@ VA 651 VA 661 Univeral Slip Ring End Head Suppor for Bei ‘sod Brive End lad Sappot (or Beating tava f Tezoval FOR OTHER TOOL APPLICATIONS SEE CROSS-REFERENCE CHART ON PAGE 39 Page 61 i BIBLIOGRAPHY Prestolite Section ‘Alternator Service Manuals, dated July 5, 1961, July 6, 1962, July 26, 1962 The Eleceric Autolite Go., Toledo, Ohio sler Section Doge Passenger Car 196] Service Procedure Manual No. 81271-0060 Chrysier Corporation, Dodge Division, Detroit 31, Michigan Delgo-Remy (Delootron) Section Deleo-Remy Service Bulletins IG-186, 1G-261, IR-263, 1G-262, IR-262, IR-263, IR-264 Deleo-Remy Instruction Book, DR9O1i, dated November, 1962 Deleo-Remy Division, General Motors Corporation, Andérson, Indiana ece-Neville Section Leece-Neville 6000 Series Alternator Maintenance Instructions Teece-Noville 3508, 9593, 3626, 3629, 9630, 3691 Regulator Maintenance Instructions The Leece-Neville Go., Cleveland, Ohio 1a Section ‘Motorola Service Manual 68P410S6A01, dated April, 1962 Motorole, Tnc., Franklin Park, Tlinois Ford Section Ford Galaxie and Mercury Monterrey 1963 Shop Manual Supplement, form #7098-6 Ford Moter Company, Dearborn, Michigan ACKNOWLEDGMENTS We wish to thank the following individuals for their assistance in the preparation of specific sections of this manual: Mr. F.C. Brewster, The Motorola Corp. Mr, W.J. Lantzer, The Leeco-Neville Co. Mr. W. Clark, Ford Div. Mr. P.A. Laeper, The Electric Autolite Co. Ford Motce Company Mr. EIR. MeKinley, Deleo-Remy Div. , Mr. D. Fairchild, Ford Div., General Motors Corp. Ford Motor Company Mr. H.M. Riddle, The Electric Autolite Co. Mr. 8. L. Huber, Delco-Remy Div. , Mr. R.W. Schmock, The Leece-Neville Co. General Motors Corp. Mr. RIL. Sheets, Deleo-Romy Div., Mr. Mu. Huntzinger, Deleo-Remy Div. , General Motors Corp. General Motars Corp. Mr. Rea. Winsauer, Motorola, Inc. PHOTO GREDITS Chrysler Corp. , Delco-Remy Div. , General Motors Corp. , The Electric Autolite Co. , Ford Div., Fard Motor Company, The Leece-Neville Co. , Motor Service Magazine, Motorola," Inc. TF YOU WISH TO OBTAIN ANY OP THE TOOLS ILLUSTRATED IN THIS MANUAL... DRAF TOOLS are stocked by leading distributors everywhere. if your local distributer cannot supply you, you may order direct from the factory. We reserve the right to forward orders to your nearest distributor, unless specified to the contrary. “F For prices of additional copies of this manual, write: PUBLICATIONS DEPT, DRAP TOOL CO., ING. P.O, Box 830 WHITE PLAINS, N.Y. ALTERNATOR BULLETIN SERVICE Your alternator service manual represents the latest factory-approved service information ° available at the time of publication, While the basic design of the alternator is firmly . established, there are constant product improvements resulting in changes and additions to specifications, service procedures, etc. , as well as the introduction of other new alternator systems. ‘The DRAF Alternator Bulletin Service 1s specifically designed to permit you to keep abreast of these changes and additions as they are made. Published quarterly, it ts available on a subscription basis of $1.00 per year. To subscribe, {ill out one of the handy subscription order forms bound into this manual and mail it with your remittance. - Page 4ALTERNATOR SERVICE PRECAUTIONS ===————=—— 1, Reversed battery connections will damage the rectifiers. Battery polarity should be checked with a voltmeter before connections are made to be sure that the connections correspond to the vehicle battery ground polarity. 2, HEbooster batteries are used for starting they must be connected properly to prevent dam- ‘age to the rectifiers. The negative (-) cable from the booster battery must be connected to ‘the negative terminal of the vehicle battery and the positive (1) booster cable to the positive terminal. Always disconnect the battery ground strap before replacing any alternator. '3, When a "Fast Charger" is used to charge the battery, the vehicle battery cables should be disconnected. The "Past Charger" should never be used as @ booster for starting the vehicle. Failure to observe these precautions may result in damage to the rectifiers. ‘4. The field circuit must never be grounded between the alternator and the regulator. Grounding of the field terminal at either the alternator or the regulator will damage the regulator. '5. Connections of the stator leads to the rectifiers should be made in accordance with the recommendations of the manufacturer. These recommendations are fully described in ‘each alternator system section of this manual. 6, Grounding of the alternator output terminal will damage the alternator and/or clrouit. ‘his ie true even when the system 1s not in operation since no circuit breaker is used and battery is applied to the alternator output terminal at all times. 7. The alternator must not be operated on open circuit with the field winding energized or the unit may be damaged. Tighten all circuit connection: 8, Do not attempt to polarize the alternator, No polarization is required. Any attempt to do so may result in damage to the alternator, regulator, or circuits. 9. Donot shert the bending tool to the requlator base when adjusting voltage or the regulator will bedamaged. The bending tool should be insulated by taping or installing a plastic sleeve. ————==== ALTERNATOR TROUBLE SHOOTING 1, ALTERNATOR FAILS TO CHARGE 3, Regulator voltage winding open. 1, Blown fusible wire in voltage regulator. 4, Regulator base improperly grounded. E hitter aie belt tose * '. REG ;ONT/ OXIDIZE} 2 ae ee eete rings, V+ HRIGIATOR CONTACTS CHTDIZED 4. Sticking brushes. 2. Regulator air gap improperly set. &, Open field circuit. 3, shorts field coll wind 6. Open charging circuit. ian ote 7, Open circuit in stator windings. VI. REGULATOR CONTACTS BURNED 8, Open rectifiers. 1. High regulator setting. ee entot saxre 2. Shorted rotor field coll windings. 1. Alternator drive belt loose. VIL. REGULATOR VOLTAGE COIL WINDINGS 2, High resistance at battery terminals. BURNED 3 High resistance in the charging circuit. 1, High regulator setting. Bion omiere in ig Pay ‘o,cogtne © (Vist, REGUIATOR CDWEADT PORT ETUC 1. Poor ground connection between the 5. Open stator winding . alternator and the regulator. 1, LOW OUTPUT AND A LOW BATTERY 1, High resistance in the charging circutt. 2. Low regulator setting. 3. Shorted rectifler. Open rectifier 4, Grounded stator windings. 1X, NOISY ALTERNATOR 1, Alternator mounting loose. 2, Worn or frayed drive belt. 3, Worn bearings 4. Interference between rotor fan and IV. EXCESSIVE CHARGING RATE TO A PULLY stator leads ot rectifiers. CHARGED BATTERY 5, Rotor or rotor fan damaged. 1, Regulator set too high. 6. Open or shorted rectifier or stator 2, Regulator contacts stuck. winding. 7, Loose Pulley. Page 5SSPRESTOLITE ALTERNATOR SERVICE MANUAL= Fig. | 1-Alternator Charging Cirouit with Fig. 2~Altenator Charging Ciroult with a Delta Connected Alternator ‘2 "Wye" Connected Alternator I. INTRODUCTION ‘he alternator charging cirouit consists of the battery, the alternator, the alterna~ tor voltage regulator, circuit breaker, the ignition switch, the ammoter or cherge indicator light, the charging circuit wiring and the vehicle frame. See figures 1 and 2. ‘The alternator differs*from thé conventional D.C. shunt generator in that the armature is the stationary member and is called the stator while the field is the rotating member and is called the rotor. With this construction the higher current values involved in the ‘armature or stator may be conducted to the external circuit through fixed leads and con- ‘nections rather than through a rotating commutator and brushes as in the D.C. generator. ‘The comparatively small values of current supplied to the field may be conducted with~ out difficulty through small brushes and rotating slip rings. ‘The alternator employs a 3 phase stator winding in which the phase windings are electrically 120 degrees apart. The rotor consists of a field coll encased between two four-poled interleaved sections producing an 8 pole magnetic field with alternate north ‘and south poles. By rotating the rotor inside the stator, an alternating current (A.C.) 18 induced in the stator windings. This alternating current is rectified (changed to D.C.) by silicon diodes and brought out to the output terminal of the alternator. Six silicon diode rectifiers are used and act as electrical one-way valves, Three of the diodes have negative polarity and are pressed into an aluminum heat sink which is grounded to the slip ring end head. The other three diodes have positive polarity and ‘are pressed into a simflar heat sink which is insulated from the end head and connected to the alternator output terminal. ‘Since the diodes have a high resistance to the flow of current in one direction and a low resistance in the opposite direction, they may be connected in a manner which ‘allows current to flow from the alternator to the battery in the low resistance direction. The high resistance in the opposite direction prevents the flow of current from the battery to the alternator. Because of this feature no circuit breaker is required between the alternator and the battery, although on some applications a circuit breaker is used. Residual magnetism in the rotor field poles is negligible, and therefore, the starting {Held current must be supplied by an external source, or in this case, the battery which Page 7F=PRESTOLITE ALTERNATOR SERVICE MANUAL = is connected to the field winding through the ignition switch and regulator. As in the D.C. shunt generator, the alternator voltage is regulated by vary- ing the fleld current, This is accom- plished through the use of a dual contact voltage regulator unit. No current regu= lator Is required since the alternator has self-limiting current characteristics. Tl. DESCRIPTION The alternator is designed to supply the electrical demands of the vehicle battery and the assessory circuits through a wide range of engine speeds. It is particularly adaptable to applica~ tions requiring comparatively high output at idle or low engine speeds. ‘The alternator is somewhat lighter ‘and more compact in design than a conven- tonal D.C, shunt generator of comparable electrical size and is equally as simple to service and test. See figure 3. Fig.3-The Prestolite Alternator The principle components of the alter nator are described as follows: A. The stator consisting of a laminated iron core on which thé three phase windings ‘re wound in slots around the inside circumference. A pair of leads is connected to each of the three points of the three phase winding. One of each pair of leads connects to a negative diode and one to a positive diode, B. The rotor consisting of a single field coil encased between two,four fingered inter- Jeaved iron sections assembled on the shaft, The two ends of tho field coil are connected to two slip rings which are insulated from each other and from the shaft. The roller bear- ing end of the shaft is hardened. G. The slip ring end head supporting the rectifier heat sinks, a pre-lubricated roller bearing, in which the rotor shaft rotates, the brush holders and brushes, and the field and output terminals. D. The drive end head eupporting a pre-lubricated ball bearing in which the drive end of the rotor shaft rotates. E. The rectifiers pressed in the rectifier brackets or heat sinks and connected to the stator leads. Fame fue = [= [Siieasyjerranty: Sac Se, Exploded View of AlternatorS=PRESTOLITE ALTERNATOR SERVICE MANUAL= ON VEHICLE TEST ‘To test alternator system on vehicle or bench make the various tests described in Section IX, paragraphs 3 and 4, "Tests and Adjustments. When repairing the alternator, complete disassembly may not be required. In some cases it will be necessary only to perform those operations which are required to repair or replace the defective part. However, the complete overhaul is covered step by step to provide detailed information on each operation. A. Preliminary Disassembly 1, Remove the through bolts and tap lightly on the head ends with a plastic or rawhide hammer to separate ends from the rotor. Remove the drive end head and rotor assembly. , 2. Remove the nuts and lockwashers from the negative rectitier bracket studs and the nuts, lockwashers, flat washers and insulator bushings from the positive rect!- fier bracket studs. Separate the slip ring ond head from the stator. NOTE: The positive heat sink is identified by the larger studs. The pos: tive rectifiers are Identified by red markings and the negative rectifiers by black markings. B. Brush Removal ‘Hoth brushes should be replaced if worn to 5/16" or less in length. ‘Toremove the msulated brush from the slip ring end head, grip the brass tormanal on the end of the brush lead with pliers and pull it out of the field terminal insulator bushing, If a field terminal stud Is used, remove the nuts and lockwashers and pull the stud through the insulator bushing. Rémove the scrow that attaches the ground brush lead to the end frame. If the brushes are located on the outside of the ship ring end head on a brush holder plate assembly, the plate may be removed by snipping the insulated field lead at the brush holder. NOTE: Make sure that brush springs ere not lost when the brushes are removed from the holders. ©. Pulley Removal When removing the pulley nut it is necessary to prevent the pulley from slipping. Place a fan belt in the pulley groove and carefully place pulley ina vise. Close vise slowly on belt avoiding excess vise pressure on pulley. 1, Remove pulley nut and place puller arbor D15 on rotor shaft. 2. Position pulley removal jaws (©KS07 in groove of pulley and the other end on the puller arbor nut. 3, Hold adapter jaws and puller arbor in position with tool sleeve. 4, Place puller arbor D15 in the hexagonal opening of vise holding fixture VA650. See figure 4. 5. Support rotor with hand and turn pallor arbor with wrench until pulley ts removed. > NOTE: The use of vise holding fix- ture VA6S0 prevents possible damage to rotor and drive end head. ee enimia Stem ik EE nl Gencnawe sinus i ill Pig. 5-Removing Drive End Head Fig. 6-Removing Drive End Head Bearing D, Drive End Head Removal T, Remove woodruff key, fan and spacer. 2. Position puller arbor D15 on rotor shaft and place drive end head removal jaws CKSIi over bearing retainer plate. 3. Remove the drive end head in the same manner as described in paragraph C. See figure 5. NOTE: Do not attempt to remove by supporting the end head and pressing ‘on the shaft. ‘This will rosult in distortion of the end head or stripping of the retainer plate screws. . E. Drive End Head Bearing Removal (Vise Method) * 1, Remove the screws and washers on the inside of the drive end head and remove bearing retainer plate. * 2. Genter support VA 668 on the inside of drive end head and position bearing remover VA603 on the inner race of bearing. 3, Carefully place entire assembly ina vise and slowly close vise jaws until the bearing 1s pressed out of the end head. See figure 6. F. Slip End Head Bearing Removal 3@ Method) * 1, Support slip ring end head on support VA661. 2. Position bearing remover VAGO4A in the roller bearing and carefully place entire assembly ina vise. See figure 7, 3. Clése vise slowly pressing out the bearing. G. Rectifier Removal (Vise Method)* Before removing the rectifiers, test each rectifier as described in Section V, paragraph C. ‘arbor press may be used in place ot re Pig.7-Removing Slip Ring End Head Bearing Page A-10== PRESTOLITE ALTERNATOR SERVICE MANUAL= Fig. 8-Removing Rectifier Fig. 9-Testing Rotor for Grounds 1, Cut rectifier wire as near to the crimped sleeve as possible, 2. Support heat sink at rectifier lead ond with support VA665 and place rect!- fler remover VA608B on rectifier. 3, Carefully place entire assembly in a vise closing vise Jaws slowly until the rectifier is pressed out of the heat sink. Seo figure 8. V. INSPECTION AND TESTING OF COMPONENTS: A, Upon completion of the disaésembly all parts should be wiped clean and visually i Inspected for wear, distortion and signs of overheating or mechanical interferenc. | B, The stator windings and leads should be examined for insulation failures of de- | fects. A shorted phase winding of rectifier will normally be evidenced by discoloration, | t t Shorted stator coils or shorts between stator phase windings are not easy to determine. An chmmeter which will accurately Indicate variations of resistance in the low range of 1 ohm increments will be helpful. Output voltage readings across each phase winding of the Delta or "Wye" connected stator will indicate trouble if the three Voltage readings are not essentially the camo when the rotor current is steady and while the rotor 1s turning at constant speed such as 1000RPM. If stator trouble is definitely Indicated; and the above tests cannot be satisfactorily made, install a new stator. . Totest for shorted rectifiers without disconnecting the stator leads, use Draf Toster No, VAG8B, Touch one test probe to a rectifier ~ hheat sink and the other probe to the lead from one of the rectifiers in that heat sink. Then Teverse the position of the leads, The test lamp should light in one direction and go out in - the otherdirection. If the lamp lights in both { directions, one or more rectifiers in that heat | sink are shorted, ‘Todetermine whichrectifierts |__| (ACS) shorted, the stator leads must bedisconnected and the above test repeated on each rectifier, D. The rotor should be tested for grounds and for shorted turns in the winding. The Ground test is made with Draf Tester No. VAG864 peer Probe on a slip ring and the other probe on the rotor core. See figure 9. If the bulb lights the totor winding 1s grounded. E. To test for shorted turns, check rotor field current draw as shown in figure 10. Using| the theostat, adjust the voltage to 10 volts and Fead the field current draw on the ammeter. Page A-11SPRESTOLITE ALTERNATOR SERVICE MANUAL= Pig, ll-Installing Rectifier Fig.12-Installing Slip Ring End Head Bearing Excessive current draw indicates shorted turns fn the fleld winding . F. Check the bearings for roughness or excessive clearance to determine if they should be replaced. NOTE: New bearings are prelubricated, additional lubrication 1s not required. G. The alternator end housing may be wiped clean with a cloth dampened in solvent if excessively dirty, but should not be buffed as this will destroy the special treatment given to inhibit corrosion, VI. ASSEMBLY A, Rectifier Installing (Vise Method)* 1. Support the heat sink on support VA666 and start new rectifier squarely into the heat sink with rectifier installer VA609. 2, Carefully place entire assembly in a vise closing slowly until the rectifier 1s fully pressed into the heat sink, See figure 11. 3, Strip the insulation back 1/4” on the stator leads and reconnect them to the rectifiers. The connector sleeves should be crimped on the rectifier leads. NOTE; Do not solder these connections as the excessive heat may damage the rectifiers. Clean all wires before crimping. jlip Ri stall} \* 1. Support the inside of the slip ring end head with support VAGO6A. Position bearing installer VA605A over roller bearing making sure that bear- ng enters slip ring end head squarely. 3, Carefully place entire assembly in a vise closing slowly until the bearing is flush with the outside of end head. See figure 12. C. Drive End Bearing Installing (Vise Method) * ‘1. Install the felt retainer and crinkle washer. 2, Support drive end head on the larger side of suppost VAG61 and insert drive end bear- ing squarely into drive end head. 3. Place bearing installer VA605A on bearing and carefully place entire assembly in a vise, closing vise slowly until the bearing is flush with the inside of the bearing hub. See figure 13. a ‘*Arbor press may be used in place of vise. _Fig. 13-Installing Drive End Head Bearing Page A-12== PRESTOLITE ALTERNATOR SERVICE MANUAL Fig.14-Installing Drive End Head Fig.15~Proper Brush Assembly on . ‘Brush Holder Plate D. Drive End Head Installing (Press Method) 1, Install retainer plate and gasket on the drive end head. “Place snap ring and retainer on rotor shaft. 2. Assemble press kit VA65S in a vise in accordance with instructions contained on page 21, ? 3, Posifion the bearing and drive end head on the rotor shaft. 4, Place entire assembly in the opening of press support. 5. Position installer VA603 on the inner race of bearing and insert special adapter A651 on top of installer VA603. See figure 14. 6. Press the bearing and head on the rotor shaft until the bearing contacts the snap ring retainer. See figure 14, NOTE: The use of special adapter VA651 serves as a centering guide for the ‘arbor and prevents possible damage to installing tool. E. Pulley Installing 1. Install the spacer on the rotor shaft, 2. Install the woodruff key, fan, pulley, lockwasher and pulley nut, NOTE: When tightening the shaft nut, it is necessary to prevent the pulley from slipping. Place a fan belt in the pulley groove and carefully place ina vise. Close vise slowly on belt avoiding excess vise pressure on pulley and tighten shaft nut. F, Brush Installing Install ground brush with screw to the end frame. Connect the insulated brush tothe field terminal. If the brushes are mounted on a brush holder plate, as on outboard enclosed slip ring models, the ground brush load eyelet fits on the slip ting cover mounting stud. The insulated brush lead is soldered to the brush holder. Make sure that both leads fit through the fiber slots. The insulated brush lead should loop around the outer edge of the brush holder plate. See figure 15. Install brush springs and spread the brushes with brush spreader AL615, so that they will clear the slip| “ag when the rotor and drive end head assembly {s installed. See figure 16. On some end heads, a thin flashing covers one ofthe holes. With the brush spreader tool inserted in the hole, the flashing canbe easily broken with two or three light taps on the tool, Fig. 16-Installing Brushes with Brush Spreader Tool Page A-13SS=PRESTOLITE ALTERNATOR SERVICE MANUAL= Fig.17-Wiring Diagram of a Typical Altemator Charging Circuit G. Final Assembly 1. Install the negative rectifier heat sink in tho slip ring end head and replace lockwashers and nuts. Replace the insulator bushings on the positive heat sink studs and install the heat sink in the end head. Replace the outer insulator bushings, washers and nuts. 2, Manually press the stator in position on the slip ring end head and install the assembled drive end head and rotor. Make sure that the stator leads do not interfere with or touch the rotor. If too much pressure is oxerted on the brush spreader tool, the brush leads may be torn loose from their connections, Check that the through bolt ‘holes Line up on the two end heads. (There are no locator pins used.) Install and tighten the ‘through bolts. 3. Remove brush spreader AL61S and make sure the brush leads do not drag on the rotor and that the rotor turns freely when rotated by hand. Fig.10-Regulator with Gover Removed VII. ALTERNATOR BENCH TEST Upon completion of assembly, the alternator should be tested for output as per sec- tion X, paragraph A. This test is made to determine whether the alternator is capable of doliveting rated output. The alternator must meet output specifications before regulator tests and adjustments are attempted. VIM. VOLTAGE REGULATOR This alternator regulator consists of a voltage regulator and a circuit breaker and can be identified by four terminals marked I, F, Aand B. (See figures 17 and 18.) No current regulator is required because the alternator is inherently self-limiting. A The circuit breaker unit has a built-in polarity sensing feature which acts as a safety device to isolate the alternator output terminal from battery potential when the system is not in operation. This eliminates damage to the alternator, wiring harness and components of the charging system if a battery was accidently installed with incorrect, ground polarity. ‘The circuit breaker is a dual contact unit with the upper stationary and upper movable contacts closed in the "at rest” position. The circuit breaker winding has a tap Page A-14SPRESTOLITE ALTERNATOR SERVICE MANUAL= at approximately 1/3 of the winding distance from one end. This tep is connected to the regulator "I" terminal. When the ignition switch is tumed on, the winding is enorsicey at the tap and from this point, there are two paths for current to flow. One path through each portion of the winding. “this differential operation establishes two magnetic fiolac, fone opposing the other and the upper contacts remain closed. . The alternator rotor winding is energized through a Portion of the circuit breaker Winding to the circult breaker upper contacts and through the regulator upper contacto ce the regulator field terminal and to the alternator rotor winding. As alternator voltsce incteases and ts applied to the regulator “A” terminal and to the circult broaker sever contacts, it opposes the voltage in this partion of the winding to the tap; thereby reducing current flow, and in turn reduces the magnetic field, ‘The cutteat flow is the winding connected between the tap and regulator ground remains undisturbed and its magnetic field overcomes the reduced bucking field from the other Portion of the winding. ‘The circuit breaker armature pulls down to connect the battery and alternator together, The circuit breaker will not connect the alternator and battery together if battery should be accidently connected with reverse polarity, B. Voltage Regulator ‘The voltage regulator is a dual contact type. (See figure 18) The regulating resistor (RI, figure 17) is connected between the field terminal and the circuit beeshor frame, and it is in series with the rotor winding when the regulator armature to ia the float position. The upper contact 1s connected to the circuit breaker frame and inselated from the regulator base. The lower stationary contact 1s grounded to the regulater be The movable armature contacts (upper and lower) are mounted on a stainless steel reat ey to a spring loaded armature and are connected electrically to the Tegulator field terminal. The regulator voltage cotl, consisting of many turns of fine wire, {s connected between ground and the circuit breaker yoke, Its voltage is direct from the alternator = battery charging system when the circuit breaker lower contacts are closed. The ckeuit 4s completed through ground from the regulator base to the alternator frame, A second resistor (R2, figure 17) is connected between the regulator field terminal and ground. ‘The purpose of this resistor is to provide an alternate path for voltage wucen Induced in the rotor coll each time the regulator contacts open thus. reducing arcing scross the regulater contacts. {It is electrically across the rotor winding.) A third resistor (R3, figure 17) is used to stablize circuit breaker operation and 4s connected from the "I" terminal fo regulator ground. In the "at rest" position, the upper movable contact is held against the upper stationary contact by armature spring tension, When system voltage is low, current flow through the voltage coil is also low and the magnetic pull 1s not strong enough to overs gome armature spring tension. In this position, system voltage te applied to tho rote Held coll. Alternator output at this time is not regulated and, therofere, may be fall out= Put, depending on rotor speed. 4s system voltage increases, the magnetic pull of the voltage coll overcomes armature spring tension and the contact vibrates between the upper contact ands "flost™ Position. In the “float” position, the rotor fleld circuit 1s completed through Ri resins. ‘The movable contact is vibrating between the upper contact and the "float" position te control voltage when the vehicle electrical system current demands are relatively high and engine speed is that of normal driving. When the electrical load demand is low and engine speed 1s high, the alternator cutput voltage tends to increase. Under these conditions, the magnetic pull of the valtege coil is high and pulls the movable contact against the lower stationary contact. This momentarily grounds the end of the rotor field winding and. output drops. As the movable contact vibrates betwaen the "float" position and the lower contact, system veltoce 1s controled within very close limits for high speed, minimum load operevion, Page A-15=PRESTOLITE ALTERNATOR SERVICE MANUAL= Fig.19-Testing Voltage Drop in Fig. 20-Alternator Output Test on Charging Circuit Vehicle 1X. TESTS AND ADJUST! ‘MENTS ‘Testing of the alternator charging circuit may be done as a part of 4 periodic main= tenance inspection, or in the diagnosis of charging system difficulties. Tn either case, the procedure and test preparations are the same. CAUTION: To avoid damago to the regulator, do not at any time connect direct Battery to the regulator field terminal and ground. A. Giroult Tests Boforo any tes Jts are made on the alternator or regulator, the battery should be checked and the circuit inspected for faulty wiring or insulation, loose or corroded con~ cnetions and poor ground circuits. Check alternator belt tension to be sure the belt is tight enough to prevent slipping under load, Any unfavorable conditions noted in this inspection should be corrected as required before proceeding with electrical tests. NOTE: Disconnect negative or positive battery cable from battery before Making any test connection, Failure to observe this step may result in damage to the 1, Battery Test: system. Test the battery with a hydrometer or voltmeter. If not fully charged, if should be removed and placed on charge, A fully charged battery may be Installed for test purposes. 2. Chas roult Resistance Test: Make connections as shown in figure 19. Disconnect the charging circuit lead from the slternator output terminal. Connect an am~ peter in series between the alternator output terminal and the disconnected charging Bieuit lead. Connect a voltmeter across the external charging circuit. The negative Golimeter lead is connected to the positive battery terminal post and the positive voltmeter eee Sonnected to the charging circuit lead so that the voltmeter will not include the voltage drop across the test ammeter. Reconnect the battery cable, Now start engane and adjust the speed and electrical load to obtain 10 ampores in the charging circuit. The voltage drop through this circuit Lesnid not exceed -3 volt. If mare, locate and correct the high resistance before proceed~ {ng with tests. Continue with 10 ampere charge rete and connect the voltmeter to each of the other positions shown in figure 19, The voltmeter readings should not exceed those Shown foreach position. If more, locate and correct high circuit resistance connection. ‘Make alternator output test, as covered in the following paragraph before testing the voltage regulator. 3, Jt; The alternator output test is made to determine whether ‘Migrnator Output Test the alternator is Capable of delivering its rated output. ‘The alternator must meet output Specifications bofore regulator tests or adjustments aro attempted. Use fully charged battery. e belt tight.) Disconnect the battery ground cable before test meter connections are made as shown in figure 20. Reconnect the battery ground cable and connect the carbon pile Page A-16==PRESTOLITE ALTERNATOR SERVICE MANUAL= tneostat across the battery. Be sure the carbon rise rheostat 16 in the “off” position before Ponnecting the leads. ‘Connect an accurate engine tachometer to the engine's electrical system, and start the tone. Adjust engine speed to 1750 R.P.M Guternstor should be approximately 4200. P.M.) {Bhast the carbon pile theostat to obtain 14.2 Adiispter reading and observe the ammeter. Tt Yeluld be the rated alternator output plus or ninus 2 amperes. Tf on or more rectifiers are open, the alternator output reading will usually be 3 or ae mee amperes Dolow full output, If ene cr more fectifiers are shorted, the alternator output a o Teil usually not exceed 10 amperes, end it will Pig. 21-Voltage Regulater Test hum oF growl. 7 Operational Circuit Breaker Check: Tum on the ignition switch, charge indi- ‘ator lamp shoal light. Start engine, Light should go out. Stop engine, and with Ggiition switch off, charge indicator lamp should not be lighted. I trouble 1s indicated, check the battery, wiring and all connections, ignition switch, Light bulb, and alternator output. If an ammeter {s used with this regulator, in suse ic the charge indicator Light, the ammeter should not indicate discharge when the piston switch end all accessory switches are in the "off" position. Taqulator ig the last item to be tested, The regulator is usually not the trouble ea fae Sater Items listed above aro checked and irregularities cerected, the regulator or circuit breaker unit will usually need no adjustment. 5. Voltage Regulator Test: Tho first part of this test checks the operating voltage af the regulator when operating on the upper contact, Test connections are shown 1n figure 21. Use fully charged battery. ‘start engine and adjust speed to obtain approximately 1600 alternator R.P.M. tun on linhts snd secessories to Obtain a 10 to 12 ampore charge rate. Operate the sys~ tom at this speed and load for 15 minutes to normalize the temperature, (This regulator is temperature compensated.) Gyele the eystem by stopping and restarting the engine, then note the voltmeter reading. TPseriously out of adjustment, a rough setting may be made. The final setting {e not made until the "spread" between operation on the upper contact and operation on the lower contact 1s established, ‘This value 1s determined in tho next part of the test which checke voltage when the regulator is operating on the lower grounding contact. Test connections remain the same as for the previous part of the test. Increase engine speed to obtain 3500 alternator R.P.M. minimum, and turn off all Ushts and tccessories. Voltage should increase and amperage should decrease. The “spread” in Voltege should be ae indicated on specification page. The battery must be fully charged to make this test for "spread" between operating on upper contacts and operating on lower contacts. Check the spread using a 12 to 15 ampere load while the alternator 1s operating at 3800 R.P-M, minimum, Switch the load on and read the voltmeter ~ switch the load off and wait is seconds, then again read the voltmeter. ‘The difference between the two readings is the "spread A 1/4 ohm resistor may be used in the charging circuit to cheek operation on lower grounding contacts. The final regulator reading may now be made after cyeling the system ~ adjust if necessary. Use 12 to 18 ampere load. ‘Wovveconmend the use of a 2000 ohm radio head phone while checking the spread. Connect the head phone from the regulator field terminal to ground. are not to acci~ dontly ground the field d- damage to the regulator contact reed and wir While operating on the upper contacts , the frequency will be rather slow compared to the uch faster frequency of point operating on the lower grounding contact. During certain Conditions of engine speed and load, the regulator armature is In the float position with neither the upper nor lower set of contacts operating. The regulator armature float may Page A-17S=PRESTOLITE ALTERNATOR SERVICE MANUAL= parrerr camoon PE Fig. 22~alternator Output Test on Fig. 23-Circuit Breaker Test ‘Test Bench ‘occur at approximately 2400 alternator R.P.M., depending upon the regulator setting and regulator operating temperature, along with state of charge of the battery. (Head phone will detect this condition.) ‘With a cold regulator and a fully charged bettery, turn on headlights for one minute to remove surface charge before operating the engine. If on generator-regulator test bench - remove surface charge from battery with a carbon pile. If the "spread" is greater or less than specified, remove the regulator cover and adjust by loosening the stationary contact support screw and moving the support up or down, (A small amount of up or down movement will usually make quite a change in spread.) Raising the stationary support will increase the voltage "spread." Replace the cover and reduce the alternator speed to approximately 1800 R.P.M. and repeat the first part of the test with the regulator operating on the upper contact. If the voltage setting is not within specifications, remove the cover and adjust by bending the lower spring hanger. (Use insulated spring hanger bending tool.) Replace the cover and cycle after each trial adjustment to obtain accurate readings. After replacing cover, be sure to run at least 3 minutes before reading voltmeter. X, BENCH TESTS AND ADJUSTMENTS To avold damage to the requlator, do not at any time connect direct battery to requ- lator fic uinal and ground. ‘A. Alternator st ‘The alternator output test may be made on a generator-alternator-regulater test. bench. No regulator is needed. Make meter connections as shown in figure 22. The connections will be ~ ammeter botween alternator "A" terminal and battery positive terminal, Battery negative terminal to alternator frame, Jumper lead connected from alternator "F" terminal to alternator "A" terminal, and with voltmeter connected from alternator "A" terminal to alternator frame. ‘Carbon pile rheostat connected across the battery terminals. Test as above with alternator at 4200 R.P.M., adjust carbon pile to 14.2 volts on voltmeter. The ammeter should read the rated alternator output plus or minus 2 amperes. B, Circutt preaker Test ‘Check and, iFnecessary, adjust core gap and point gap. Without pre-heating and with regulator at room temperature, check or adjust circuit breaker unit rapidly. (As the regulator heats up - due to current flow in the windings and resistors ~ closing and opening voltage will change.) Connect the regulator as shown in figure 23. (Two #57 lamp bulbs must be used.) Alternator speed constant ~ approximately 2000 R.P.M. Gover must be on for all voltage reading; Page A-18=PRESTOLITE ALTERNATOR SERVICE MANUAL= Close switch, $-1. Adjust potentio~ meter theostat R-1 slowly to raise alternator ‘output voltage from less than 2 volts to circuit breaker closing voltage, as indicated on the voltmeter. Circuit breaker closing to be detween 6.0 and 9,0 volts. Circuit breaker closing is indicated by lamp LA-2, lighting. Closing adjustment is made with arme~ ture spring tension. (Increasing tension, increases closing voltage.) After closing ‘adjustment is complete and with regulator not heated, adjust R-l to increase alternator output voltage to 14.0 volts, as indicated on the volt= meter. Open switch, S-1. Lamp LA~2 should remain lighted. Adjust R-I slowly to reduce alternator output voltage from 14.0 volts. Ciroult breaker should open between 13.0 and 13.5 volts. Circuit breaker opening is indicated by lamp LA-2, going out. Lamp LAvl ts used to load the regulater circuits during bench testing and adjustment, Pig. 24-VR Core Gap Adjustment ©. Regulator Tests If the regulator voltage is unstable or cannot be adjusted to specifications in the above test, the following bonch tests and adjustments should be made. 1, Voltage Regulator Contact Gap: Contact gap 1s checked by placing the proper gauge between the lower movable contact and the lower stationary contact. Adjust by bending the upper stationary contact support up or down. Be sure that proper contact alignment is maintained. (See specification page for proper gauge size.) 2. Voltage Regulator Core Gap Adjustment: To check the voltage regulator arma~ ture core gap, connect a 457 bulb in series with a 12 volt battery between the regulator SP" terminal and base. (See figure 24.) Place a round wire gauge between the armature and core, on the side of the brass stop rivet nearest the center of tho core head. (Brass stop rivet head on under side of armature.) Care should be taken not to press on the contact reed as this will affect the reading." (See specifications for gauge size.) The lower movable armature contact should barely touch the lower stationary con tact when the armature is pressed down against the small end of the gauge and the lamp should brighten, With the large end of the gauge between the armature and core, the light should remain dim. ‘To adjust to specifications, loosen the stationary bracket attaching screw and move the bracket up or down. NOTE; This is a préliminary adjustment only, as the core gap may be changed slightly when Voltage "spread is established as covered in “Regulator Test" above. D. Serv! 7 The contacts on the voltage regulator may be cleaned, if rough or oxidized, with ‘a number 6 American Swiss equalling cut file. (Use care not to remove an excess of con~ tact material.) After filing, the contacts should be cleaned with a strip of lint-free tape saturated with a few drops of lighter fluid and drawn between the contacts, Then repeat with a dry strip of tape to remove residue. ‘Use insulated adjusting tool when setting or adjusting the regulator or circuit, breaker. 8 specification page for other data. Page A-19=== PRESTOLITE TEST SPECIFICATIONS al ed ec ALB 12 60 ap BD 10.0 24-27 | 14,2 60 2300 wc [a] a] on | wo | 2a24| 142 | as | 2000 wo fifa x @ | 100 | 2024 | 142 | «0 | 2000 | «o] m w | 100 | 2324) 142 | a0 | o100 V2, 35 a BD 10.0 23-24 14.2 35 4600 2} wo) Nw wo | 100 | 1917] 142] 2 | 500 2] ss} a wo | 100 | 2026] 142] ss | 2900 ¢{ 3s] a w | so | 2223| 7a | as | ao0o al lon | wo] 24z6| raz] sa | 3700 m4 | 2] wo | z00| 910] 204] a0} 2200 wo} 20] 1ara] 2e4| 30] 2900 wo | 20} tata] zea] 55] 2000 wo |. 100] 2024] 142] 20] 2200 wo | 100] 2426] 12] 75] aooo w | 100 2426 142 100] 4300 ie4 Gre peliive GrOUNG, Be Bure Ploy Ts Kiown 2.—Most alternators in these series are Bi-directional rotation; however, some ‘use a fan which must be driven clockwi= ALTERNATOR SERVICE MANUAL VA 655 UNIVERSAL ALTERNATOR PRESS KIT ‘THE ONLY PORTABLE PRESS ESPECIALLY DESIGNED FOR ALTERNATOR SERVICING - ‘With your D 15 Arbor and VA650 Vise Holding Fixture, this press will perform all reguired pressing operations on all alternators. TEATURE Eliminates damaging expensive parts. Saves time and increases profits. Assembles in less than a minute. Made of rugged aircraft aluminum, Weighs less than 3 Ibs. Stores easily saving valuable bench space. ‘Engineered by DRAF. ASSEMBLING INSTRUCTIONS 1, Assemble press kit as shown in figure 1 observing the following: ) Upper Support Rails have circular cutouts and must face each other. ) Lower Support Rails have rectangular cutouts and must face each ‘other. 2, Insert Vise Holding Fixture VA650, with hole end up, into lower support rails as shown in figure 2. 3. Place the lower exposed section of Vise Holding Fixture VA650 in a vise so that lower support rails rest on top of vise jaws. Tighten vise Jaws. 4, Insert Puller Arbor D 15 in upper support rails as shown in figure 2. 5. "Square up" press and firmly tighten all wing nuts. Page 21= DELGO-REMY (DELCOTRON) ALTERNATOR SERVICE. MANUALS " DELCO-REMY (Delcotron) SERVICE TOOLS For Alt General Motors Cart! es Dares [YA 670 _| conan lotsa aor. | DRAF DESCRIPTION NO. - Di Tana Aa TI ORT Pa enone aca Bane Bod Foes Manoa a can Dt Fe eae “A ata aay Romo ek | — vet ReraTale A Sp Rag nd Faas Sp staring TAB Sia ad ne Sg a ema ¢ vA Tce Rens Diss) Cleo mt VA609. Univers! Reaifier (Diode) Cal Tostaller we a et Taal Rigames Rl ae POs ae Tana es e asa Spee ag | TTenoval sas Delve En Frame Support for Beatiog Installing FOR OTHER TOOL APPLICATIONS SEE CROSS-REFERENCE CHART ON PAGE 39 ge D-36a ——DELCO -REMY "DELCOTRON"* SERVICE MANUAL=— (5.5" Frame Diameter Type) 1, INTRODUCTION “pelootrons"# are designed and constructed to give long periods of trouble-free service witha minimum amount of maintenance. The rotor is mounted on aball bearing at thedrive ‘end, and a roller bearing at the slip ring end, and each bearing has a grease reservoir which eliminates the need for periodic lubrication. Only two brushes are required to carry cur- rent through the two slip rings to the field coil which is mounted on the rotor. The brushes are extra long and under normal operating conditions ‘will provide long perlods of service. ‘The stator windings are assembled on the inside of laminated care that forms part of the "Delcotron” frame. Six rectifier diodes are mounted inthe slip ring end frame and are connected to the stator windings. The six diode: replace the separately mounted recti- fier ag used in other types of applica~ tions, and they act to change the "Delcotron’ “Delcotron”. high voltages. ‘Atypical "Deleotron" is shown in figure 1, and a crosi BAT" TERMINAL GRD" TERMINAL Fig.J-Typical "Delcotron"” ‘¢. voltages to d.c. voltage which appears at the "BAT" terminal on tho ‘capacitor, or condenset, mounted inthe end frame protects thediodes from sectional view is illustrated sn figure 2. ‘*General Motors Trademark rommo _£6)s SBN wee we DIODES, ws Fig.2-Cross-Sectional View of Typical "Delcotron™ Page D-37UNIVERSAL ALTERNATOR TOOL ti SET S882 SEESSRALOODS BES SSe888 Feceerepsee ner VA 640A — UNIVERSAL ALTERNATOR “SERVICEMASTER™ TOOL SET” for COMPLETE alternator servicing on ALL systems! Romoves and installs: Bearings Diodes Slip Rings + with ail operations in the vise! EXTRA BONUS: — FREE WITH EACH SET OF TOOLS! 363-4 108-page, factory-approved Alter- nator Service Manual! Dp 756 24" x 32" Too! Board for wall mounting. Lithographed in two colors, FACTORY-APPROVED ©ALTERNATOR f B TOOL CROSS-REFERENCE CHART This chart shows the wide use and application of every DRAF Alternator Service Tool, Wherever Pocelble, DRAF engineers have combined design features 0 ‘give you the greatest value for your ‘too! dollar. ALTERNATOR SYSTEM thet eSCIPTION ccsien pevcornon FoRD LEECE:, MOTOROLA PRESTOLITE * Gwoga Puller Arbor, NuR and Sleeve ele x x = Pulley Removal Jovs x * x = Paley ene Frame Removal Jaws x Stn‘aig Removal Jaws * x Be Ree erame Removel Jams 7 Bove End Frame Removal Jews x ix x orve Ey rome Removal Jews : Orv ENpuley and Drive En x = 2 1 Boarng Removal Jaws * 1 va 603, | Unwertal Drve End Frame installr x eo pom 7 x Ya 604a | Universal Bearing Remover x x x x x Yh Goes | versal Bearing Installer : eoheLoe * x Xk GER | Unereat sip fing Ena Frame Support a for Bearing installing LJ 7 “ " ‘A 607A 1 Siip Ring End Frame Support 5 7 : | for Diode Removal - va 6088 | Unwersal Diode Remover * « * 7 WA Goo | Unveral Diode Insta zl * = a SA Ge | Brush Soreoaer x PYRG | Banta Vise Hotaing Fsture and 7 ae Te 7 2 | Pres Suppor WA 651. | Unversal arbor Alignment Collar 7 wolel x im x VA 6st? Unversal Prose Kt z raga] 8 a Wa GSE | Rew Bearing Remover and intaler = "VA 657. | Press-Fit Pulley Adapter Kit i x * YA Get | Unversal Shp Ring End Frame Support Ur stetg Remora and Orve « x in|» : “ ; Bane'Sibor tor bening retaline | Hest Sink Suppor for Bode Femoval x x a eee Suptert for Diode instaling > x * Brn Hoiing Pe Le Pilly Service Sot x Gnersal Heat Dam Sat - Toh wb. z S | Rotor Separetor x * x | Rotor Separator “ * | Gniverset Rotor Pole Shoe, tnstaler * x |x| Loote Newte Rotor shat Support | : * _} Uren Reto Sat Suppor ap ae ‘| TESTERS a 3: gece e a i Tel aad Kit : 7 ee ye Dibbe Stor and Rotor Tester" ™ x et ef ae Denotes New Too! eWhen combined, becomes D 1910 Puller====DELCO- REMY. "DELCOTRON" SERVICE MANUAL Tl, IMPORTANT Since the "Delcotron” and regulator are designed for use on only one polarity system, ; the following precautions must be observed when working on the charging circuit. tt Failure to observe these precautions will result in serious damage to the electrical equipment. : 1, When installing a battery, always make absolutely sure the ground polarity of the 2 battery and the ground polarity of the "Delcotron" are the same. : 2, When connecting 4 booster battery, make certain to connect the negative battery : terminals together and the positive battery terminals together. 3. When connecting a charger to the battery, connect the charger positive lead to i the battery positive terminal and the charger negative lead to the battery negative terminal. 4. Never operate the "Delcotron" on open circuit. Make absolutely certain all con- nections in the circuit are secure. 5. Do not short across or ground any of the terminals on the "Delcotron" or regulator. {ry 6. Do not attempt to polarize the "Delcotron". . INSPECTION Even though the “Delcotron" is constructed to give long periods of trouble-free ser~ i 1 vie a regular inspection procedure should be followed to obtain the maximum’ life from the "Delcotron. t Inspection t The frequency of inspection is determined largely by the type of operating cond!~ ; tons, High speed operation, high temperatures, and dust and dirt all increase the wear : of brushes, slip rings and bearings. i ‘At regular intervals, inspect the terminals for corrosion and loose connections, ‘and the wiring for frayed insulation. Check the mounting bolts for tightness, and the belt for alignment, proper tension and wear, Belt tension should be adjusted in accord- ‘ance with engine or vehicle manufacturer's recommendations. When tightening belt ten— sion, apply pressure against the stator laminations between the end frames, and not against either end frame. ‘Noisy Generator Noise from a “Delcotron" may be caused by worn or dirty bearings, loose mounting i bolts, a loose drive pulley, a defective diode, or a defective stator, DISASSEMBLY | After extended periods of operation, or at time of engine overhaul, the “Delcotron" may be removed from the vehicle for a thorough inspection and cleaning of all parts. 4 ‘The "Delcotron" consists of four main components---the two end frames, the stator, 4 and the rotor. ie When repairing the "Delootron” complete disa: smbly may not be required. In some { cases it will be necessary to perform those operations which are required to repair or 4 replace the defective pert. However, the complete overhaul {s covered step by step to i provide detailed information on each operation. si ‘A. Preliminary Disassembly f ‘Take out the four thru-bolts, and soparate the drive end frame and rotor assembly i from the stator assembly by prying apart with a screwdriver at the stator slot. ‘The fit 4 ‘botwoen stator and frame is not tight, and the two can be separated easily. Note that ¥ the seperation is to be made between the stator frame and drive end frame. After disas~ a embly, place a piece of tape over the slip ring end frame bearing to prevent entry of 4 dirt and other foreign materiel,= DELCO-REMY "DELCOTRON" SERVICE MANUAL=== qo hold stator securely in the end frame, insert two thru bolts through clearance oteg of end frame with the heads resting against the shoulder of the stator frame. toler stotor holders VA668 onto the threaded ends of thru bolts and hand tighten, ure 6. S00 OEE, This operation permits safe handling of end frame and stator during APrervice operations not requiring stator removal. 8. moval ‘Wie the slip ring end frame assembly 1s separated from the rotor and drive end rape sazombly, the brushes will fall down onto tho shaft and come in contact with the faptcant. If tho brushes are to be reused, they must be thoroughly cleaned with @ soft doth. Also, the shaft must be thoroughly cleaned before assembly. ‘the brush springs should be inspected for any evidence of damage or corrosion. Ifthere 1s any doubt a8 to the condition of the brush springs, they should be replaced. Timove the brush holder assembly from the end frame by detaching the two brush holder assembly screws. . Pulley Removal Late models have a hexngon-shaped hole inthe pulley end of the rotor shaft instead of « ‘moodrulf key, Place the hex end of VA 673. in opening of rotor shaft and the other end tha vise, See figure 3. —""" |, Remove shaft nut, washer and position puller arbor D1S on rotor shatt. 2! Place pulley removal jaws CK507 in groove of pulley and the other end on the puller arbor nut. 3. Hold removal jaws and puller arbor in position with holding sleeve. 4] Place puller arbor DIS in the hexagonal opening of vise holding fixture VA 650, see figure 4. %. Supporting rotor with hand, turn puller arhor with wrench until pulley is removed. NOTE: Tho use of vise holding fixture VA6SO eliminates possible damage to rotor and drive end frame. D. Drive End Frame Removal T. Remove fan, woodruff key and collar. 2! Position puller arbor D15 on rotor shaft and place drive end frame removal Jews CKSII on bearing retainer plate of drive end frame. '3, Remove the drive end frame in the same manner as described in paragraph C. See figure 5. Fig.4-Removing Pulley Page D-41shake Si ‘ === DELCO-REMY “DELCOTRON" SERVICE MANUAL: Fig.5-Removing Drive End Frame Fig.6-Removing Drive End Frame Bearing NOTE: Do not attempt to remove by supporting the end frame and press~ ing on the shaft, This will result in distortion of the end frame or stripping of retainer plate screws. E, Drive End Bearing Removal (Vise Method) + 1, Remove the three bearing retainer plate screws, bearing retainer plate and gasket. 2. Center support VA663 on the inside of drive end frame and position bearing remover VA603 on the inner race of bearing. 3. Carefully place entire assembly in a vise and slowly close vise jaws until the bearing is pressed out of the end frame. See figure 6. 4, If the bearing 1s in satisfactory condition it may be reused and should be filled one-quarter full with Delco-Remy lubricant No. 1960373 before reassembly. CAUTION: Do not over fill as this may cause the bearing to overheat. F, ‘Blip Ring End Frame Bearing Removal (Vise Method) * The bearing in the slip ring end frame 18a press fit and should be replaced if its, grease supply is exhausted. No attempt should be made to relubricate and reuse the bearing.. 1, Remove tape and support the fend frame on support VA661. 2, Position bearing remover VA6O4A. 1n the roller bearing and place entire as- sembly carefully na vise. See figure 7. 3. Close vise jaws slowly until bearing is pressed out of frame. G. Stator Removal, 1, On earl connectors attaching diode and stator leads ‘by cutting the connectors below the crimp with end cutters. 2. On current models remove all three stator lead attaching nuts. ‘Arbor press may be used in place of vise. —_Fig.7-Removing Slip Ring End Frame Bearing Page D-42é -—— DELCO - REMY "DELCOTRON" SERVICE MANUAL Fig, 8-Exploded View ot Heat Sink Assembly 3. Separate the stator from the slip ring end frame by prying apart with a sorew- driver. The fit between the two is not tight end separation can easily be made. Diode Removal (Vise Method) * ‘When servicing diodes note that negative diodes have black markings on the case and positive diodes have red markings on the case. Always test diodes as described on page 45 before removing. On garly modele s gull shaped heat sink te used. It 1s necessary to remove the heat sink for diode replacement. This is done by detaching the two terminal bolts from the end frame and cutting the diodes below point of crimp. ‘On current models @ horseshoe shaped heat sink with terminal type diodes is used. Terminal type diodes eliminate cutting connectors and soldering terminals to stator leads. is not necessary to remove the heat sink for diode replacement. However, if desired, {t may be removed by detaching the “BAT” and "GRD" terminals from the end frame and the serew attaching the condenser lead to the heat sink. Note carefully the proper stack-up of parts for reassembly as shown in figure 8 1. Position support VA607A over diode in end frame or support VA66S over diode in heat sink. 2, Place diode remover VA608B on diode. 3° Carefully place entire assembly in a vise closing vise jaws slowly until diode 4s pressed out of end frame or heat sink. See figures 9a and 9b. ‘NOTE: Support VA607A is cut-a-way end slotted to fit over the wires and ‘around the bosses of the slip ring end frame, This tool must completely surround the diode. CAUTION: Do not strike the diode as the shock may demage the other diodes. may be usod in place of vi Fig. 3b-Removing Diode From Slip Ring End Frame 4 Page D-43 Pat asampSERVICE MANUAL === DELCO- REMY “DELCOTRON (ctex ror orouNos) (oor ror ores) (eater fox sHonts AND Ores) connanaéren Fig.10~Checking Rotor for Grounds, (eves FoR FEN) (ex ron enous) Shorts and Opens Fig.l-Chocking Stator for Opens and Grounds V. TESTING OF COMPONENTS ‘The rotor may be checked electrically for grounded, open, or short circuited field colls. To check for grounds, connect Draf Tester No VAG688 or an ohmmeter from either slip ring to the rotor shaft or to the rotor poles. If the lamp lights, or if the ohmmeter reading is low, the fleldewindings are grounded. (figure 10). ‘To check for opens, connect the Tester or ohmmeter to each slip ring. If the lamp fails to light, or if the ohmmeter reading 1s high (infinite), the winding is open. {figure 10), ‘The windings are checked for short-circuits by connecting a battery and ammeter in series with the two slip rings. Note the ammeter reading and refer to Delco-Remy Service Specifications contained on page 59, An ammeter reading above the specified value indi~ cates shorted windings. An alternate method is to check the resistance of the field by connecting an ohmmeter to the two slip rings. (figure 10). If the resistance reading is below the specified value, the winding is shorted. The specified resistance value can be determined by dividing the voltage by the current given in Specifications on page 59, If the rotor is not defective, and the "Delcotron" fails to supply rated output when checked ag covered in the section entitled Checking “Delcotron" Output, the trouble is in the stator or rectifying diodes, ‘Stator Checks ‘The stator windings may be checked with Drof Tester No, VAB88 or an chmmeter. If ‘the lamp Lights, or if the meter reading is low when connected from any stator lead to the frame, the windings are grounded. If the lamp fails to light, or if meter reading is high when successively connected between each pair of stator leads, the windings are ‘open. (figure ll). A short circuit in the stator windings 1s difficult to locate without laboratory test ‘equipment due to the low resistance of the windings. However, if all other electrical | | | | | | F |== DELCO- REMY "DELCOTRON” SERVICE MANUAL checks are normal and the generator fails fo supply rated output, shorted stator windings are indicated. ‘Diode Checks Zach diode may be checked electri- colly fora shorted of open condition. Any Gne of the methods outlined below may be used. ‘CAUTION: Do not use 110-volt test Tights on diodes. A, Ohmmeter Method Ope method of checking diodes is touse an ordinary obmmeter commonly found in service stations. The lowest range scale on the ohmmeter should be used, and the ohmmeter should have a es 11/2 volt cell. To determine the cell a <> a veto arn tho Sloot f the lowest Caney ctomen scale, and then connect the ohmmeter leads to a voltmeter. The voltmeter Fig.12-Checking Diodes will indicate the cell voltage. With the stator disconnected, check a diode in the heat sink by connecting one of the ohmmeter leads to the heat sink, and the other ohmmeter lead to the diode lead, and note the reading. (figure 12). Then reverse the chmmeter lead connections, and note the reading. If both readings are very low, ot if both readings are very high, the diode 1s defective, A good diode will give one low reading and one high reading. Check the other two diodes in the heat sink in the same manner, To check a diode mounted in the end frame, connect one of the chmmeter leads to the end frame, and the other ohmmeter lead to the diode lead (figure 12), and note the reading. Then reverse the ohmmeter lead connections, and note the reading. If both readings are very low, or if both readings are very high, the diode is defective. diode will give one low reading and one high reading. Check the other two diode: the end frame in the same manner. 1 B. Test Lamp Method “ A good. 1s in In alternate method of checking the diodes is to use a Draf Tester No. VA688 in place of the ohmmeter. ; Do not use 10-volt test lamps to check diodes. With the stator disconnected, connect the test lamp leads across each diode as previously described first in one direction and then in the other. If the lamp lights in both checks, of fails to light in both checks, the diode is defective, When checking a good diode, the lamp will Light in only one of the two checks. ‘Special Tester Method ‘Special diode testers are available which operate without disconnecting the stator. ‘To use these testers, follow the tester manufacturer's recommendations. ‘Silp Ring Servicing Tf the slip rings are dirty, they may be cleaned and finished with 400 grain or finer polishing cloth, Spin the rotor in a lathe, or otherwise spin the rotor, and hold the polishing cloth against the slip rings until they are clean. ‘CAUTION; The rotor must be rotated in order that the slip rings will be cleaned ‘evenly, Cleaning the slip rings by hand without spinning the rotor may result in flat spots on the slip rings, causing brush noise. : ‘slip rings which are rough or out of round should be trued in a lathe to .002 inch ~* imaxdmum indicator reading. Remove only enough material to make the rings smooth and round. Finish with 400 grain or finer polishing cloth and blow away all dust. Page D-45 mre me: p== DELCO- REMY "DELCOTRON" SERVICE MANUAL Pig.13-Installing Diode in Heat Sink Fig.4-Installing Diode in SIipRing End Frame Vi, REASSEMBLY Ay Diode Installing (Vise * retort the heat sink and or slip ring end frame with support VAG66, and start new dice squarely into the heat sink and or slip ring end frame with diode installer VAGO9. 2. Carefully place entire assembly in a vise, closing slowly until the diode ts fully provsed Anto the heat sink and or slip ring end framo. See figures 19 and Wt 3. if hoat sink has been removed install it back into the end frame following care- filly the proper stack-up of parts. If the heat sink being installed 18 a now one substi- BY he viachers provided for the old matching washera on the terminalo, Also substitute the new rubber vibration dampeners for the old ones. The rubber vibration dampenors ‘should always be replaced if they have become hardened. B. Stator Installing E T, On current models place the new stator onto the end frame, locate connectors over the leads and attach all three stator lead attaching nuts. ne 1G arly models crimp the connectors with pliers only tight enovgh to hold the connectosr ome the leads. After crimping the connectors fill themwith a resin core 60% tin and 40% lead solder. C. Slip Ring End Frame Bentina i ise. * {, Support the inside of the slip ring end frame with support VAS06A. 2, Position bearing installer VA60SA over roller bearing making sure that bear- tng enters slip ring end frame squarely. 3, Carefully place entire assembly in fa vise closing slowly until the bearing 1s flush with the outside of frame. See figure 1S. 4, Place wide piece of tape over boar ing to prevent entry of dirt and other foreign matter. ‘Arbor press may be used in place of vise. Fig.1S-Installing Slip Ring End Frame Bearingoe ty ——— DELCO - REMY "DELCOTRON® SERVICE MANUAL==—= ®. gy ¥ Fig.16-Installing Drive End Bearing Pig.17-Installing Drive End Frame D. Drive End Bearing Installing (Vise Method)* 1. Support drive end frame on the large side of support VA661 and insert bearing 2 squarely into the drive end frame. y 21 Place bearing installer VAGOSA on bearing and position entire assembly in a vise. 31 Close vise slowly until the bearing is flush with the inside of the bearing hub. see figure 16. 4 Install gasket, bearing retainer plate and three screws to hold bearing retainer plate in place, Install a now bearing retainer plate if the felt seal in the old retainer a plate ts hardened or excessively worn, Saturate tho felt seal with S.A.E. 20 oil. E. Delve End Frame Installing (Press Method) 1, Install spacer on rotor shaft. i 2! Assemble prese kit VA6SS in accordance with instructions contained on page 21. 3, Position the bearing and drive end frame on the rotor shaft. 4, Place entire assembly in the opening of press support. a 5. Position installer VA603 on the inner race of bearing and insert special adapter + VAGSI on top of installer. See figure 17. 6. Press the bearing and end frame on the rotor by turning arbor with . _awrench until the bearing contacts the spacer on the roter. ‘NOTE: The use of special adapter VAGS1 servos a a centering guide for the arber and prevents possthle damage to installing tool. e. 1. Install the brushes into the brush holder end insert brush holder pin VA667 into the hole at the bottom D HOLE FoR PIN i of the brush holder to retain the brushes. Seo figure 18. 2. Attach the brush holder assem ‘, i bly onto the end frame, noting carefully the ee 2 in proper stack-up of parts as shown infigure 18. te q ‘thtbor press may be used in place of vise. i Page D-47—} yoreantes se see DELCO- REMY “DELCOTRON" SERVICE MANUAL =—— BRUSH HOLDER JEMBLY DELCOTRON. Trane | Fig. 19-Holding Brushes in Brush Holder Fig.20-Checking "Delcotron" for Output 3. Allow brush holder pin VA 667 to protrude through the hole in the end frame. See figure 19. Final Reaszenbly fall collar, woodruff key, fan, pulley washer and shaft nut using tool VAG73. . When tightoning the shaft nut {t'ts necessary to prevent the pulley from slipping. Place a fan belt in the pulley groove and carefully place in a vise. Close vise slowly fon belt avoiding excess viso pressure on pulley and tighten shaft nut to 50-60 ft, Ibs, GAOTION: If oncessive pressure is applied against the roter, tho assombly may become distorted. 2. Remove tape over slip ring end frame bearing and remove stator holders. Assemble the two end fremes only. Tighten thru bolts. Withdraw brush holder pin VA. 667 allowing the brushes to drop onto the slip rings. . Rotate the pulley slowly by hand to be sure that the rotor spins freely and that leads are not striking rotor. ‘Vil. OUTPUT CHECK ‘To check the “Delootron" on a test bench, make electrical connections as shown 4n figure 20, operate at specified speed, and check for rated output as given in Delco- Romy Specifications on page 59. Adjust the load rheostat, if necessary, to obtain the desired output. ; On negative ground "Delcotrons", connect the negative battery post to the "Delcotron" frame, and on positive ground "Delcotrons" connect the positive bat- tee en a “Delcotron" frame. [conronin] a Rowe rien owned Tower emp tom tpg es | Lava Heb Cen hemo iat vers One Vida mp cn ng te at alt one evar od onesie np ott | Obert od am | Compe ccowaaine sees eoriens [eae | osm bonis ore errow i oe ovo at mp om oa eae seer abe Gromeed "DELCOTON” CHES eater ae ech pr of eas Anyrasing bah | Opan Movie ou woh pr eteds | Ft es Onn [beds | Oem cue did, ane Tonvotnarvoviow | Shamed aur. tm ning oot | Oven 1aenien ian cron dota, es rove | tampon | Oper econ toc Sennen | some Page D-48eae eines Raped * ==DELCO-REMY (DELCOTRON) ALTERNATOR SERVICE MANUAL TWO-UNIT REGULATORS (DOUBLE CONTACT VOLTAGE REGULATOR TYPE USED WITH "DELCOTRONS" *) FOR "DELCOTRON" SPECIFICATIONS, SEE PAGES 58 and 59 Figure 1—Typical two-unit regulator. This bulletin covers maintenance and checks of double contact regulators commonly used with the continuous-output self-rectifying a,c. gener- ators called “Deleotrons.”* A typical double contact regulator is shown in Figure 1. This regulator has four terminals and is used in circuits with an indicator lamp. Some Models may have a fifth terminal on.the under- heath side of the regulator to which a condenser for radio suppression can be connected. CAU- TION: Do not connect anything to this terminal other than a condenser. ‘The terminals are of the slip-connection type, and ‘8 special connector on the vehicle ‘wiring harness is keyed to mating slots in the regulator base to insure proper connections. Also, a pro- jection on the connector body serves to latch the assembly together. This prevents disconnections due to vibration, The assembly can be discon- nected by lifting the latch slightly. (Fig. 1) A double contact voltage regulator unit and a field relay unit make up the regulator assembly. ‘The voltage regulator unit operates to limit the “Delcotron” voltage to a pre-set value whereas the field relay connects the “Deleotron” field Winding and regulator winding directly to. the battery. When ignition switch is first turned on the charge indicator lamp lights. Then, when the “Deleotron’” begins to charge, the indicator lamp goes oul, indicating the system is operating normally. If the lamp should come on when the “Delcotron” is in operation, trouble in the system is indicated. * General Motors Trademarie Page D-49 i { at = DELCGO-REMY (DELCOTRON) ALTERNATOR SERVICE MANUAL== REGULATORS Bach model regulator used with the “Deleotron” is designed for use on only one polarity system. ‘To determine the polarity note the marking on the regulator base, or refer to Delco-Remy Serv- ice Bulletin 1R-186, to determine if polarity of the regulator is negative or positive. IMPORT- ANT--On electrical systems using these regula- tors, the polarity of the regulator, the “Deleo- tron” and the battery must be the same. When ‘insialling any one of these three units, do not make any connections without first checking the polarities. ‘The regulators covered in this bulletin may be used with different types of “Deleotrons.” Al- ‘though a typical model of “Deleotron” is shown Jn the wiring diagrams which follow, all testin procedures in this bulletin apply regardless o! the type of “Delcotron” used in the circuit. OPERATING PRINCIPLES A typical wiring diagram showing internal cir- cuits of the regulator is illustrated in Figure 2. Following is a brief description of the operating principles of the units in this type of circuit. When the ignition switch is closed, before the engine has started, the indicator lamp lights to indicate the. “Deleotron” is not charging. The current flow can be traced from the battery to the “BAT” terminal on the switch, through the indi- ator lamp and resistor which is in parallel, and ‘then through the voltage regulator contacts. From here it continues to flow on through the “Deleotron” field winding to ground, completing auncrion fin the circuit back to the battery. Current through this circuit energizes the field windings sulfi- ciently to insure voltage build-up in the stator windings when the engine starts, The voltages generated in the stator windings are then changed or rectified by the six “Deleotron” di; oes toa dc. voltage which appears atthe “BAT” or output terminal on the “Delcotron.” The resis. tor allows more current to flow through the field winding to insure voltage build-up in the stator windings. ‘As the “Delcotron” begins to operate, voltage from the “R” or relay terminal is impressed through the regulator No. 2 terminal across the field relay winding, causing the relay contacts to close. This connects the regulator No. 4 termi- nal directly to the battery through the field relay contacts, causing the indicator lamp to go out. “Deleotron” field current then flows from the battery to the regulator No. 3 terminal, and then through the field relay contaets and voltage regu- lator lower or series contacts to the field winding. As the speed of the ““Delcotron” increases, the voltage at the “BAT” terminal of the “Delco- tron” also increases. This impresses a higher voltage through the field relay contacts and across the voltage regulator shunt winding, The increased magnetism created by this higher voltage across the winding causes the lower or series contacts of the relay to separate. The fleld current then flows through a resistor which reduces the field current, This reduced field cur- ‘rent causes the “Deleotron” voltage to decrease ‘thereby decreasing the magnetic pull of the voltage regulator shunt winding. Consequently the spring causes the con- tacts to reclose. This cycle repeats many times per second to limit the “Delco- tron” voltage to a pre-set value, ‘As the “Delcotron” speed increases even ‘ACTO88 ImoIcATOR further, the equator Tie _YOUTAGE. Rey _AEGULATOR ‘DEICOTEON Figure 2—Typical wiring diagram showing internal circuits, Page D-S0 ‘resistor, connected the contacts, is not of sufficiently value to maintain voltage control on the contacts. Therefore the voltage in- reases slightly causing the upper or hhorting” contacts to close. When this happens, the “Deleotron” field winding is shorted and no current passes thro. the winding, With, no current in the field winding, the “Deleotron” voltage decreases, which also decreases the mag- netism in the shunt winding and the upper contact points open. With these points open, field current flows throu the resistor and the field winding. the voltage increases, the contacts re- close. This cycle then repeats many times per second to limit the “Deleo-bate eR Figure 8—~Typieal wiring diagram showing basic lead connections, ‘4zon” voltage to a pre-set value at high gener- ator speeds, ‘The voltage regulator unit thus rates to limit the value of “Deleotron’” voltage throughout the “Deleotron” speed range. Conse- quently the electrical accessories are protected from excessive voltage which would cause Sainage, ANALYZING CHARGING SYSTEM TROUBLES A typical wiring showing basic lead ‘connections to the regulator is shown in Figure 3. Note: An ammeter may be used in this circuit without an indicator lamp. In this case, sections pertaining to the indicator lamp do not apply. ‘Trouble in the charging system will usually show ‘up as one or more of the following conditions: A, Faulty indicator lamp operation. B. An undercharged battery as evidenced bj slow cranking. ” O- An ove 1d battery as evidenced by excessive water usage, The following precautions must be observed when, working on the charging circuit. Failure to these precautions will resvit in serious damage to the electrical equipment, © Do not polarize the “Delcotron.” Do not short across or ground ai of the ‘on the “Delcotron” or regi tor. » == DELCO-REMY (DELCOTRON) ALTERNATOR SERVICE MANUALS== REGULATORS © Never operate the “Deleotron” on open circuit. Make absolutely cer- tain all connections in the circuit are secure. © Since the “Deleotron” and regula- tor are designed for only one po- larity system; always make abso- lutely sure the ground polarity of the battery and the ground polar- ity of the “Deleotron” are the same when installing a battery. © When connecting a booster bat- tery, make certain to connect the negative battery terminals to- gether and the positive battery terminals together. © When connecting a charger to the battery, connect the charger posi- tive lead to the battery positive terminal and the charger ne tive lead to the battery negative terminal. Before making any electrical checks, visually in- spect all connections, ineluding the’ slip-on con- nectors at the regulator and “Deleotron,” to make sure they are clean and tight, then proceed. Since the regulator terminals are of the slip-on type, universal regulator testing kit VA676 must be used during testing so that meter connections HARNESS CONNECTOR Figure 4—Checking indicator lamp eireit. Page D-51== DELCO-REMY (DELCOTRON) ALTERNATOR SERVICE MANUAL== REGULATORS WIRING HARNESS: CONNECTOR Figure $—Checking indicator lamp eireuft. can be made to the terminals. CAUTION: To check the charging system, Insert the adapter into the regulator, making connections only as shown in the illustrations. Avoid contact with the units when replacing the regulator cover. A. INDICATOR LAMP CIRCUIT ‘The indicator lamp on many applications is a No, 87 bulb rated at 12 volt 2 candlepower. If the in- dicator lamp, fails to light, turn the ignition switch to the “IGN” position, but do not start the e. Momentarily (for not more than 10 sec- onds) connect a jumper lead from the adapter to ground as shown in Figure 4. If the lamp does not come on, check for a burned out bulb, or an open in the wiring between the battery and the jumper lead. If the lamp comes on, connect the jumper as shown in Figure 5, If the lamp comes ‘on again, the circuit is open in the regulator. If it does not come on, there is an open in the field lead between the regulator and “Deleotron” or in the “Deleotron” field. Failure of the lamp to go out with the “Delco- tron” in ration is an indication of trouble elsewhere in the system. The possible causes of this are covered under Steps 1, 4, and 5 in Page D-52 “Undercharged Battery” section. Also, if the Jamp fails to go out when the ignition switch Ss turned off, the “Deleotron” probably has a shorted diode in the heat sink. The shorted diode will reduce the “Delcotron” output and cause a jis battery. Also, a discharged battery will oceur overnight with the vehicle not operat- ing, sinee the battery will discharge through the shorted diode and field winding even though the switch is turned off. B, UNDERCHARGED BATTERY ‘This condition, as evidenced by can be caused by one or more of the following conditions even though the indicator lamp may be operating normally. 1, A loose “Deleotron” drive belt. 2. A defective battery. 8, Excessive circuit resistance. 4, An open resistor. 5. Malfunction of field relay. 6. A defective “Deleotron.” 7. A low voltage setting, 1. Loose “Delcotron” Drive Belt: ‘The “Delco- tron” drive belt should be tightened in accord- WIRING HARNESS ‘CONNECTORMe m= DELCO-REMY (DELCOTRON) ALTERNATOR SERVICE MANUAL== REGULATORS wiRin ‘CONNECTOR vas76 Figure 7—Checking field relay. ‘once with engine or vehicle manufacturer's rec- mendations, 2 Defective Battery: A battery which is sul- Fhatelh or one with an intermittent “open” at either a terminal post or in one of the cell con- nectors, will remain in an undercharged condi- tion under normal operating conditions. 8. Excessive Circuit Resistance: Visually inspect ail connections to make sure they are clean and tight. ; 4, An Open Resistor: To check for an open re- sistor (connected to the ignition switch “ACC” terminal), connect a voltmeter from the adapter to ground as shown in Figure 6. Turn the igni- tion switch to the “ACC only” position. If the vollmeter reads zero, the resistor is open, The resistor may be a separate unit, or it may be in the form of resistance wire. The resistance value ds 10 ohms, and the wattage rating is 6.25 watts minimum, on many applications. 5. Malfunction of Field + If the indicator lamp operates normally, the field relay is operat ing normally, and no further checks need be made on the field relay. However, if the indi; eator lamp fails to go out with the “Delcotron” m operation, the fault may be in the field relay, or in the “Deleotron,” ‘To determine which is at fault, proceed as follows: 4, “Make connections to the adapter as shown in Figure 7. b, Operate the “Delcotron” at moderate speed, and observe the voltmeter reading. ¢. If the voltmeter reading is 5 volts or above, and the indicator lamp fails to go out, the field relay is defective and must be checked as covered in “Testa and Adjust- menta” section, . If the voltmeter reading is below 5 volts, trouble in the “Deleotron” is indicated. Proceed to section entitled “Defective ‘Del- 6, Defective “Delcotron”: To determine if the “Deleotron” is operating properly, proceed os follows: ‘a. Connect an ammeter in the eireuit at the “BAT” terminal of the “Deleotron,” and a voltmeter from the “BAT” terminal to ground. b. Make connections to the adapter as shown in Figare 8 e. Turn on switch, operate “! "at specified speed, and check for rated output as given in Deleo-Remy Service Specifications CAUTION: Load the battery with a carbon pile ‘rheostat or accessories to prevent high voltage. Do not allow the “Delcotron” voltage to exceed the recommended voltage setting of the regula- tor. WIRIN CONNECTOR ia== DELCO-REMY (DELCOTRON) ALTERNATOR SERVICE MANUAL=—= REGULATORS If the “Delcotron” does not provide rated out- ‘put, it should be checked as covered in the appli- cable Deleo-Remy Service Bulletin. 1. Low Voltage Regulator Setting: If no circuit defects ate found, yet the battery remain un- dercharged, the cause most likely is a low voltage regulator setting. In this ease, proceed to section entitled “Tailoring The Voltage Setting.” C, OVERCHARGED BATTERY An overcharged battery as evidenced by exces- sive water usage, can be caused by: 1. A shorted battery cell. 2, Excessive circuit resistance. 8. Ahigh voltage regulator setting. 1, Shorted Buttery Cell: Checks for shorted bat- tery cells should be made as this can cause the battery to be overcharged. 2, Excessive Cireuit Resistance: Visually inspect ail comections to make rare they are clean and it. 3, High Voltage Regulator Setting: If no circuit detects arg foun yer the betters romans overs charged, the cause is probably ® high voltage regulator setting. In this case, refer to section entitied “Tailoring The Voltage Setting.” TAILORING THE VOLTAGE SETTING It is important to remember that the voltage set- ting for one type of operating condition may not be satisfactory for a different type of operating condition, Vehicle underhood temperatures, operating speeds, and nighttime service all are factors which help determine the proper voltage setting. The proper setting is attained when the UPPER CONTACT ARM POINT OPENING [ff (BEND To ADJUST POINT (LowER POINTS JUST TOUCHING), AIR GAP (LOWER POINTS JUST TOUCHING) TURN NUT TO SET AIR GAP Figure 10—Checking voliage regulator air esp. battery remains fully charged with » minimum use of water. If no circuit defects are found, yet the battery remains undercharged, raise the by 3 volt, and then check for an improved battery condition over a service period of reasonable length, If the battery remains overcharged, lower the setting by .8 volt, and then check for an improved battery condition, Recommended voltage setting procedures are covered in seo- tion entitled “Tests and Adjustments.” ‘TESTS AND ADJUSTMENTS ator checks and adjustments are made as follows: VOLTAGE REGULATOR UNIT ‘Three checks and adjustments are required on the voltage regulator unit: (1) point opening, (2) sir gap, and (8) voltage setting. If the yoltage ean be properly adjusted the point open- ing and air gap need not be checked. 1. Point Opening: With the lower contacts touching, measure the point opening between the upper contacts as shown in Figure 9. Ad- just by bending the upper contact arm (Fig. 9), being careful not to bend the hinge. 2, Air Gap: Measure the air gap with a fecler gauge between the armature and core when the Jower contacts are touching as shown in Figure 10. To adjust the air gap, turn the nylon nut located on the contact support (Fig. 10). NOTE: Only an approximate voltage regulator air gap setting should be made by the “fecler gauge” method, The final air gap setting must be$ osicon MY (DELCOTRON) ALTERNATOR SERVICE MANUAL== Bs to check and adjust the volt- * age setting, Dr “lowe! A. Connect an ammeter and {BL Voltage Setting: The volt- cover, “qliusting the voltage setting, Sleays refer to wpecifcations, aver specified difference ‘voltage ‘the upper ower sets of ais covered in the next at which the regulator jes with chai as fol- 434 ohm resistor with a rating of 25 watts or more in series in the circuit at the “BAT” terminal on the “Delcotron.” (Fig. 11) In case the battery is discharged, the 14 ohm resistor will limit the “Deleotron” output to 10 amperes or less which is required when checking and adjusting the voltage setting. VARIABLE RESISTOR WIRING HARNESS CONNECTOR REGULATORS REGULATOR Figure 11—Connections for checking voltage vetting. B. Make connections to the adapter as shown in Figure 12, Use a 25 chm 25 watt variable resistor in series with the “Delcotron’® field winding at the regulator “F” terminal, and connect a jumper lead from the adapter to the “Deleotron” output or “BAT” terminal as shown. Also, connect a voltmeter from the adapter to ground, as shown. Turn the variable resistor to the closed or “no re- sistance” position. C. Operate the “Deleotron” for 15 minutes at approximately 1500 engine rpm (approxi- mately 3500 “Deleotron” rpm). Leave cover on regulator to establish operating tempera- ture "Accensoris and lights must be ‘turned D. After the 15 minute warm-up period, cycle ‘the regulator by the following procedure: (a) Turn the variable resistor in the field cireuit to the “off” or full resistance position. (b) Disconnect the lead at the No. 4 termi- nai on the wiring harness connector. (@) Re-connect the lead at the No. 4 termi- nal on the wiring harness connector, can (a) Return the variable resistor to the closed or “no resistance” position. Page D-55= DELCO-REMY (DELCOTRON) ALTERNATOR SERVICE MANUAL == REGULATORS E, To adjust voltage setting, turn adjusting screw as shown in Fig, 1§, IMPORTANT: In order to prevent accidental ground: consequent damage to internal sor Barts While removing cover ‘or replacing cover always perform the following steps “q through “e” in the order listed. a. Disconnect regulator adaptor No. 4 lead af wiring harness connoctor, isconneet jumper generator “BAT terminal, Remove, or install, cover. Reconnéet jumper lead at generator . Reconnest No. 4 lead at harness con- a ae CAUTION’ hoor turn sorow sieshuioe to mate ae lege, tare ca alas ee feat fom ADJUSTING SCREW] — f”"“Krtar making the setting, eycle the regula tor as covered in “Step D" (TURN TO ADJUST VOLTAGE SETTING) Figure 13—Adjusting voltage setting (@) Bring engine speed up to 2600 (approximately 6000 “Deleotron’ oa) and note the voltage setting, Refer to Deleo-Remy Service Bulletin 1R-186 for specifications, The regulator should be operating on the upper or shorting contacts. If it will not operate on the upper contacts, the battery is in an extreme state of discharge, and must be at least partially re-charged before Prceecting, The methods of identity. upper or lower contact operation are covered in Step I. AIR GAP. Figure 15—Checking field relay point opening. (CHECK WITH POINTS JUST TOUCHING) G. Then, operate at 2500 engine rpm (approxi. 6000 “Deleotron” rpm), and setting. Re-adjust if necessary. H. Always cycle the regulator as covered in “Step D” before the final voltage setting on the alonetor ‘Always read final setting with cover in place. I. After making the voltage setting while oper- ating on the upper set of contacts, check the voltage setting while operating on the lower set of contacts as follows: Slowly increase {he reslatanee of the variable resistor wi ie engine operating at 2600 rpm (approxi- mately 6000-"Delcotron” rpm) unth the regulator begins to operate on the lower set of contacts. ‘Then note the voltage reading, i iy and refer to Deleo-Remy Service Bulletin Ma 1R-186 for specifications. NOTE: If turn- oe Figure 1d—Checking feld relay air gap. ing the variable resistor does not cause the i 13 : Page D-56 ssgulator to operate on the lower set of con regulaveturn the variable resistor to the “no tacts ance” position, turn the carbon pile to resitly load the battery, and then adjust the slighle resistor to cause the regulator, to iy on the lower set of contacts. Usually, operon on the vehicle headlights can substi tite for the earbon pi ‘the most desirable method of determining Fat the regulator is operating on the lower that eontacts is to use earphones connected pee the regulator “FP” terminal to ground. {rothe variable resistor is turned, end oper- ‘Mon changes from the upper set of con: iets to the lower set, the earphone sound er fade away and stop completely and Yhen return when the lower set of contacts iegine to operate. The alternate method is ttobserve the voltmeter change from one Niue to another, but this is less desirable nee it is not as accurate, J. The difference in voltage between the opera- tion of the upper set, of contacts and the ower set is increased by slightly increasing the air gap between the armature and center VARIABLE RESISTOR VOUTMETER WIRING HARNESS CONNECTOR Figure 16—Checking ‘eld relay closing voltage. =p DELCO-REMY (DELCOTRON) ALTERNATOR SE REGULATORS HEEL IRON (BEND TO ADJUST CLOSING VOLTAGE) Figure 17—Adjusting field relay closing voltage, of core and decreased by slightly decreasing the air gap. See Figure 10 for changing the voltage regulator air gap. If it is found neces. ary £0 make this air gap adjustment, it will be necessary to recheck the voltage setting of both sets of contacts. Always final Voltage setting with cover in place. FIELD RELAY UNIT ‘Three checks are required on the field relay: (1) air gap, (2) point opening, (8) closing voltage. 1. Air Gap: With the regulator removed from the vehicle, check the air gap with the points just touching as shown in Figure 14, If adjust- jnent is necessary, carefully bend the flat contact support spring. 2. Point Opening: Measure the opening between the points, and adjust by bending the armature stop. (Figure 15) 3, Closing Voltage: The closing voltage of the field relay may be checked as follows: ‘A. Connect a 50-70 chm variable resistor and & voltmeter to the adapter as shown in Figure 16. ‘Turn variable resistor to the open or “gull resistance” position, and leave the ig- nition switch in the “off” position. Page D-57 RVICE MANUAL== es i== DELCO-REMY (DELCOTRON) ALTERNATOR SERVICE MANUAL——= REGULATORS B. Slowly decrease resistance and note closing voltage of the relay. Adjust by bending heel irop in the manner illustrated in Figure 17. NOTE: If the field relay unit does not, have an armature stop, a point opening check is not required. MAINTENANCE ‘The voltage regulator contacts should not be cleaned uniess the olectrical performance indi- cates it is necessary. A sooty or discolored condi: tion of the contacts is normal after a relatively short period of operation and ig not an indica. tion that cleaning is necessary, However, if the voltage fluctuates as evidenced by an unsteady voltmeter reading when checking the voltage set- ting, the contacts may have excessive resistance or be sticking and they, therefore, should be cleaned. CAUTION: Before cleaning contacts, ‘make sure the unsteady voltage is not. being caused by loose connections or high resistance elsewhere in the system. ‘The contacts on the voltage regulator unit are of a soft material and must not be cleaned with a file. A strip of No, 400 silicon carbide paper or equivalent folded over and then pulled back and forth between the contacts is recommended as a satisfactory method of cleaning. After cleaning, the contacts should be washed with trichlorethy- Tene or aleohol to remove any residue. If the voltage control has not improved, repeat the cleaning and washing process. ‘To clean the field relay contacts, use a thin, fine- eut, flat file, Remove only enough material to clean the points. Never use emery cloth or sandpaper to clean con- tact points. VA 676 UNIVERSAL ALTERNATOR-REGULATOR TESTING KIT Page D-58== DELCO-REMY (DELCOTRON) ALTERNATOR SERVICE MANUAL == i lit | os Anos. Y B “40 | 3000 te: N B ‘60—[-s000-|“s-] I WN 61 | oT BR 3 50 82. W. ¥ 2 50] 000 | —52-| . Ww cps 2 40_| 5000 | 42 x EY 35 0 | tooo || i W pepe 32 ‘605000 ' cy Er 82 ‘66 | 6000 | 62 f wf Tey 38 | 000 | 62 ' {ino0e20 | -N-| 16-263 -|-C [8 a 0[ 5000 | a2 {tioosst |-N[~1G-262-[-c |B} “32_| 2000 [60 | “6000 | 62 [iitosee | N-|-1¢-262 -o] | ‘82 | 000 | 50 6000-| 68 {if00623- | 16-262 [c | B ‘23 | 2000 | 40 |" s000 | 42 jrovezt | N7] 16-202 | ¢_[ 8 "38-|-2000~|—40~[-s000-| az ‘ xia CLE 8 000-| “to 000-42 Rp ie2e [es | 2000"| 80 | 5000 | 2 : Ro ie2e |B {a5_[B000{ 85 —| “000 |~37. LB ‘33 | 2000_| 40 | ~6000-| 4 | N a [-a1_[Bo00: s000_| Be w pepe 35-2000 5000" | 37 x ote 25—[ B00 ‘000 | 37 5 TE 2 000 82 No rete] [28 5000 _| RC C [88 32_| ‘5000. | 6a c a e000 | a wpa i Es 5000 | —37 No] 16-267 z Pa 000 | a |e WN} 1¢20 [co | 3 25 | Bo00_| 37 N | 1G-262 | C [ B| [25 ‘6000 | 87 Np 16202 | OB a '5000-| 32 N_|1G-262 B 38 ‘Bo00 | 42 Nise ops z ‘5000 [ 82} ik ‘furnished without fan. Fan determines direction of rotatic ; SPECIFICAT! FOR REGULATORS USED WITH DELCOTRONS e : 5 Field Bal Voltage Regulator ts Stirs | Er en] me Te a y seu | soon | as ree SS lems SE | AS, eer] g i Teer] Troe 82 [a teas [er is. i Tusb06 [IRB PEON ene [a “p16 _[-080_[28-3.7 080. No.t ‘ 19607 | iR-263 |B | N_ | 42i0 ane) 016 | 080 [63-83 | 060 Noi ee |, Pista Neer fo sees “a6 Not t ‘iiiesi2 | ir-262 |B | N | 4209 = sens] 018 030_ [23-37 | 060 No. i } i ‘+ Tolerance plus or minus 10%. t I RE- VOLTAGE CHART i Begilator Ambient Temperature z ‘Degrees Fahrenhelt 6 86 sos | 5 | sas | 165 | 185 5 Guart No Voluge Seting [100.160 [inease [sar1ee [13504 |1a4142 |1o20 | 131389] t ‘Note: Operation on lower contacts must be 1-A volt lower than on upper contacts, | SPECIFICATIONS FOR INDICATOR LIGHT RELAY }OTOROL ALTER Se Apotoved and Recomended pray [8 ey HO! @* cK 503 CK 507 non HLL 9 @G x 512 cK SIS VA 03, VA 630 VA 653 VA 634 VA 656 emovel “Front Housing Removal Jews ‘Front Housiag Installer ‘Universl Beating Towler ‘Universal Vise Poller Holding FareINTRODUCTION Motorola Alternator and Electronic ‘System is designed for 6 and 12 volt “electrical systems. Three 12 volt, negative ground, systems only, are discussed in this manual, See figure 1, ‘The following chart fF tows tho complete Hat of models evaileble: y Alternator Barly Current Regulator 4 Motelno, Systemno, systemno. Model no, <: AIBNKA51 —a30 ASSNI2—TVRI2XI i RI2NXS50 MOorMMON AMONI2—TVRI2XI , ‘AL2PKS50 MOP adorl2 TVRI2XL i ‘AL2Nx600 45 ASSNIZ TYRI2XL é AGNX350_-ASON6 ASSN6 = -TVROXI2 ¢ 2SPX350-ASOPG ASSP6 —TVROXI2 Four types of pulleys aro available to e fit belt sizes from 3/8" to 3/4" in single and double groove pulleys. Some models utilize f @ friction-fit (press-fit) pulley. An auxiliary § Pulley is also available to fit these models for dual belt installations. ‘The maximum belt size for the friction-fit (pre: Fig. 1Motorola Alternator fit) pulley is 1/2". ‘The mechanical construction of the alternator differs from the DC generator in that the field rotates and the (armature) generating windings are stationary. ‘The field current necessary to control the output of the alternator is supplied from the alternator. The rectifier circuit using 6 silicon rectifier diodes. regulator controls the currept fed to the field via the brushes and rotor slip rings The alternator produces power in the form of three phase alternating current and 2 voltage. The alternating current is rectified to direct current by a three pha: See figures 2 and 3. Since the diodes full wave will pass current in only one direction (irom alternator to battery or load) the alternator does not require the use of a cutout relay. ‘The entire DC output of the system passes through the isolation diode. This pro- ® yides the system with several distinct advantages: 1. It prevents the battery from discharging through the regulator and alternator fleld without the use of relays or a switches. 2, Tt provides a means of operating the charge indicator lamp that is used MOTOROLA ALTERNATOR SERVICE MANUAL === WSOLATION. */ DIODE JavelusaRy outer TERMINAL TERMINAL, DIODE. lawxd ary ISOLATION outPur "TERMINAL TERMINAL Pig. 3- 45 Ampere Alternator Circuit M-91MOTOROLA ALTERNATOR SERVICE MANUAL y on some cars. Electrically, the indicator ~ lamp is connected across the isolation i diode, See figure 4, When the system is operating properly the alternator output volt~ age {s very nearly the same as the battery 8h voltage, so that the voltage potential across an the igolation diode 1s low and the lamp does , Ai not light indicating that the alternator 1s + charging. B ‘The alternator output current is controlled : by the current flow through the fleld coll (Cotor). The amount of current required 1s determined and controlled by the regulator. Since there is very little residual magnetism in the alternator it 1s necessary to supply only a small amount of excitation current to the field (rotor) to start the process of current generation. ‘The 75 ohm resistor supplies this Starting current when the ignition is turned on. eran Soe figure 4, This resistor should also be wired See area Oe Oe in parallel 4f used with an indicator light. Once the alternator is excited a voltage is developed at the auxiliary terminal and the voltage regulator takes over control of the system voltage. Il, DESCRIPTION ‘The principal parts of the Motorola alternator are shown in figure 5, II, TESTING PRECAUTIONS ‘The following precautions must be observed when making any tests: 1, The battery must be in good condition and fully charged so that the alternator output can be completely controlled with an external load. 2, Do not short field terminal of alternator to ground. 3. Do not disconnect voltage regulator while alternator is operating. 1. Bearing, rear 17. Insulator Sleeve 2, Bearing, front 18. Nut, square (font & rear housing mtg) 4. Bolt (font @ reer housing mtg) «19. Pulley & Fan Assembly 5. Brush & Holder Assembly 20. Retainer, rear bearing 7. Cover, ‘brush hole 228. Rotor Assembly 9) Diode ‘Assembly, isolation 23.” Screw, drive 11! Diode Assembly, negative 24A. Spacer, fan & pulley assembly 13) Diode Assembly, positive 26. Stator Assombly p 14. Housing, front 27." Washer, insulating 15. Housing, rear 28, Washer, ineulating 16, Insulator Sleeve 23, Washer, split spring (front bearingretainer) 4 1 Fig. S~Exploded View of Alternator=== MOTOROLA ALTERNATOR SERVICE MANUAL ALTERNATOR ‘ourPur caaue Fig. 6~Alternator System Test 4, Do not disconnect load (alternator output lead) from alternator while the alternator is operating: ~~ ~ es 5. Do not remove alternator from car without first disconnecting the negative (-) battery cable. If battery must be removed, disconnect negative cable first. 6. Observe proper polarity when installing battery. The negative terminal must be connected to the ground. Reverse polarity will destroy the rectifier diodes. 7. When charging battery in car, disconnect the positive battery terminal. Connecting charger in reverse will also destroy rectifier diodes. IV. ON VEHICLE TESTS ‘A. Altornator System Test ‘This test checks the current output of the alternator to determine if the system 4s functioning properly. 1. With the engine off, disconnect output cable from alternator output terminal and connect an ammeter with a range of 0-60 amperes in series with output terminal and output cable. (Polarize meter). 2. Connect a carbon pile load to the negative side of ammeter and negative bat~ tery terminals. Connect a voltmeter to alternator output terminal and negative battery terminal, Soo figure 6. 3. Start engine and allow 15 minutes for temperature stabilization. Slowly increase load with carbon pile and increase engine speed until rated current output 1s, reached. The voltage at the output terminal should be at least 13 volts but not more than 15, Tf voltage exceeds 15 volts at rated current output, replace or check the voltage regulator. If the system operates normally at low engine speeds but rated output cannot be obtained at high engine speeds, check fan belt for proper tension. 4, Remove carbon pile load immediately after engine 1s stopped to avoid dis~ charging battery when alternator is not operating. The alternator system is functioning properly if the output current of the respective model is within § amperes of rated output at a temperature of 75°, If the current output is below normal and the output terminal voltage exceeds 13 volts, check isolation diode or replace with a known good diode. If the rated current output is obtained at the specified output terminal voltage check the battery charging circuit as described in paragraph C. If output is below specifications make the alternator output test as described in paragraph B. M-93MOTOROLA ALTERNATOR SERVICE MANUAL Be itor Out This test excludes the regulator from the alternator system. ‘GBUITION: De net cteconnect alternator field terminal wire while alternater is operating, 1. With the engine off, connect volt= ter, ameter and carbon pile as shown in figure 6, Disconnect field terminal wire, Con- Pate dd chm damp. theostat from output terminal | COMET YOXNETEE to field terminal, (Test points Aand B.) See figure 7. | Preto OUTPUT 2, Set Field Resistor at maximum TeRnINAL resistance, start engine and observe voltage at output terminal. Voltage must not exceed 15 volts. Tf necessary, increase alternator load to reduce voltage. NOTE: A fully charged battery does not present a load to the alternator. If maximum Held current 1s applied to the alternator field Fig, 7-Alternator Output Test with no loed on the alternator, the output volt age of the alternator will exceed the safe meximum value of 15 volts resulting in over~ charging of the battery and possible damage to the alternator. 3. Continue to increase load with carbon pile and decrease field resistance, while maintaining less than 15 volts at the output terminal, until their {sno resistance in the field circuit. With no resistance in the field circuit maximum field current is being applied to the field coil. The rated output at the output terminal should be 13 to 15 volts. hock the resistance wire for continuity with a 75 chm ohmmeter or replace. Be sure the resistor wire makes a good electrical contact at the ignition coil and auxiliary terminal. "NOTE: The charge indicator light used on some cars functions in the same manner as the resistor wire by supplying the required initial field starting Current. AB a safety precaution alwaya check the reaistor wire when test- ing the alternator. If the resistor wire is open and the charge indicator lamp burned out, it will render the alternator inoperative. 4, If rated output cannot be obtained, check the brush assembly for poor con- nections, broken, worn or sticky brushes. C. Battery Charging Circuit Test ‘This test checks the condition of the battery charging circuit and negative ground return circuit, Battery connections should be cleaned and tightened prior to test. 1. With the engine off, connect an ammeter in series with alternator output terminal and output cable. Connect a carbon pile load to the positive and negative bat- tery terminals. See figure 8, : ‘oureur véRm @. ‘CONNECT VOLINETER AS SHOWN (DOTTED LINES) FOR BATIERY GROUND RETURN CIRCUIT TEST (SEE TEXT) Fig. 8-Battery Charging Circuit Test4 SNe EMTS ae tees ecm nee tare MOTOROLA ALTERNATOR SERVICE MANUAL EES Te sa var sary Sa wre HOUR carmen none, a1 Fig. 9-Alternator & Regulator Bench Tost 2, start engine and adjust engine speed and carbon pile load for 10 amperes of alternator Output. Measure the charging circutt voltage drop from the negative side of Gmmeter to the positive battery terminal. If voltage drop exceeds .3 volts, check all wiring and connections in charging circuit. 3. A voltage drop test across each connection will locate any faulty connections. Connect voltmeter from alternator ground terminal G to negative battery terminal. If Voltage drop of battery return clrouit exceeds . 15 volts, check battery ground cable con— nections at engine and or grounding straps between body and engine, if any. Make cer— tain alternator {s well grounded through its mounting bracket. V. ALTERNATOR BENCH TESTS ‘the following tests may be performed in place of or in addition to the On Vehicle ‘Tests described in Section IV. A. Alternator System Test Gonnect a? HP electric motor with a pulley arrangement which will produce 3000 to 4000 alternator RPM. Alternator must turn clockwise. Mount alternator using @ mounting bracket. Mount regulator on heat sink. (clamp may be used). Connect ammeter, Voltmeter, #57x indicator lamp and carbon pile. See figure 9. Start electric motor and perform Alternator System Test as described in Section IV, paragraph A. B. Alternator Output Test “Make same connections as described in paragraph A. See figure 9. Disconnect the voltage regulator plug and field terminal wire, Start electric motor and perform Alternator Output Test as described in Section IV, paragraph B. C. Isolation Diode Voltage Leakage Test Fxcessive leakage through the isolation diode will discharge battery. The rate of discharge 1s dependent upon the amount of leakage. Normal leakage is less than .001 amperes which is insignificant. T. Connect alternator and regulator to battery as shown in figure 9. Do not operate alternator. 2. With a voltmeter, measure the voltage from auxiliary terminal F to ground terminal G. ‘The voltage appearing at the auxiliary terminal should not exceed «1 volts. ‘NOTE: Regulator must be connected to the alternator and must be in good operable NOTE ion A defective regulator or regulator leads willgive erroneous voltage readings. M-95MOTOROLA ALTERNATOR SERVICE MANUAL 4 4 & i & ‘BEGINNING OF TEST i TO AVOID DAMAGING 4 AMMETER (SEE THX Fig. 10-Rotor (Field Coil) Test D. Rotor (Field Coil) Test This test checks the condition of the field coil (rotor) for open or shorted fleld coll turns, excessively worn or sticky brushes and open connections. 1. Before making connections set rheostat to maximum resistance of 40 ohms. Construct a field current test circult as shown in figure 10. Connect test circuit to field and ground terminals. (Tost points B and G). 2. Slowly reduce resistance of rheostat to zero. With full battery voltage applied to Held coll, the field current of the alternator should be as per specifications. 3. If the field current is not within the specification limits, inspect brushes for excessive dirt, cracking or breaking and bad connections. Inspect slip rings for excessive dirt and bad connections. Turning rotor by hand while taking a reading with ‘an ammeter will indicate if brushes are making good electrical contact. A slight fluctuation of .2 amps can be expected . 4. If the field current is above specification limits, the field coil is either shorted to the rotor or has shorted turns. If the field current is zero, the field coil or coil to slip ring connection is open. If the field current is considerably less than speci fleations, there is either a weak coil to slip ring connection or brush to slip ring connection. E. Rotor (Field Coil) Continuity Test ‘Connect the test probes of an ohmmeter to field and ground terminals (test points Band G). See figure 10, Resistance reading should be, approximately, 6 ohms. If resist ance is high, field coil is open. i ij i it VI. DISASSEMBLY When repsiring this alternator complete disassombly may not be required. In some cases it will be necessary to perform only those operations which are required to repair or replace the defective part. However, the complete overhaul is covered step by step to provide detailed information necessary for each operation. A. Brush Assembly Removal Remove the two tapping screws and cover. Pull brush assembly straight out sufficient to clear the locating pins, then laft brush assembly out. see figure 11. Fig. 11-Removing Brush Assembly M-96=== MOTOROLA ALTERNATOR SERVICE MANUAL————= Fig, 12-Removing Pulley ~ Friction Fit Type Fig, 1g-Removing Pulley- Threaded Shaft Type B, Pulley Removal Ay Heer He fon Fit (Press Fit) Models a. Firmly attach pulley adapter kit VA657 to pulley. bi. Position puller arbor D 15 with spacer plug VA652 on rotor shaft. ¢. Place pulley removal Jaws CKS12 in groove of pulley adapter and the ‘other end on the puller nut. d. Hold removal jaws and puller arbor in position with tool sleeve. ©, Place puller arbor D 15 in the hexagonal opening of vise holding fixture VA650 as shown in figure 12. £, Support alternator with hand and turn puller arbor with a wrench until pulley 1s removed. g. Remove pulley adapter kit from pulley. The use of vise holding fixture VA6S0 prevents possible damage Yo rotor and front end housing. 2, Threaded Shaft Models removing the shaét nut it {s necessary to prevent the pulley from slipping Place a fan belt in the pulley groove and carefully place pulley ina vise, Close vise slowly on belt avoiding excess vise pressure on pulley. ‘a. Remove shaft nut, washer end position puller arbor D 15 against rotor shaft. b. Place pulley removal jaws CK507 in groove of pulley and the other end on the puller arbor nut. c. Remove the pulley in the same manner as described in the preceding paragraph. See figure 13. d. Remove fan and woodruff key. c. oval c Seadoo mar move ‘mute a jamhers Remove isolation diode assembly from holding studs. E ston jousinas : Here ghe the four Tisesh bolts and nuts. Insert a small bladed screwdriver in the stator slots between stator and front housing. 2. Apply prying pressure at several points around the stator to extract rotor and front housing as an assembly. Do not burr the stator core which will make re-assembly +. difficult. “See figure 14. Do,not ingert screwdriver SARTON, or thom 1718" to vols damaging stator winding.Fig, 15-Removing Rear Bearing Fig. 16-Removing Split Spring Washer 2. Rear End Boating Removal : ‘The rear end bearing is also a friction fit with the rotor shaft. 1, Position puller arbor D 15 with edapter VA653 on rotor shaft and place the ‘thin end of bearing removal jaws CK503 eround the bearing equally spaced. 2. Remove the rear end bearing in the same manner as described in paragraph B. See figure 15. P. Spt Spring Washer Removal ‘Compress the ears of the split spring washer with a long-nosed pliers as shown in figure 16. Lift washer to free it from its seated position in the front housing. G 5m ~ With the split spring washer removed, position puller arbor D 1S on rotor shaft. 2. Place front end housing removal jaws CKS13 equally spaced around housing. 31 Remove front end housing in the same manner as described in paragraph B. See figure 17. ‘H. Front End Bearing Removal Tho front ond bearing is @ friction fit with the rotor shaft. 1, Position puller arbor D 15 on rotor shaft and place the thin end of bearing removal jaws CK S03 around the bearing equally spaced, 2. Remove the front end bearing in the See figure 18. 3. No furthor disassembly of the rotor 1s required. The balance of the rotor is not serviced separately. fe manner as described in paragraph B. Fig. 18=Removing Front End BearingFig. 19-Removing Stator and Diode Assembly osm rod asa (OCT AYEDMARENGS,_ se nsamnowsie@ I. Stator ode Assembly Removal ‘Fig.20-Removing Diode Assembly Tie Gresent time, Motorola recommends only complete diode assembly replace- ment, When servicing diodes, the following precautions must be observed: DIODE SERVICING PRECAUTIONS. Do not interchange diode assemblies. Positive diode assemblies have rod markings while negative diode assemblies have black markings. Do not eivike any diode as the shock may damage other diodes. Do not touch any diode with a soldering iron. ‘Do not unsolder stator to diode wire junctions. Do not bend stator wires at junctions. ‘Do not exert excessive stress on dicde leads. + "1. Remove the four lock nuts, insulating washers and the stator and diode assem blies. Note the stack-up of parts for proper reassembly as shown in figure 19- 2. Garefully uncolder leads from diodes by grasping the diode lead with pliers between the diode and stator lead to be unsoldered. See figure 20, (This procedure will insure proper heat dissipation while protecting the diode.) ‘VII. TESTING OF COMPONENTS ‘Upon completion of disassembly, all parts should be wiped clean and visually inspected for wear, distortion and signs of overheating or mechanical interference. Replace any worn or broken insulation washers, etc. and inspect all tapped holes for good threads. ‘A, Brush Asser T. Insulation Test: Connect the probes of an ohmmeter or 110 volt test lamb to fleld terminal and bracket. (Test points A and D) See figure 21. Resistance should be high (intinite) or test lamp should not light. “If resistance 1e low ot test lamp lights, brush assembly is shorted and must be replaced. 2. Contintlty Test: Connect the probes of an ohmmeter to field terminal and Brush (Tost points A and C). Use an alligator clip to assure good contact to brush. Resistance Pig. 21-Brush Assembly Tests M-99MOTOROLA ALTERNATOR SERVICE MANUAL g.8 Fig.22-Field Coil Resistance Test reading should be zero. brush and lead wire are being moved. Eand D). Resistance reading should be zero. B. Field Coil Resistance before or after disassembly . Fig.23-Stator Leakage Test ("Out of Circuit") Move brush and brush lead wire to make certain that the brush lead wire connections are not intermittent, Resistance reading should not vary whon Connect the probes of an ohmmeter to bracket and grounded brush (test points Repeat continuity test on brush lead wire. ‘This test checks the field coil for leakage or shorts and may be performed } 1, Alternator assembled Remove brush assembly as described in Section VI, paragraph A, Connect the probes of an chmmeter or 110 volt test lamp to one of the slip rings and ground terminal (test points G and P). See figure 22, 2, Alternator disassembled Connect the probes of an ohmmeter or 110 volt test lamp to one of the slip rings and rotor shaft. Ohmmeter resistance should read infinite or test lamp should not light. If resistance is not infinite or test lamp lights, leakage or a short exista between field coil and rotor. C. Stator Tests All stator tests excopt the "Out of Circuit leakage test are made with the diode assembly disconnected from the stator as described in Section VI, paragraph 1. 1, “Out of Cirouit" Leakage Test: Connect the probes of an ohmmeter or a 120 volt test lamp to one of the rectifier diode terminals and to stator (test points IN and Q) Sce figure 23. Resistance reading should be infinite or test lamp should not light. If resistance reading is not infinite or test lamp lights, high leakage or a short exists between stator windings and stator must be replaced. 2. Leakage Test: This tost checks for shorts or leakage between the stator coil windings. Always check type of winding before making stator tests. 30 and 40 ampere models use a "Wye" type winding while 45 ampore models use a "Delia" type. See figures 24 = i) Le Fig.24-"Wye" Type Stator Winding Fig.25-"Delta® Type Stator Wi M-100MOTOROLA ALTERNATOR SERVICE MANUAL LEROY Fig.27-Stator Leakage Test (45 Ampere Models) nae: Fig. 26-Stator Leakage Test (30 and 40 Ampere Models) f a. 30 and 40 ampere models: With the wire functions separated, connect one of the probes of an ohmmeter or 110 volt test lamp to test point U. Connect other i ‘test probe to test point V and thru to W. Connect test probes to test points V and W. See figure 26. b. 45 ampere models: With the wire junctions separated, connect one of Hi the probes of an ohmmeter or 110 volt test lamp to test point R. Connect other test probe i to test point $ and thru to T. Connect test probes to test points § and 'T. See figure 27, Resistance should be infinite or test lamp should not light, If the resistance i 4 reading is not infinite or the test lamp lights, high leakage or a shart exists between stator windings and stator must be replaced. - Continuity Test: ‘ ‘a. 30 and 40 ampere models: With an ohmmeter, measure the resistance of each winding in the stator between test points U-U", V-V' and W-W'. See figure 26. ’b, 45 ampere models: With an ohmmeter, measure the resistance of each winding in the Stator between test points R-R', $-S' and T-T', See figure 27. - Resistance should not exceed .1 ohm. NOTE: Only an open condition can be detected with a commercial type ohmmeter. If the alternator has been disassembled because of electrical malfunction, replace stator only after all other components have been checked and found to be satisfactory. D. Diod 1, Test Lamp Method; With the stator wires disconnected from the rectifier diode assembly, connect diode tester VA 688 to a 12 volt battery. Connect one of the test probes to the diode plate stud and touch each of the diode terminals with the other test probe. See figure 28 Reverse connections a A ‘The dicde tester should Light tn one e RY Drone es Ae 9 tte lone rLATESTID direction only, If the diode tester lights in both, directions, the diode is shorted; if the diode tester does not light at all the diode is open. When an open of shorted diode is found the com- (Ve plote diode assembly must be replaced. ‘CAUTION: Do not use a 110 volt test lamp when making any diode tests. Observe diode servicing precautions contained in Section VI, Paragraph I. Fig, 28-Diode Test aMOTOROLA ALTERNATOR SERVICE MANUAL Fig. 29-Installing Stator and Fig. 30-Proper Diode Wire Dress Diode Assembly 2. 83 : If using a special type diode tester, follow the tester manufacturer's test procedures. Vu. REASSEMBLY A, Sigior and Diode Assembly Installing 6 . Grasping each diode lead with a pliers, carefully solder diode assemblies to each stator lead wire. ‘CAUTION: Make sure that only enough heat is applied to insure a good connection. Overhoating may damage the diodes. 2. Carefully inspect each dicde to make sure that no solder has run down on to it. 3, Insert rectifier and stator assembly into the rear housing. Attach all insulating washers and nuts. See figure 29. Dress diode wires against the rear housing as shown in figure 30. NOTE: The positive diode assembly must be insulated from the rear housing. 4. Install rubber bearing retainer in hub of rear end housing. See figure 30. 3. Rront Bearing installing 1. Asser ‘press kit VA65S in accord— ance with instructions contained on page 21. 2. Support the front end housing in press on the larger side of support VA661., 3, Position bearing installer VA605A, ‘over the outer race of bearing. Make sure that bearing enters front end housing squarely. See figure 31, 4. By turning the arbor D 15 with wrench, press the bearing into the end housing until the bearing is flush with the inside of the bearing hub. M-102LL SE RN EEE ESET TT ET EE TET TIS MOTOROLA ALTERNATOR SERVICE MANUAL yas > A ist ne ea «| mace or atari roo. Twa ‘oe, vie ‘ust ert sins Shae OF SHA Fig. 32-Installing Split Spring Washer Fig. 33-Installing Front End Housing C. Split Spring Washer installin T. Insert the split spring washer into hub of front housing. Compress each wave of washer with @ wooden dowel as shown in figure 32, Seat washer into groove of hub with long-nosed pliers. GAUTION: Do not use a screwdriver or any small object to compress washer that oan slip off and damage bearing seal. D. Front End Housing Installing T. With the split spring washer installed, position front end housing and beering squarely on rotor shaft. 2. Using press kit VA655, place entire assembly in the opening of press support. ‘Support rotor shaft on eupport VA6S6. 3. Place installer VA603 on inner race of bearing and insert special adapter \VA654 on top of installer. 4. Using the same procedure as described in paragraph B, press front end housing end bearing on rotor until bearing contacts shoulder on the rotor shaft. See figure 33. NOTE: The use of special adapter VA654 serves as a centering guide for the arbor and prevents possible damage to the installing tool. E. Pulley installing T. Friction Fit (Press Fit) Models: ‘a. With a generous coat of "Moly Cote Graphite Lubricant" on rotor shaft, install pulley spacer and fan. b. Using press kit VA65S, position rotor and front end housing in the opening of the press support, Support rotor shaft on support VA 656. c. Place pulley squarely on rotor shaft end insert special adapter VA 654 on hub of the pulley. d. Using the same procedure described in paragraph B, press pulley on the rotor shaft until the pulley and spacer contact the inner race of the front end bearing, See figure 34. 2. Threaded Shaft Model Inatall woedrull key, fn, pulley, lock~ washer and shaft nut. NOTE: When tightening the shaft nut xt is necessary to prevent the pulley from slipping. Place a fanbelt in the pulley groove and carefully place pulley in a vise. Clase vise slowly on belt avoiding excess vise pressure on pulley andtighten shaft nut Fig. da-Installing Pulley ~ Friction Fit Type M-103MOTOROLA ‘ALTERNATOR SERVICE MANUAL Fig, 36-Installing Isolation Diode Assembly (80 Ampere Models) F, Rear Beat stall T, Using press kit VAGSS, place entire front end assembly and pulley in the opening of press support. 2. With the rear bearing centered on rotor shaft, position bearing installer VA 656 on the inner race of bearing. 3. In the same manner as described in paragraph B, press bearing on the rotor shaft until bearing contacts the shoulder of the rotor shaft. ‘See figure 35, G. Final Assombl Ene MSnble font and rear end housing assemblies, Hand pressure should be suffictent to seat reer bearing into rear housing. Make certain that the rear bearing retainer is properly seated in the rear housing hub. 2. Align the stator slots with rear and front end housing bolt holes. The brush assembly and the belt tension flange of front end housing must be 1n the same relative position to each other. 3. Spin alternator rotor to see that the rotor is not rubbing against the diode wires. Make certain that the positive rectifier diode plate has been properly insulated from the rear end housing. 4, Install through bolts and tighten Install brush assembly. tion Diode Assembly Installi ‘CAUTION: Before installing isolation diode assembly make certain that the positive diode plate has been properly insulated from the rear end housing. 1, 30 Ampere Models: Install the {solation diode assembly to the positive recti- fier diode studs and attach locknuts. See figure 36, (Insulation is not necessary.) + 40 at 2 Models: Install the isolation diode assembly to the positive and negative diode studs. Attach insulating sleeve and washers as shown in figure 37. (The isolation diode assembly must be insulated from the negative diode stud.) evenly. Fig. 37 Installing Isolation Diode Assembly (40 and 45 Ampere Models) M-104 f jawed Di: eo? dMOTOROLA ALTERNATOR SERVICE MANUAL Tig, 88-Pre-Installation Test Fig. 39-Pre~Installation Test (80 Ampere Models) (40 and45 Ampere Models) IX, PRE~INSTALLATION TEST Connect the test probes of 2 110 volt test lamp to the auxiliary and ground terminals (test paints Fand G). Soe figures 38 and 38, Reverse connections, Test lamp should light in one direction only. t X. REGULATOR i ‘The Regulator is an all-electronic, transistorized device. See figure 40. No mechan ical contacts or relays are used to perform the voltage regulation of the alternator system. ‘The electronic circuitry should never require adjustment and the solid state active { elements used have proved reliable enough to warrant a sealed unit. The system is, i temperature compensated to permit the ideal charging rate at all temperatures. ‘The voltage regulator is an electronic switching device. It senses the voltage appear- ing at the auxlliery terminal of the alternator and supplies the necessary field current for haintaining the system voltage at the output terminal. ‘The output current is determined by the load such as headlights, heater, etc. The diagram of figure 41 shows a complete voltage regulator circuit. When the voltage appearing at the auxiliary terminal of the alternator rises to a predetermined value {14-4 volts), the voltage which appears across the Zener diode is the critical Zener voltage - and the Zener diode conducts. The conduction of the Zener diode permits current to flow inthe base of T-1. This causes transistor T-1 to turn on and reverse bias transistor T-2, thus turning off the current applied to the alternator field. When the system voltage drops [ below the predetermined value, the Zener diode stops conducting, T-1 tums off and T-2 turns on. When transistor T-? is switched on, field current again is supplied to the Pig. 40-Motorola Regulator Fig. 41-Voltage Regulator Circuit M-105MOTOROLA TEST SPECIFICATIONS=—=————S— 4 : atterontr. The operation of transistor T-2 is offectivaly ike switch turing the ; alternator field current on and off as the electrical supply voltage varies due to the : I Varying electrical load. This action occurs many times a second, so fast it cannot be detected in the alternator output. Thermistor (Rt) is a temperature compensating resistor. Its resistance varies with ©, temperature and controls the operating point of the Zener diode so that a higher system i + voltage Js produced in cold weather, when needed, and a lower system voltage in warm +, A i weather. ' Al h XI. REGULATOR TESTS “y 4 A, Regulator Output Test ei i 4 Regulater Pate tins be chooked with an alternator that is functioning properly. “~.", i Ai Make the same test connections as described im Section IV, paragraph A. See “al figure 6, Mert engine and slic 16 minites for tonpetature stablization. Slowly we increase load with carbon pile and increase engine speed to obtain 10 amperes of current ne! output, Output terminal voltage must be as per specificotions. If voltage 15 less than | specifications, the regulator must be replaced. oy “NOTE: Measure ambient temperature of requlator by placing @ reliable a thermometer 1" away from regulator case. E B. Regulator Bench Test d ‘Make the same connections as described in Section V, paragraph A. See 4 figure 9. Start electric motor and follow the same procedures described in the preceding paragraph. 4 MOTOROLA TEST SPECIFICATIONS Motel No. ALTERNATOR ALANX451 [news] ‘AL2NXE00 Rotation Clockwise at drive end = All Modéts ~ Voltage 1% 12 1% Rated Output _(Amperes) at 15 volts 30 40 5 Brushes (Number) 2 2 2 Field Current: Minimum (amperes) 12 1.8 1.8 Maximum ~ (Amperes) 7, 2.4 2.4 Minimum Acceptable Output at 75°F 25 38 40 ‘Ground Polarity Negative | Negative | Negative . Output Control VE WR va _| ‘Medel_No. VOLTAGE REGULATOR TVRIZNX1 7 Volts 2 (Ground Polarity Negative Operating Voltage (10 Ampere Load) Temperature CF) ‘ao® [100° [1207 [140% 160°] Minimum 1395] 13.60 [13.68 ]13.60 [14.90 Maximum 14.75 | 14.60 14.45 [14.28 [14.13 e Tolerance = a All tests to be made with a fully charged battery. ~ All Models —