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Service Manual - Leece-Neville 8SC/SCJ Alternator
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1. If Dim C or D is out of tolerance or excessive wear is present then proceed with this procedure Note Use caution not to damage field wires during the following procedures Step 1 Unsolder field wires from slip ring Fig 2 Step 2 Remove slip ring from shaft Fig 3 Note Use caution not to damage end of shaft during slip ring removal Step 3 Cut nylon spacer off shaft and discard Fig 4 Remove _ nylon spacer www prestolite com Step 4 Clamp on bearing separator and press bearing inner race off shaft Fig 5 Note Use caution not to damage shaft or field wires Step 5 Apply high temperature silicone sealant on rotor Fig 6 Step 6 Place new nylon spacer on shaft Fig 7 Step 7 Press bearing inner race onto shaft Fig 8 Note Use caution not to damage field wires gt ee a during installation TA N a E bis see x J 7 A ly hig rature one se App h tempe a silic alant ah i i P j A 4 rer e Bee it p r f Oa ig M i Na i i A i r aa i E E _ _ Place nylon spacer f Jonto shaft Press on bearing inner race ae pe T i gt e aa o oye ry a rA _ d e a 7 a e re ioe Sie 11 12 Step 8 Insert field wires through slip ring Fig 9 Step 9 Press slip ring onto shaft Fig 10 Note Use caution not to damage field wires while performing Step 9 and press
2. LF Remove 3 stator PSSS Unsolder leads ee nuts lt t i l Tn f Ea i i e k lt as a aif NWA AN ee D EAA Remove hardware anq insulators from terminals m Sy ib v kun paa 1 1y Step 8 Flip the rear housing over and remove all hardware and insulators from the three terminals Fig 9 Step 9 Remove rectifier from rear housing Fig 10 i x Remove washer and Front bearing change Step 1 Remove steel washer and felt IF a amp seal from shaft Fig 1 Step 2 Press rotor from front housing Fig 2 Step 3 Remove spacer and three front bearing retaining screws Fig 3 Step 4 Press front bearing and seals from front housing Fig 4 ef Fo p y A 4 Remove Spacer n Am Stee Se ie f fe a ME e DP E Bo www prestolite com Step 5 Remove seal from front housing i Step 6 Remove seal from front bearing retainer Fig 6 Note On opposite sides of the front housing and bearing retainer are two holes Insert a punch into these holes and tap with a ham mer to remove the seals Step 7 Insert front housing seal Fig 7 Step 8 Insert front bearing retainer seal Fig 8 Note When installing seals press on the outer diameter Failure to do this can cause damage to the seals gt S A Insert seal Insert seal l N Step 9 Press bearing into front housing Fig 9 Note When installing bearings press
3. on slip ring outer diameter to prevent damage Step 10 Wrap field wires around slip ring posts and solder Fig 11 Recommended solder SNL5PB85 Figure 12 shows you the proper arrangements of components in the rotor J Wrap field wires around pes slip ring posts and solder ie www prestolite com Rear bearing change Step 1 Remove snap ring from rear housing Fig 1 j Ge a gt ir i Step 2 Press old seals and bearing from rear housing Fig 2 _ l Ss Ss gt 3 EF i z retainer ia rl eae T d Step 3 Pack new bearing and seal cavities with grease Fig 3 Recommended grease High temperature synthetic bearing grease Step 4 Press seal into real housing Fig 4 Note When installing seals press on the outer diameter Failure to do this can cause damage to the seals Use caution not to contaminate grease Press in first han seal LED 13 14 Step 5 Press bearing into rear housing Fig 5 Note When installing bearings press on the outer diameter Failure to do this can cause damage to the bearing Step 6 Press seal into rear housing Fig 6 ig Step 7 Install snap ring into rear housing Fig 7 Figure 8 shows you the proper arrangements of components in the rear housing Press in seal P n www prestolite com _ j a a i z k Press in rear bearing D Installing
4. on the outer diameter Failure to do this can cause damage to the bearing Step 10 Install front bearing retainer Fig 10 Step 11 While holding front bearing retainer in place turn over housing Apply blue locktite to three mounting screws and install into front housing Fig 11 Step 12 With a grease needle inject grease between the seal and the bearing Fig 12 Note Grease needle can be purchased at any auto parts store Recommended grease High temperature synthetic bearing grease GA oo X a Apply grease between bearing and seal Fig 12 A Torq ue Screws 24 30 in lbs www prestolite com Step 13 Turn housing over and with the grease needle inject grease between the seal and the bearing Fig 13 Step 14 Figure 14 and 15 shows the proper amount of grease that needs to be applied Note The grease added between the bearing and the seals adds an additional protective measure in preventing dust from penetrating the bearing This grease provides no lubricating properties to the front bearing Figure 16 shows you the proper arrangements of components in the front housing 10 Slip ring rear bearing inner race change Inspect rotor and measure key items in Fig 1 If Dim A or B is out of tolerance a new rotor will need to be purchased Refer to SP 1017 to determine correct replacement part number
5. rotor into front housing Step 1 Press rotor into front housing Fig 1 Note When pressing rotor support front housing as close to the bearing as possible to prevent damage to the front housing Use caution not to damage slip ring when pressing rotor into front housing Step 2 Slide spacer onto shaft Fig 2 Step 3 Slide felt and steel washer on shaft Fig 3 15 Alternator Assembly Instructions 16 Alternator Assembly Step 1 If replacing rectifier remove screw and wire furnished with replacement rectifier Fig 1 Step 2 Slide 10 carriage bolt into replacement rectifier and insert black insulating sleeve over the bolt Fig 2 Step 3 Insert insulators into rear housing Fig 3 Step 4 Insert rectifier ring into rear housing making sure the insulating sleeve Fig 2 doesn t fall off While holding the rectifier in the housing flip the housing and install the terminal hardware Fig 4 Step 5 Flip housing over route regulator sense leads per figure and attach to rectifier ring Fig 5 Note To determine polarity of regulator sense leads look at the regulator wire colors connecting to the alternator Trace these wires through the connector to determine correct polarity Red Positive orque Black Negative 30 35 in Ibs f Step 6 On certain models solder leads to rectifier Fig 6 Recommended solder SN15PB85 www prestolite com mf q Figure 7 gives y
6. TECHNICAL SERVICE MANUAL SERVICE MANUAL FOR THE SSc SCd SERIES ALTERNATOR BASIC SYSTEM TROUBLESHOOTING AND REPAIR A A Prestolite Leece Neville electric HEAVY DUTY SYSTEMS 7585 Empire Drive Florence KY 41042 800 354 0560 www prestolite com Table of Contents Front Bearing Change _ _ 6 _ Slip Ring Rear Bearing Inner Race Change 10 13 Rear Bearing Change Installing Rotor Into Front Housing 15 Alternator Assembly Instructions 16 www prestolite com Causes of Charging System Failure Charging system malfunction is identified by the battery 1 OVERCHARGED BATTERIES caused by one ora combination of the following Description A Defective Battery B Defective regulator The 8SC SCJ series alternators are air cooled belt C Poor sensing lead contact to regulator or rectifier driven units designed for heavy duty diesel engine assembly applications 2 UNDERCHARGED BATTERIES caused by one or a These units feature an integral voltage regulators combination of the following fully enclosed brushes built in rectifier assemblies with solid lead frame and extra large heat sinks a A Loose belts corroded broken loose or dirty dynamically balanced rotor and heavy duty stator terminals broken wiring undersize wiring and bearings The 8SC SCJ series comes in a vast defective batteries array of features which includes remote sense B Alternator field circuit malfunction cau
7. een if equipped Fig 18 Step 17 Install fan i M 7 a Pte Av 3 FPI vag j ta M E A aah 3 T i ot of ri 3 P e J iA TS j _ lie Ha err 3 A an orque n a E i i p 20 25 in lIbs 1 i A Tila Np aya ul a F VEDET 4 hee j iA Lit J NE Figure 19 gives you an isometric view of the rear housing to show correct placement of components Note Two insulating washers are located between the housing and trash screen mounting foot 19 Manufacturing OE Sales 400 Main Street Arcade NY USA 14009 Phone 585 492 1700 Fax 585 492 1660 A Prestolite Electric Distribution Aftermarket Sales 7585 Empire Drive Florence KY USA 41042 Phone 859 525 8801 800 354 0560 Fax 800 997 6202 3 Leece Nevie HEAVY DUTY SYSTEMS
8. model sensing leads which are connected to the positive you have questions on and you will find hyperlinks that and negative rectifier assemblies or on some will take you to information pertaining to that model models this is done externally through a remote You can also contact our technical support hot line at sense S terminal When the output voltage 1 866 288 9853 deviates from the set voltage the regulator takes corrective action to maintain the output voltage at Good information to reference would be our training the proper level For more detailed information on manual PP 1127 or our training CD PP 1216 how an alternator works please see our training CD PP 1216 Alternator Disassembly Step 1 Remove trash screen from alternator if equipped Fig 1 Step 2 Remove regulator by removing 4 screws and unplug connector Fig 2 Step 3 Remove brush holder cover brush wires and brush holder Fig 3 and 4 Step 4 Flip unit over and remove the pulley nut fan and four thru bolts 5 and 6 att He i PAIS Ti w Remove pulley nut pP and fan bie Remove AEF Screws N m E Remove screws R E and brush wires RE Remove 4 thru bolts www prestolite com Step 5 Lift front housing splitting alternator Fig 6 Step 6 Remove three stator nuts then remove stator from rear housing Fig 7 Step 7 On certain models unsolder leads from rectifier Fig 8 SW a Se ere WE
9. ou an isometric view of the rear housing to show correct placement of components Step 7 Place stator into rear housing and attach three AC nuts Torque nuts to 35 30 in lbs Fig 8 Step 8 Place front housing rotor assembly onto a flat surface Fig 9 Step 9 Gently lower rear housing assembly onto front housing assembly Wipe any grease contamination off the Slipring Fig 10 Note Use caution not to damage the rear bearing seal when performing Step 9 Fig 11 Sa 2 os tof Hite 17 18 Step 10 Flip alternator over Insert 1 2 alignment rod into mounting holes Fig 12 Step 11 Apply 242 locktite to alternator thru bolts Install thru bolts and tighten to 45 40 in lbs Remove alignment rod Fig 13 Step 12 Flip alternator over Verify that the brush insulator shield is in place Fig 14 Step 13 Install brushes and tighten screws Connect field wires to brushes Fig 15 Step 14 Install slip ring cover and gasket Tighten screws Fig 16 www prestolite com D orque 40 45 in lIbs Oe P A p orque a 20 25 in Ibs Fim Bar Install screws anc brush wires orque ae 20 25 in lbs Siam fe ee Se Phe gt Pye ee Ss ba ihe z ee ae gt mh r gt Pi rd A Ne Ne a _ Install slip ring cover and tighen screws Step 15 Plug regulator into alternator and tighten mounting screws Fig 17 Step 16 Install trash scr
10. sed by one self excite ignition excite lamp and Multipower or a combination of the following Technology Poor contacts between regulator and brushes No residual magnetism in rotor Defective regulator Damaged or worn brushes Mode of operation The vehicle battery supplies excitation to the field coil rotor coil through the regulator and brushes to Damaged or worn slip rings create a magnetic field around the rotor and through Poor connection between slip ring assembly the stator and field coil leads g Rotor coil shorted open or grounded 7 ODA d o When the rotor is set in motion the moving magnetic field induces an alternating current AC in the stator C Alternator generating section malfunction caused windings This output current increases with the by one of the following speed of the rotor a Stator phase s shorted open or grounded The AC produced in the stator is converted to b Rectifier assembly grounded direct current DC by the positive and negative c Rectifier s shorted or open rectifier assemblies The rectifier assemblies are connected to the alternator output terminals to On Vehicle or Test Stand Troubleshooting provide DC output for charging the batteries and to satisfy the vehicle electrical loads Detailed information can be found on our web site at www prestolite com The regulator monitors the output voltage through When on our web site look up the alternator
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