SI ALTERNATOR 1 R E HOUSING ASSEMBLY 9 FIELD COIL ASSEMBLY 221 SCREW 4 R E HOUSING ASSEMBLY BEARING INNER RACE BEARING ROTOR ASSEMBLY CAP Figure 23
18. anufacturer s instructions and repeat the Rated Output Check to verify alternator operation If bench test equipment is available proceed as follows 1 Mount alternator in test stand according to test stand manufacturer s instructions IMPORTANT Battery or battery set must be 1 fully charged for test results to be valid NOTICE When a 12 volt carbon pile load test is used to diagnose a 24 volt system attach load test only to 12 volt potential in battery set Attaching a 12 volt load test to a 24 volt potential will damage the carbon pile With carbon pile load turned off and with battery or battery set fully charged make electrical connections as shown in Fig 41 Battery voltage and ground polarity must be same as system in which alternator is used Check and record battery or battery set voltage before proceeding with test CARBON PILE VOLTMETER Figure 41 Alternator Bench Test 33 34 SI ALTERNATOR With carbon pile load off start test stand and slowly increase alternator speed to highest rpm shown under Cold Output specifications in 33 34 SI Alternator Specifications at the end of this manual Observe voltmeter If voltage does not increase but remains at or below previous reading Step 2 there 1s no alternator output Turn carbon pile load off and stop test stand Residual magnetism 10 rotor may have been lost Skip to Step 5 If voltage increases above 15 5 volts on 12 volt system or a
19. bove 31 volts on 24 volt system voltage 1s uncontrolled Turn carbon pile load off and stop test stand Recheck alternator for proper assembly If alternator has been assembled properly replace regulator as described under Unit Repair Also check field coil for shorts and replace if defective If voltage is proper proceed to next step With alternator running at highest rpm shown under Cold Output in Specifications turn on carbon pile load and adjust to obtain maximum alternator output on ammeter If ammeter reading 18 within 15 amps of Cold Output in Specifications alternator is good Turn off carbon pile load and stop test stand If ammeter reading is more than 15 amps below specification alternator is not operating properly Turn off carbon pile load and stop test stand Return to Unit Repair section in this manual and re diagnose the alternator CAUTION Do not allow jumper lead to be accidentally grounded while connected to battery insulated terminal If the free end of this lead is accidentally touched to the alternator housing or other grounded areas the jumper lead may quickly get hot enough to cause a skin burn or to damage the jumper lead Keep jumper lead carefully insulated from grounding during this procedure PAGE 21 EQUIPMENT NEEDED e Jumper Lead 18 ga min no fuse To restore residual magnetism in alternators with an R or T terminal alternator ground terminal must be connected to ba
20. d Bearing Outer Race Bearing Inner Race Frame Drive End Bearing Ball Regulator Diode Trio Bridge Rectifier Field Coil amp Support Rotor Assembly Stator Assembly Capacitor Fan Pulley Not Shown Plate Cover Retainer Bearing Bushing Rectifier End Package Output Terminal Package Relay Terminal Package Indicator Light Terminal Package Hardware Field Coil Leads Stator Leads Insulator Grommet Qty A ld ld dl dl ld dl dl dl do N A GON Re 33 34 SI ALTERNATOR Illus No Name 18 Output Terminal Package 181 Nut Hex Head 182 Washer Flat 183 Insulator 184 e Insulator Housing 185 Insulator Connector 186 Strap Output 187 Stud Output 19 Relay Terminal Package 191 Nut Hex Head 192 e Washer Lock 193 Stud Relay 194 Insulator Terminal 195 e Washer Square 196 Insulator Housing 197 Washer Flat 198 e Strap Relay 199 e Nut Hex Flanged 20 Indicator Light Terminal Package 201 Nut Hex Head 202 Washer Lock 203 Stud Indicator Light 204 Insulator Terminal 205 e Washer Square 206 Insulator Housing 207 Washer Flat 208 Strap Indicator 209 e Nut Hex Flanged 21 Hardware Package 211 Nut Lock 212 Washer Flat 213 Bolt Thru 214 Screw Retainer 215 Collar Shaft 216 Screw Cover Plate
21. d I on cover plate finger tight 1f used 4 Ground screw and lockwasher assembly 223 through ground wire lead 115 into threaded hole in rectifier end housing 1 located on top of 33 SI or on side of 34 SI finger tight a TIGHTEN 1 Ground screw and lockwasher assembly 223 to 6 N m 55 1b in NOTICE Use suitable open end wrench to hold nut 181 hex heads on R and I terminal studs 193 and 203 See Fig 49 PAGE 25 2 Hex head nut 181 on POS terminal to 7 N m 65 Ib in 3 Hex nuts 191 and 201 or R and I terminals to 2 N m 20 lb in if used INSTALL OR CONNECT 4 PIN terminal cap on any terminals not used or any PIN connections 5 Vehicle battery cable to battery s 33 34 SI ALTERNATOR SPECIFICATION The typical 33 34 SI field coil specs for 12V is 5 5 9 0 amps at 12V or 1 4 2 1 ohms at 80 F The field coil specification for 24V models is 2 9 3 6 amps at 24V or 6 9 8 1 ohms at 80 F The 32V model field coil specifications are 1 4 1 9 amps at 32V or 17 0 21 4 ohms at 80 F Cold Current output at 80 F is shown in the following Amperes O 80 F 1800 rpm 5000 rp table Alternator Model 12V 110A 12V 135A 24 32V 60A For further information on rotations and exact specification number on these or other Delco Remy America products Call 1 800 DRA 0222 PAGE Illus No 26 Name Housing Rectifier En
22. d to Unit Repair 33 34 SI ALTERNATOR CLAMP ON AMMETER Y VOLTMETER 33 6219 Figure 9 Rated Output Check F RATED OUTPUT CHECK TEST EQUIPMENT NEEDED e Voltmeter e Ammeter current capability at least 15 amperes higher than alternator rating e Variable Carbon Pile Load Test CAUTION Failure to disconnect grounded battery cable at battery before removing or attaching battery cable at alternator output terminal may result in an injury If a tool is shorted to the battery cable connector at the output terminal the tool can quickly heat enough to cause a skin burn or the tool or cable may be damaged Refer to Fig 9 for test equipment hookups as described 10 following steps If inductive pickup clamp on type ammeter is used place current clamp on alternator output lead and skip to Step 4 If series ammeter is used disconnect grounded battery cable at battery first Install ammeter in series with alternator output terminal Reconnect grounded battery cable at battery NOTICE When a 12 volt carbon pile load test is used to diagnose a 24 volt system attach load test only to 12 volt potential in battery pack Attaching a 12 volt load test to a 24 volt potential will damage the load test With load turned off attach carbon pile load test across battery Attach voltmeter lead to grounded battery terminal observing proper polarity for system Leave other voltmeter lead
23. ds to capacitor lead F and grounding tab T See Fig 15 This check should show an open circuit REGULATOR To remove regulator 6 for testing remove sense lead nut 218 bridge to regulator stud connector 219 and 2 screws 217 1f not removed previously and screw 224 Disconnect TI terminal sense lead strap to allow regulatorremoval See Fig 16 Note Discard insulated screw 1f insulation 1s fractured during removal 217 224 RECTIFIER END Cl i HOUSING ASSEMBLY REGULATOR SCREW 2 INSULATED SHORT Ls NUT CONNECTOR 33 6227 Figure 16 Removing Regulator 33 34 SI ALTERNATOR Check regulator on approved tester for SI type regulators If regulator tests good return it to service If it tests bad replace it Install regulator as described later in this section RECTIFIER BRIDGE 7 Use the ohmmeter or for digital meters the diode check function of the multimeter to check the rectifier bridge 8 Bridge may be checked in place in the RE housing 1 All terminals must be disconnected from the threaded phase studs R terminal and output terminal straps 198 amp 186 may be raised approximately one inch 2 5 cm above rectifier for removal of diode trio 7 or rectifier bridge 8 Check 6 diodes as follows Place negative ohmmeter lead on grounded heat sink Touch positive ohmmeter lead firmly to metal diode clips that surround each of the 3 threaded studs All 3
24. e bushing into hole in lug on rectifier end housing 1 Install bushing flush with inside of lug to allow maximum distance between two hinge lugs for mounting Final position of hinge bushing will be adjusted during mounting See Fig 27 33 34 SI ALTERNATOR PAGE 15 7 Add ball and roller bearing lubricant 1948791 until cavity between plug 222 and bearing outer race 2 1s about half full placing grease so that 11 touches 6 edge of the bearing outer race in several places around the outside of the bearing Cover opening with tape to prevent contamination 8 Turn leads so that they will be properly positioned after installation See Fig 29 Place field coil and support 9 into rectifier end housing 1 guiding leads through hole into electronics compartment and aligning mounting holes in support with screw holes in rectifier housing Ensure leads do not touch housing Install 4 17 field coil and support attachment screws 221 3 1 RE HOUSING INSTALL FLUSH screws used in early production ASSEMBLY WITH INSIDE 17 BUSHING OF LUG 33 6235 Figure 27 Installing Mounting Hinge Bushing 6 Position new bearing 2 into rectifier end housing 1 with seal toward rotor assembly 10 as assembled Press bearing outer race into housing center hole until flush with machined face inside housing See Fig 28 Push plug 222 into end of housing until outside edges are flush with edge of RE housing 1 RE HOUSING ASSEMBLY 9
25. erminal be connected to the battery insulated positive for anegative ground system terminal and that a ground path be provided between the alternator housing and the battery ground terminal See Figure 3 Insulated units will have a battery Pos and battery Neg terminal for Output and Ground connections BATTERY Figure 3 Basic One Wire System The P terminal may be used in a circuit to power an indicator light and or to lower the engine speed RPM at which the alternator will turn on Typical system wiring using this type of circuit is shown in Figure 4 This is commonly referred to as a one wire system with T terminal or as a two wire system External connections to the 33 34 SI alternator are made to terminals shown in Figure 5 The standard output terminal isa 1 4 28 thread With this type of terminal the exposed metal parts will have battery voltage when connected to the battery 33 34 SI ALTERNATOR OPTIONS OEE i l BATTERY ALTERNATOR Figure 4 One Wire System with I Terminal Other connections to the 33 34 SI series include an R relay P indicator light terminal and a ground lead connection to the alternator s rectifier end housing An R or relay terminal is located on the rectifier end frame next to the output terminal This terminal may be used to operate some types of charge indicators an ADLO system a tachometer or similar device by providin
26. ess internally both terminals are wired to the same place In that case rewire the R terminal to the rectifier bridge stud as shown in Unit Repair section NO OUTPUT TEST EQUIPMENT NEEDED e Voltmeter e Jumper Lead 18 ga min no fuse Note that 33 34 SI alternators must be connected to a battery for the voltage sensing circuit to allow initial turn on refer to section on Features When properly connected and system checks indicate a no output condition use the following steps to determine 1f the alternator requires repair 33 34 SI ALTERNATOR 1 IMPORTANT 1 For alternators without an I terminal in use battery positive voltage at the output terminal and residual magnetism in rotor are necessary for alternator to turn on With engine stopped use voltmeter to verify that battery voltage is present in cable at output terminal If not locate and correct cause of voltage loss Residual magnetism in the rotor is sometimes lost during servicing of the alternator The rotor can normally be remagnetized without removing alternator from application CAUTION Do not allow jumper lead to be accidentally grounded while connected to battery terminal If the free end of this lead is accidentally touched to the alternator housing or other grounded areas the jumper lead may quickly get hot enough to cause a skin burn or to damage the jumper lead Keep jumper lead carefully insulated from grounding during this proced
27. g voltage pulses at a frequency of 8 pulses for each revolution of the alternator The current draw of the accessories being powered through this terminal must not exceed 4 amperes and operate at approximately one half of system voltage The R terminal may be 10 24 threaded or the pin type GROUND R TERMINAL OUTPUT TERMINAL 34 SI 7 GROUND 33 6215 Figure 5 33 34 SI Electrical Terminals 33 34 SI ALTERNATOR The I terminal is connected internally to the field circuit An indicator light connected in series with this terminal will glow whenever there 17 a voltage difference between the positive side of the field circuit and the system voltage at other side of the indicator light During normal alternator operation the light will be off since the diode trio output voltage equals the system voltage Current passed through the field winding during engine start up results in a lower alternator turn on speed A diode or resistor may be used instead of a light bulb 11 no indicator lightis needed See Fig 4 Upto 1 ampere of current may be passed through this circuit to aid in alternator turn on An T terminal is normally a threaded stud type with a 10 24 thread A threaded 1 4 hole with screw and lockwasher assembly in the rectifier end housing is provided to connect a ground lead if used otherwise the ground path is through the mounting hardware and brackets to the engine On replacement units a
28. ghten all ground circuit connections If this does not correct excessive voltage drop check ground circuit cables for improper sizing or high resistance conditions Correct as necessary If within 15 amps of rating alternator is good Look elsewhere for cause of problem If more than 15 amps below rating repair or replace alternator CARBON PILE TEST PROBE CLAMP ON AMMETER BATTERY ALTERNATOR Figure 10 Test Bench Schematic 33 34 SI ALTERNATOR REGULATOR QUICK CHECK NOTICE On some alternators on certain engine configurations a 5uf capacitor has been installed to the output terminal and attached with a cover screw Remove the capacitor DRA 1985444 before performing Regulator Quick Check A No Output condition may be caused by a defective regulator This can be determined by the following procedure CAUTION Do not allow jumper lead or probe to touch strap or battery while connected to ground If the free end of this lead is accidentally touched to battery voltage the jumper lead may quickly get hot enough to cause a skin burn or to damage the jumper lead Keep jumper lead carefully insulated from battery and alternator voltage surfaces during this procedure Install and hook up alternator Fig 10 in test bench at least 5 hp and remove rectifier cover plate Attach one end of a test lead to alternator ground and the other to a sharp test probe Fig 11 Spin alternator at approximately
29. ing fasteners in any other manner could result in part or system damage If diagnosis determines that alternator repair 1s needed remove alternator from engine according to manufacturer s instructions DISASSEMBLY AND BENCH CHECKS TEST EQUIPMENT NEEDED e Multimeter e Regulator Tester ALTERNATOR NOTICE On some alternators on certain engine configurations a 5uf capacitor has been installed to the output terminal and attached with a cover screw Remove the capacitor DRA 1985444 before performing Regulatror Quick Check 1 Remove screws 216 and rectifier end plate 15 to expose electronics compartment See Fig 12 2 Inspect electronics compartment for contamination for shorted or grounded wires and for loose connections If contamination is present clean and dry compartment before proceeding The protective coating on all electronic components is a good insulator and must be scraped off to get a good contact for test equipment probes OHMMETER USE WITHOUT BATTERY VOLTMETER USE WITH BATTERY CLAMP ON AMMETER 6 REGULATOR 217 SCREW 224 SCREW 33 6223 Figure 13 Checking Field Coil Resistance PAGE 10 FIELD COIL Disconnect 2 field leads A from regulator 6 See Fig 13 by removing 2 insulated regulator attachment screws 217 Use ohmmeter or voltmeter ammeter and battery to check resistance of field coil Compare to Field Check ohms or volts and amps in Specifications at the
30. lectrical loads off use voltmeter to check voltage at battery terminals Battery electrolyte temperature must be below 120 F 49 C PAGE 6 For a 12 volt system readings should be stable around 13 5 14 5 volts and in no case go above 15 5 volts For a 24 volt system readings should be stable around 27 28 volts and in no case go above 31 volts One wire system If voltage is erratic or goes above 15 5 volts 31 volts on 24 volt system check internal sense circuit and regulator as described under Unit Repair TERMINAL ACCESSORY PROBLEMS Disconnect lead from R terminal Start engine and run at moderate speed Check system voltage across battery terminals with engine running Record voltage Use voltmeter to check voltage between R terminal and alternator ground screw or other clean metal ground If voltage is near half of system voltage R terminal output is O K Note that this is a pulsating signal so some voltmeters may give an unsteady reading If no voltage 1s present replace diode trio assembly as described under Unit Repair If the voltage is nearly the same as the alternator output voltage check the voltage at the other small terminal If that voltage is near half system voltage the R terminal leads were connected to the I terminal Connect them to the R half voltage terminal If both terminals are near alternator output voltage replace the diode trio assembly unl
31. locate and correct shorted condition between the light and alternator If indicator light goes out diode is shorted in rectifier Locate and replace diode as described under Unit Repair SYSTEMS WITH VOLTMETER NO INDICATOR LIGHT OR WITH LIGHT WORKING PROPERLY TEST EQUIPMENT NEEDED e Voltmeter If battery is undercharged indicator light remains on while vehicle is running or system voltmeter shows operating voltage is below acceptable range With engine stopped and all electrical loads off use voltmeter to check system voltage across battery terminals Record voltage Start engine and run at moderate speed Check system voltage across battery terminals with engine running If voltage reading at battery terminals is different from reading showing at system voltmeter if equipped locate and correct cause of incorrect reading If voltage is lower than reading previously recorded with engine stopped there is no alternator output Proceed to section on No Output If voltage is higher than previous reading with engine stopped alternator output is present Proceed to Rated Output Check If battery is overcharged as evidenced by excessive water use or electrolyte spewing from battery vents or light bulbs or other electrical equipment have shortened life due to suspected high system voltage or system voltmeter reads above normal range With fully charged battery engine running at moderate speed and all e
32. ontinue unless the electrical demands of the system cause the system voltage to fall below the voltage setting Should this happen the regulator will again allow full field current to flow so that the maximum output of the alternator at the given speed temperature and system voltage is realized An internal sense lead installed between the output terminal diode heat sink and regulator stud is used for voltage control TROUBLESHOOTING Trouble in the charging system will normally be indicated by one of the following e Indicator light on with engine running e Indicator light off with key on engine not running INDICATOR INDICATOR LIGHT ll OUTPUT TERMINAL i KEY INDICATOR LIGHT I CONNECTOR TERMINAL CONNECTOR DISCONNECTED CIRCUIT _ 33 34 SI ALTERNATOR e Undercharged or overcharged battery e Short life of light bulbs or other electric equipment caused by abnormally high system voltage e System voltmeter readings outside normal range e Incorrect or no operation of accessories connected to alternator R terminal Diagnose system as follows See Fig 8 A ALL CHARGING SYSTEMS TEST EQUIPMENT NEEDED e Belt Tension Gage e Battery State of Charge Indicator 1 Check electrical system wiring and battery terminals for poor connections or other obvious conditions that might resultin shorts opens grounds or high resistance Correct as neces
33. or is installed Gf not carefully push on grommet with a blunt instrument to seat it in the well The stator must be fully seated in housing at this time Note If necessary place wood blocks on opposite corners of the stator frame and use arbor press or tap blocks with hammer to seat stator frame against rectifier end housing Do not push against windings Rectifier bridge 8 to RE housing 1 Install one rectifier bridge attaching screw 224 through grounded heat sink into RE housing Fig 31 Finger tighten RE HOUSING 8 RECTIFIER BRIDGE SCREW Figure 31 Installing Rectifier Bridge Capacitor 12 to holes in end of rectifier bridge 8 Fig 32 Install ground screw 224 through capacitor 12 grounded heat sink and into RE housing Finger tighten Output strap 186 over insulated rectifier and capacitor holes If new output terminal assembly install per instructions in package Insulated capacitor attaching screw 226 through output strap 186 capacitor connector 12 and into RE housing Finger tighten 33 34 SI ALTERNATOR RECTIFIER END HOUSING RECTIFIER BRIDGE CAPACITOR OUTPUT STRAP SCREW SCREW INSULATED LONG 33 6239 Figure 32 Installing Output Terminal and Capacitor INSPECT Regulator mounting area for presence of grease or dirt Fig 33 Good electrical contact 11 necessary in this area NOTICE Do not immerse or wet regulator with solvent Internal damage
34. paper tag is present identifying the ground screw remove and discard the tag The screw and lockwasher assembly should be installed in the housing regardless of whether a ground lead is connected to prevent entry of dirt and water All electronic parts of the alternator are specially coated for environmental protection against moisture and dirt and the alternator is inside cooled by air drawn through inlets in the rectifier end frame and exiting from the drive end frame behind the fan REGULATOR CAPACITOR R 1 i 1 l l 1 i I 1 l I l 33 6216 Figure 6 Alternator Schematic PAGE 3 OPERATING PRINCIPLES An alternator is a voltage creating machine The voltage regulator limits the maximum voltage that the alternator will produce at the output terminal by controlling the magnetic field present in the stationary field The output voltage induced in the stator and rectified by the diodes allows current to flow to satisfy the electrical loads placed on the system up to a maximum current thatis characteristic of the alternator design Schematics of the alternator circuitry are shown in Figure 6 standard unit and Figure 7 insulated unit With the alternator rotor turning a magnetic field around the stationary field coil is conducted by the rotor poles to induce voltages in the stator windings The faster the rotor turns
35. r housing If indicator light comes on with jumper lead in place repair or replace alternator as described under Unit Repair If indicator light does not come on with jumper lead in place verify that alternator is properly grounded by touching jumper lead to another ground source If lamp still does not light locate and correct open circuit in indicator light circuit Circuit fuse may be open or light bulb may be burned out Correct as necessary If indicator light comes on while engine is running but is not on with engine stopped and key switch in run position Leave key in run position with engine stopped Disconnect indicator light lead from alternator This will be at the IP terminal Use fused 5 amp jumper lead to ground indicator lamp circuit to alternator housing If indicator light comes on with jumper lead in place replace internal indicator light lead assembly orregulator as described under Unit Repair PAGE 9 If indicator light does not come on with jumper lead in place locate and correct open circuit in indicator light circuit between battery and light Circuit fuse may be open With engine running light is being powered by alternator and grounded through other circuits connected in parallel to indicator light circuit Correct as necessary Ifindicator light is on with key switch in off position Disconnect indicator light circuit at alternator If indicator light remains on
36. r may be operated in either clockwise or counterclockwise directions external fan may require changing to reverse rotation at continuous speeds of up to 10 000 alternator rpm Intermittent speeds of up to 12 000 alternator rpm are also acceptable The ambient temperature range for proper operation is 34 C to 93 C 30 F to 200 F 33 SI Performance Curve 14V or 28V 25 C LH a z RPM x 1000 Figure 2 Typical Output vs Alternator RPM PAGE 2 The solid state integrated circuit voltage regulator built into the 33 34 SI alternator limits system voltage by switching the ground circuit for the field on and off When the ground circuit 1s on field current passes from a diode trio through the stationary field coil Nominal regulated voltages of 13 8 14 0 and 14 2 volts are available for 12 volt systems and 27 5 volts for 24 volt systems For 12 volt systems output ratings of 110 and 135 amperes are available For 24 volt systems an output rating of 100 amperes is available Refer to Figure 2 for graphs of typical outputs over a range of alternator speeds For output ratings of specific 33 34 SI models refer to DRA model specifications FEATURES The 33 34 SI alternator is designed for a one wire charging system configuration One wire refers to the minimum number of lead wire connections necessary at the alternator for operation and requires only that the alternator output t
37. readings should be the same and indicate open circuits Switch leads and repeat All 3 new readings should indicate continuity Fig 17 POSITIVE HEAT SINK SIDE NEGATIVE HEAT SINK SIDE 8 8 RECTIFIER BRIDGE 33 6226 OHMMETER Figure 17 Electrical Check of Rectifier Bridge Repeat checks using insulated positive heat sink in place of grounded heat sink With negative ohmmeter lead on insulated heat sink all 3 readings should indicate continuity Switch leads and repeat All 3 new readings should indicate open circuits If all readings are correct the rectifier bridge is good If any reading is wrong an open or shorted diode is indicated and rectifier bridge should be replaced To PAGE 11 B RECTIFIER BRIDGE 226 SCREW CAPACITOR RELAY STUD RELAY STRAP NUT Figure 18 Checking Stator Windings INSULATED LONG 218 NUT 3 224 SCREW remove bridge remove nut 218 nut 199 and relay strap 198 from regulator stud 193 two bridge attaching screws 226 and insulated capacitor attaching screw 224 Lift capacitor 12 and rectifier bridge 8 from SRE housing Fig 18 STATOR 8 Disconnect the 3 stator phase leads B from the diode bridge studs by removing 3 nuts 218 Use continuity check function of ohmmeter to check stator windings See Fig 18 Place one meter lead on one of the stator phase lead connectors and check for continuity to each of the other two stator lead
38. s There should be continuity to both If not one or more of the stator coils is open replace the stator as described later in this section To check for grounds again touch one meter lead to one of the stator phase leads and touch the other meter lead to clean metal ground on the alternator housing There should not be continuity If there is continuity the stator is grounded and should be replaced as described later in this section It is not possible to detect shorted stator windings with ordinary shop equipment However if all other electrical checks are normal and the alternator has exhibited low output shorted stator windings may be the cause In such cases replace the stator as described later in this section PAGE 12 33 34 SI ALTERNATOR FINAL DISASSEMBLY NOTICE Do not damage exposed stator or field windings Bumping or scraping these windings may break the insulation and leave a place for a short circuit or ground to develop later causing the alternator to fail Protect the windings from damage by careful handling 9 To replace the field coil 9 stator assembly 11 rotor assembly 10 or drive end 5 orrectifier end bearings 2 the drive end frame assembly must be separated from the rectifier end housing Fig 19 Use 5 16 hex wrench or 5 16 hex drive in the end of the shaft to RE HOUSING hold while removing shaft nut 211 Remove washer ASSEMBLY 212 pulley 14 and fan 13 DRIVE END FRAME ASS
39. sary 2 Check alternator drive belt for proper tension Adjust to manufacturer s specifications 3 Check battery for state of charge If low recharge according to manufacturer s specifications and load test to establish serviceability Further diagnostic tests require aknown good fully charged battery for accurate results VOLTMETER 33 6218 Figure 8 Troubleshooting a 33 34 SI System 33 34 SI ALTERNATOR B SYSTEMS WITH INDICATOR LIGHT TEST EQUIPMENT NEEDED e Jumper Lead with 5 Amp Fuse If indicator light is on with engine running Stop engine Turn key switch to run position Indicator light should be on If not go to Step 3 Disconnect indicator light lead at alternator This will be the TI terminal connector If indicator light remains on locate and correct shorted or grounded condition in indicator light circuit between the light and the alternator If indicator light goes out light is working properly Proceed to C for check of system with indicator light working properly If indicator light does not come on with the key switch in the run position with the engine stopped bulb check mode Leave key in run position with engine stopped Disconnect indicator light lead from alternator This will be at the I terminal Use fused 5 amp jumper lead to ground indicator lamp circuit in harness connector to ground screw or other clean metal ground on alternato
40. t washer 105 and thread into nut 110 finger tight See Fig 46 a TIGHTEN Stabilizer bolt 109 and nut 110 to 88 N m 65 Ib ft VEHICLE WIRING INSTALLATION See Figure 47 amp 48 NOTICE On certain engine configurations a 1 5uf capacitor DRA 198544 was retrofited to some alternators INSTALL OR CONNECT pa Battery lead 112 lead capacitor 116 1f required lockwasher 182 and nut 181 onto output stud 187 labeled POS on cover plate 15 finger tight See Fig 48 Relay lead 113 lockwasher 192 and nut 191 onto relay stud 193 labeled R on cover plate finger tight if used 33 34 SI ALTERNATOR 115 LOCK WASHER RELAY STUD NUT LOCK WASHER INDICATOR LIGHT STUD SCREW 223A SCREW ASSEMBLY 34 SI ONLY BATTERY LEAD 192 RELAY LEAD 193 INDICATOR LIGHT 201 LEAD 202 GROUND LEAD 203 CAPACITOR A R NUT 223 LOCK WASHER OUTPUT STUD NUT 33 6251 Figure 47 Installing Wiring TERMINAL NUT TO BATTERY OUTPUT TERMINAL ALTERNATOR 33 6253 Figure 48 Connecting to Output Terminal 33 34 SI ALTERNATOR TERMINAL CAP PIN R TERMINAL ONLY O HEX HEAD NUT 191 or 201 O PI LOCK WASHER 192 or 202 ___ 3 STUD 193 or 203 OPEN END WRENCH TERMINAL LEAD Figure 49 Tighten Threaded I or R Terminals 3 Indicator light lead 114 lockwasher 202 and nut 201 on to indicator light stud 203 labele
41. the higher the induced voltage will be The initial voltages at start up are generated by residual magnetism in the rotor On applications with an T terminal in use this magnetism will be boosted by a small amount of current flowing through the field from the indicator light circuit As speed and output increase voltage available at the diode trio becomes sufficient to supply field current for normal operation When the output voltage exceeds the battery voltage the alternator begins to drive the system voltage If the wiring system includes an indicator light the presence of system voltage at the diode trio equalizes the voltage on both sides of the indicator light and the light goes out 1 REGULATOR Figure 7 Insulated Model Schematic PAGE 4 While the system voltage 1s below the voltage regulator setting the regulator turns on the field current and allows the alternator to produce as much output as possible for the alternator speed rpm temperature and system voltage When the voltage setting 1s reached the regulator turns the field current off When the field current 1s turned off the magnetic field in the rotor collapses and the alternator output voltage begins to fall The falling voltage causes the regulator to turn the field current back on and the magnetic field to rebuild This switching action of the regulator continues rapidly keeping the output and system voltage very close to the voltage setting This will c
42. ttery ground terminal This may be done directly or through the test stand wiring See Fig 42 Disconnect carbon pile load test from battery if still connected Disconnect any leads connected to alternator R or I terminal Connect jumper lead to battery positive Without touching other grounded areas See CAUTION Above momentarily touch flash free end of jumper lead to alternator R or TI terminal The momentary current flow into the terminal will restore the proper magnetism in the rotor Disconnect the jumper lead from the battery then return to Step 1 and repeat Alternator Bench Test ALTERNATOR INSTALLATION CAUTION Failure to disconnect grounded battery cable at battery before removing or attaching alternator BAT terminal lead may result in an injury If a tool is shorted to the battery cable connector atthe output terminal the tool can quickly heat enough to cause a skin burn or to damage the tool or cable OUTPUT TERMINAL GROUND TERMINAL R TERMINAL 1 TERMINAL BATTERY ALTERNATOR 33 6247 Figure 42 Restoring Residual Magnetism PAGE 22 33 34 SI ALTERNATOR 1 8 IN THICK FLANGE FLAT WASHER 105 1 2 13 FLANGED HARDENED STEEL ADJUSTMENT ADJUSTMENT BOLT 106 FLAT WASHER 105 BOLT 106 aad SAE GRADE 5 OR BETTER 05509 Ge e 104 HINGE BUSHING 17 ALTERNATOR a ADJUSTMENT i SSF A ON l LUG J ASA 1 5 IN
43. ure Toremagnetize rotor make sure the normal connections are made to the alternator output terminal and to the ground circuit Disconnect the wiring harness from the R terminal Momentarily connect a jumper lead from battery positive to the alternator R or unused T terminal See Fig 42 This will cause field current to momentarily flow through the field windings in the proper direction and restore magnetism Reconnect wiring harness to R terminal then recheck alternator for output For systems with an T terminal in use the indicator light current at this terminal will establish normal magnetism at each engine start up Such systems may depend on this current to help ensure a low turn on speed of the alternator With engine stopped and key switch in run position use voltmeter to check for voltage present at this terminal With T terminal connected and indicator lamp on voltage will be less than battery voltage If necessary disconnect wiring at T terminal to make this check check for battery voltage in harness wire If voltage is present proceed to Step 3 If no voltage is present check I terminal circuit for cause of voltage loss bulb may be burned out Correct as necessary 1110 conditions have been found that might prevent the alternator from turning on Step 1 or 2 remove alternator from engine in accordance with engine manufacturer s instructions and procee
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