Service Manual

Power 450™ 28 Volt Alternator

This service manual is effective for the following part numbers:

Part Number
3590028041 3590028277
3590028150 3590028284
3590028267

Rev Rev By Date Description of Change Approved By

C RJ 10/23/14 Revisions ECN3390
D RJ 12/26/14 Revisions ECN3506

9980028095 Rev_D 12/26/14 © 2012 EMP, Inc. 1

 Engineered Machined Products, Inc.
2701 North 30th Street
Escanaba, Michigan 49829
Phone: 906-789-7497
www.emp-corp.com
Service@emp-corp.com

The information contained in this manual is updated periodically. While great care is taken in compiling the information contained in this manual,
Engineered Machined Products, Inc. cannot assume liability for losses of any nature arising from any errors and/or omissions.

The information and specifications contained throughout this manual are up to date at the time of publication. Engineered Machined Products, Inc.
reserves the right to change the content of this manual at any time without notice

© 2012 EMP, Inc. 2

 Table of Contents
Table of Contents
Table of Contents .............................................................................................................................................. 3
Introduction........................................................................................................................................................ 5
Purpose ......................................................................................................................................................... 5
Service Technician Responsibilities ............................................................................................................... 5
Liability Disclaimer ......................................................................................................................................... 5
Definition of Terms ......................................................................................................................................... 5
Safety ................................................................................................................................................................ 6
Warnings, Cautions & Notes .......................................................................................................................... 6
Product Safety Warnings ............................................................................................................................... 6
Product Overview .............................................................................................................................................. 7
Tools ................................................................................................................................................................. 8
EMP Tool Kit 7530028186 ............................................................................................................................. 8
Other Tools .................................................................................................................................................... 9
Available Parts Kits from EMP ........................................................................................................................... 9
Preliminary Inspection of Power 450™ ............................................................................................................ 10
Disassembling the Power 450™ ...................................................................................................................... 10
Remove the Rear Cover .............................................................................................................................. 10
Remove F1 and AC Connectors .................................................................................................................. 11
Power and Ground Studs ............................................................................................................................. 11
Removing the Exciter ................................................................................................................................... 12
Removing the Pulley and Fan ...................................................................................................................... 12
Removing the Front Frame .......................................................................................................................... 13
Removing the Rotor Assembly and Rear Exciter.......................................................................................... 14
Separating the Rectifier Assembly from the Stator Housing ......................................................................... 15
Separating the Rectifier from the Rear Frame .............................................................................................. 15
Ground Isolated vs Non-Isolated .................................................................................................................. 16
Assembly of the Power 450™.......................................................................................................................... 17
Replacing the Rectifier Assembly to the Rear Frame ................................................................................... 17
Rubber O-Ring and Spring Washer.............................................................................................................. 17
Attaching the Rectifier Assembly to the Stator Housing................................................................................ 17
Placing the Exciters onto the Rotor Assembly .............................................................................................. 17
Placing the Rotor Assembly into the Stator Housing .................................................................................... 18
Replacing the Rear Cover ............................................................................................................................ 20
Replacing the Pulley and Fan ...................................................................................................................... 20
EMP Power 450™ Troubleshooting ................................................................................................................. 21
Mechanical Procedures................................................................................................................................ 21
Electrical Procedures ................................................................................................................................... 21
Component Inspection Values ..................................................................................................................... 25
© 2012 EMP, Inc. 3
 Table of Contents
Routine Maintenance ....................................................................................................................................... 26
Technical Help ................................................................................................................................................. 26
Wiring Schematics ........................................................................................................................................... 27

© 2012 EMP, Inc. 4

 Introduction
Introduction
Purpose
The purpose of this Service Manual is to present information and procedures required to properly service and
maintain your Power 450™ Alternator.

Service Technician Responsibilities

Ensure that the Service Technician reviews the installation/service manuals and observes proper cautions prior
to maintenance on any of the system components. Familiarization will allow for accurate troubleshooting,
diagnosis and repairs.

Liability Disclaimer
EMP cannot anticipate every possible circumstance that might involve a potential hazard. The safety
messages in this document, in related manuals, and on the product are therefore not all inclusive. If a tool,
procedure, work method, or operating technique that is not specifically recommended by EMP is used, you
must satisfy yourself that it is safe for you and for others. You should ensure that the product will not be
damaged or be made unsafe by the operation, maintenance, or repair procedures that you choose.

Definition of Terms
LH = Left Hand
RH = Right Hand
CCW = Counter Clockwise
CW = Clockwise
P450 = Power 450™
+ = Positive Terminal on the alternator
- = Negative or Ground Terminal on the alternator
Ω = ohms, the measure of electrical resistance
AC = Alternator Charge, the alternator cover marking to indicate the charge status output wire
DVM = Digital Volt Meter
F1 = Field, the alternator cover marking indicating the “Field” wire from the voltage regulator
OEM = Original Equipment Manufacturer
RPM = revolutions per minute
Strain Relief = Cable support to prevent the movement of the engine from loading the cables and terminals on
the alternator.
VAC = Alternating Current Voltage
VDC = Direct Current Voltage

© 2012 EMP, Inc. 5

 Safety
Safety
Warnings, Cautions & Notes
Three types of headings are used in this manual to stress your safety and safe operation of the
system. They appear in the text as follows:

WARNING: This symbol is used to make you aware of an unsafe condition, hazard, or practice
that can result in personal injury or death.

CAUTION: This symbol is used to alert you to a condition or practice that can cause damage to
the system or the vehicle, or both.

NOTE: Is used to provide additional information that requires special attention by the technician.

Product Safety Warnings

EMP cannot anticipate every possible circumstance that might involve a potential hazard. The
safety messages in this document, in related manuals, and on the product are therefore not all
inclusive. If a tool, procedure, work method, or operating technique that is not specifically
recommended by EMP is used, you must satisfy yourself that it is safe for you and for others. You
should ensure that the product will not be damaged or be made unsafe by the operation, maintenance,
or repair procedures that you choose.

Ensure that all safety messages and information messages are read and understood before
installation, maintenance, or any repairs are performed. The person who services the system may be
unfamiliar with many of the components on the vehicle. It is important to use caution when service
work is performed. Knowledge of the system and operation are important before the removal or
disassembly of any component.

Make sure the vehicle is in neutral, the parking brake is set, and the wheels are blocked before
doing any work or diagnostic procedures on the system or vehicle.

Disconnect the main negative battery cable and/or switch off the battery disconnect switch before
installation or servicing.

Use extreme caution when working on systems under pressure (i.e. coolant, hydraulic fluids, air,
fire suppression, etc…)

Make sure the work area is ventilated and well lit.

Make sure charged fire extinguishers are in the work area.

Reinstall all safety guards, shields, and covers after servicing the vehicle.

Make sure all tools, parts, and service equipment are removed from the engine compartment and
vehicle after all work is done.

Ensure that all system power and ground connection points are torqued to EMP specifications to
prevent system damage. Failure to follow specified torque requirements at any point of the vehicle
system power and ground can result in loose connections which can damage electronic components on
the system and will void EMP warranty.

© 2012 EMP, Inc. 6


Product Overview
The EMP Power 450™ Alternator
• Operational Speed Range:
• Intermittent Speed:
• Turn-on Speed:
• Rotation:
• Ambient Temp Range:
• Intake Air Temp Range:
• Intake Air Restriction:
• Weight:
• Dimension:
• Mounting:
• Polarity:
• Voltage Regulation:
Product Overview
1800 to 6500 RPM
8000 RPM for 30 seconds
1250 RPM
CW or CCW
-40 to 95°C
-40 to 50°C
3” Inlet Max: 1.7” H2O @ 4000 RPM
4” Inlet Max: 1.0” H2O @ 4000 RPM
100 lbs.
10.25” diameter x 16.00” length
Pad, Radius
Neg. Ground or Ground Isolated
Delco Remy P/N: 19020411, 8600025, 8600562
Figure 1
© 2012 EMP, Inc. 7
 . Tools Required
Tools
EMP Tool Kit 7530028186
EMP Tool Kit 7530028186 can be purchased separately and includes the following items.

Figure 2 - Base Fixture (7520028179)

Figure 4 - Rotor Puller (7520028210)

Figure 3 - Front Frame/Exciter Puller (7520028222)

Figure 5 - Rear Exciter/Rear Bearing Puller
(7520028223)

© 2012 EMP, Inc. 8

 . Tools Required

Figure 9 - Pulley Puller (7520028185)

Figure 6 - Rotor Bearing Press/Support (7520028184) Other Tools

• Small Gauge Wire

• Rubber Mallet
• Impact Wrench
o ¾” Socket
• Drill
o Socket Adapter
o 8mm socket
o 10mm socket
o 13mm socket
o 4mm hex driver
o 5mm hex driver
• Allen Wrench
o 4mm
o 5mm
• Phillips Screwdriver
• Diagonal Pliers/Cutters
• Torque Wrench
• Megohmmeter
• Bore Gauge/Calipers
Figure 7 - Front Bearing Press/Support (7520028183)

Available Parts Kits from EMP

Service drawings include replacement parts kits.
9940028041, 9940028150, 9940028267,
9940028277, 9940028284

Figure 8 - Stator/Rear Frame Assembly (7520028191)

© 2012 EMP, Inc. 9

Preliminary Inspection of Power
450™
Rotate alternator shaft:
If the rotor is unable to be rotated or is seized,
the alternator likely cannot be rebuilt.
Disassembly may be very difficult and many of
the parts inside may not be repairable.
Disassembling the Power 450™
NOTE: Prior to disassembly, draw
alignment markings for proper reassembly.
Figure 10 - Alignment Markings
© 2012 EMP, Inc.
Disassembly
Remove the Rear Cover
NOTE: With the alternator mounted on the
base fixture, install a ½”-13 bolt into one of the
front frame’s thread bushings. Rotate the
alternator counter clockwise until the ½” bolt
contacts the base fixture. This technique can be
used, if needed, to prevent the alternator from
rotating in the fixture when removing or
tightening bolts in future steps. (See Figure 11)
Figure 11
1. Remove the four M6x60 bolts on the rear
cover of the alternator.
2. Remove the nuts and washers of the positive
(+) and negative (-) power studs.
3. Push F1 and AC rubber grommets into rear
cover and guide the electrical connectors
through the openings as the cover is
removed.
4. With a rubber mallet, loosen the rear cover
until it separates from the alternator. (See
Figure 12)
5. Slide the cover off until fully removed.
10
 Disassembly

Figure 12 - Rear Cover Removal

Remove F1 and AC Connectors

NOTE: EMP recommends replacing F1, AC

harness and grommets during rebuild.

1. Remove the 8mm nuts as shown in Figure

13 and Figure 14. Be careful not to drop nut
or washers into alternator.
Figure 14 – F1 Connector

Power and Ground Studs

Inspect power and ground studs. If replacement is
needed it can be done at this time.

Figure 15 – Power and Ground Studs

Figure 13 – AC Connector

© 2012 EMP, Inc. 11

 Disassembly
Removing the Exciter
1. Remove front and rear exciter ring terminals
from the rectifier. Make note of their
designations – white wires to ground and red
wires to the F1 connection.
2. Cut away the two plastic wire ties from the
exciter sheathing.
M8 x 35 Bolts

Figure 18

Removing the Pulley and Fan

1. Remove the nut and discard the safety
washer from the shaft.
2. Slide the pulley off.
3. Slide the fan off. DO NOT PRY. (See Figure
19)
Figure 16 - Exciter Wire Sheathing

3. Straighten the front and rear exciter ring

terminals to allow easier removal and re-
insertion through the stator housing. (See
Figure 17)

Figure 19

Figure 17

4. Remove six M8x35 bolts from the rear frame.

(See Figure 18)

© 2012 EMP, Inc. 12


Removing the Front Frame
NOTE: Make sure to remove each M6x140
bolt flat washer. Flat washers may remain stuck
in the main front frame during disassembly.
NOTE: Be sure to complete ‘Removing the
Pulley and Fan’ section before advancing.
Disassembly
NOTE: Exciter may fall out when p-clip is
removed.
5. On the inside of the front frame, remove the
p-clip supporting the exciter wires.
NOTE: Use care when handling exciter
wires.

NOTE: Prior to disassembly, draw

alignment markings for proper reassembly. (See
Figure 10)
1. Use a hex drive bit and ensure the bolt
heads are clean. Fully insert the hex bit into
the bolt head and loosen the six M8x40 bolts
from the center of the front frame by hand.
DO NOT use an impact wrench - the drive
heads may become damaged.
2. Remove the eleven M6x140 bolts from the
outer edge of the front frame.
3. Use - Front Frame/Exciter Puller
(7520028222) to remove the front frame,
front bearing, and front exciter.
a. Insert three M8x60 flange head bolts
into the front frame utilizing every
other bolt hole. Tighten all three
Figure 21 – Front Frame P-Clip
bolts so puller tool is flush with the
front frame. 6. Separate the front exciter from the front
b. Use an impact wrench with ¾” frame by tapping them apart. If needed, use
socket to remove the front frame. a large socket to press the front bearing out
Make sure the tool threads are of the front frame. Discard the bearing as this
greased. removal process permanently damages it.
4. Mark the location of the rear exciter wires (See Figure 22)
within the stator housing. Upon reassembly,
the wires will need to be installed in the
same stator slot location.

NOTE: This disassembly process will

permanently damage the front bearing.

Figure 22

Figure 20 – Removing the Front Frame

© 2012 EMP, Inc. 13

 Disassembly
Removing the Rotor Assembly and
Rear Exciter
1. Ensure the rear exciter bolts are removed
(As shown in Figure 18) and install the Rotor
Removal Tool onto the end of the alternator.
No mounting fasteners are required. (Note
that the Rotor Removal Tool includes a
specially modified front frame.)
2. Install the flat washer and the nut onto the
rotors threads
3. Using a ¾” socket, by hand, rotate the bolts
clockwise, alternating from one bolt to the
other to keep the rotor straight. Continue this Figure 24 – Front Bearing Press Support Tool
tightening sequence until the rotor contacts
the front frame. Make sure tool threads are 7. Insert rotor’s spline end into the Support
greased. (See Figure 23) Tool. (See Figure 25)

CAUTION: Do not use an impact wrench

with this tool.

4. Remove the flat washer and nut and then

remove the entire rotor puller tool from the
alternator.
5. Carefully slide the rotor out of the stator
assembly. The rear exciter wires should be
straight and free to remove as this was done
earlier in step 3 of “Removing the Exciter”.
(See Figure 17)

NOTE: If the bearing is destroyed and the

bearing bore or stator ID is damaged, the
alternator is probably not repairable. EMP
suggests the rebuild stop at this point.

Figure 25

8. Use the rear bearing puller tool to remove

the rear exciter and bearing from the rotor
assembly. (See Figure 26)
a. Insert three M8x60 flange head bolts
into the rear exciter utilizing every
other bolt hole. Tighten all three bolts
until the puller tool is flush with rear
bearing.
b. Use an impact wrench with ¾” socket
to remove the rear exciter and
bearing.
Figure 23 – Removing the Rotor Assembly

6. Place the front bearing press/support tool

into the base fixture. (See Figure 24)

© 2012 EMP, Inc. 14

 Disassembly
Separating the Rectifier from the
Rear Frame
1. Remove the fourteen M6-25 bolts securing
the rectifier assembly. (See Figure 28)

M6 x 25 Bolts

Figure 26 - Rear Exciter/Bearing Removal

Separating the Rectifier Assembly

Figure 28 - Rectifier Removal
from the Stator Housing
1. Remove all stator winding wire ring 2. Separate the rectifier assembly from the
terminals from the rectifier supporting the rear frame housing. (See Figure 29)
diode terminals with needle nose locking
pliers. Once removed, separate the stator
housing from the rectifier assembly. (See
Figure 27)

Figure 29 - Separated Rectifier

Figure 27 - Stator Removal

© 2012 EMP, Inc. 15

 Disassembly
Ground Isolated vs Non-Isolated

Figure 30 – Non-Isolated Figure 31 – Ground Isolated

© 2012 EMP, Inc. 16

 Assembly
Assembly of the Power 450™
Replacing the Rectifier Assembly to
the Rear Frame
1. Apply a thin layer of silicone to the entire
isolator gasket surface, lay the isolator
gasket onto the rear frame and apply
another layer of silicone.
2. Place the rectifier onto the rear frame
containing the silicone coated gasket. Figure 33 - Stator Terminals
3. Apply Loctite 242 to the fourteen M6x25
bolts that secure the rectifier assembly. CAUTION: Be sure to use EMP tools to
4. Torque to 80±8 in-lbs (9±0.9 Nm) in a star press new bearings. EMP tools are matched for
pattern. the bearing.

Rubber O-Ring and Spring Washer
1. Place a new rubber O-ring and spring
washer into the bearing seat located inside
the rear frame. (See Figure 32)
Spring
Washer
O-Ring
Placing the Exciters onto the Rotor
Assembly
1. Place the rear exciter (Identified by shorter
lead wire) into the backside of the rotor
assembly. Use the front bearing press
support tool on the spline end of the rotor to
support the rotor during the press operation.
2. Apply a small amount of 90W oil to the inner
bearing race or shaft.
3. Use the rear bearing press tool to press the
rear bearing onto the rotor assembly until
fully seated. The rear bearing must be
pressed flush to the machined step on the
rotor. (See Figure 34)

Figure 32

Attaching the Rectifier Assembly to

the Stator Housing
1. Place the rectifier assembly onto the stator
housing lining up the same position when
marked prior to disassembly. (See Figure
10)
2. Secure all stator winding ring terminals with
washers and nuts to the rectifier assembly Figure 34 - Rear Bearing Press
supporting the diode terminals with needle
nose vice grips.
3. Apply Loctite 242 to all stator stud terminals.
(See Figure 33)
4. Torque to 44±4 in-lbs (5±0.5 Nm).

© 2012 EMP, Inc. 17

 Assembly
4. Place the front exciter (Identified by a long
lead wire) onto the rotor assembly.
5. Apply a small amount of 90W oil to the inner
bearing race or the shaft.
6. Use the front bearing press tool to press the
front bearing’s inner race onto the rotor
assembly until seated. Use the rear bearing
press / support tool to stabilize the base of
the rotor assembly. (See Figure 35)

Figure 36 - Torque Front Frame

3. Insert the rotor/front frame assembly into
the Base Fixture and Front Bearing Support
Tool.
4. Fasten the front exciter wire with a p-clip to
the inside of the front frame using Loctite
242 on the fastener.
5. Using the Stator Rear Frame Assembly
Tool, support the stator from a hoist or lift
mechanism and locate the front frame
assembly/base fixture directly underneath.
6. Using a small gauge wire, pull the front
exciter wires through the previously marked
location on the stator housing. Pull the rear
exciter wires through the rear frame to the
same destination with a second piece of
wire. (See Figure 37 and Figure 38)
Figure 35 - Front Bearing Press

Placing the Rotor Assembly into the

Stator Housing
1. Use the rear bearing support tool to support
the rotor assembly. Place the alternator
front frame onto the front of the rotor
assembly aligning the p-clip mounting hole
to the front exciter wire.
2. Apply Loctite 242 to the six NEW M8x40
bolts on the center of the front frame. Insert
the bolts into the threads on the rotor
assembly and torque to 142±14 in-lbs
(16±1.6 Nm) in a star pattern. (See Figure
36)

Figure 37

© 2012 EMP, Inc. 18

 Assembly
11. Apply Loctite 242 to the eleven M6x140
bolts. Insert the bolts through the front
frame outer edge of the alternator. Hand
tighten all of them in a star pattern and then
torque to 80±8 in-lbs (9±0.9 Nm) in a star
pattern. (See Figure 40)

NOTE: Make sure each M6x140 bolt has a

flat washer. Flat washers may remain stuck in
the main front frame during disassembly.

Figure 38 - Exciter Wire Guide

7. Slowly lower the stator housing over the

rotor assembly
8. Use a 6” long #2 Phillips screwdriver to
align the exciter’s six M8x35 bolt holes with
the rear frame. As the stator is lowered,
align it to the front frame using the marked
alignment points made prior to Figure 40
disassembling. (See Figure 10)
9. Pull the exciter wires through during this 12. Apply Loctite 242 to the terminals and
process. Lower the stator until the rear fasteners for the exciter wires.
bearing is seated. 13. Attach the two red exciter wires and two
10. Apply Loctite 242 to the six M8x35 bolts for white exciter wires as shown in Figure 41
the rear rotor assembly. Insert the bolts into and torque to 44±4 in-lbs (5±0.5 Nm).
the threads and torque to 203±20 in-lbs
(23±2.3 Nm) in star pattern.

M8 x 35 Bolts

White Wires Red Wires

Figure 41

NOTE: Make sure to attach wire ties to

exciter wires.
Figure 39 - Rear Rotor Bolts

© 2012 EMP, Inc. 19

 Assembly
Replacing the Rear Cover
1. Align the holes on the alternator rear cover
to the power studs and bolt holes. Rotate
the grommets to align with the power stud
hex.
2. Push the F1/AC wire lead rubber grommets
through the holes until secured onto the
cover.
3. Push the rear cover onto alternator frame
and pull the excess F1/AC wire leads
through the rubber grommets.
4. Apply Loctite 242 to the four M6x60 bolts.
Torque to 80±8 in-lbs (9±0.9 Nm).

Replacing the Pulley and Fan

1. Slide the fan onto the alternator shaft with
the fan blades facing inward towards the
alternator.
2. Slide the pulley onto the shaft with the
marked face outward from the alternator.
3. Slide on the flat washer, new safety washer,
and nut.
4. Torque the nut to 180-215 ft-lbs (245-290
Nm).
5. Bend the safety washer over onto the nut.
(See Figure 42)
Bend Safety
Washer

Figure 42 - Safety Washer

CAUTION: Make sure to bend washer over

onto nut after reassembly. DO NOT reuse old
safety washers.

NOTE: Safety washers are supplied as part

of pulley hardware kit 1370028081 (that kit is
flat washer safety washer and nut) and are also
available in packs of 10 part number 1370028231.

© 2012 EMP, Inc. 20

 Troubleshooting
EMP Power 450™ b. Rear bearing spin free and is the
bore and journal within spec? (See
Troubleshooting
Figure 44)
Mechanical Procedures i. If not within spec, replace
component(s).
ii. If within spec, proceed to
NOTE: Removing the alternator belt on the
vehicle will allow a quick evaluation without
next step.
removal.

1. Does the shaft spin freely?

a. If “No” then proceed to step 2.
b. If “Yes” then proceed to Electrical
Procedures.
2. Follow the proper steps outlined in the
manual to disassemble alternator and
inspect parts and verify they are within
spec. (See Table 1 – J,K,L,M)
a. Front bearing spin free and is the
bore and journal within spec? (See
Figure 43)
i. If not within spec, replace
component(s). Figure 44 – Rear Bearing Bore and Journal
ii. If within spec, proceed to
next step.
Electrical Procedures

NOTE: Steps 1 through 4 can be performed

while alternator is installed in vehicle

1. Verify F1 is receiving 24-28 VDC signal. If

not, troubleshoot the voltage regulator.
2. Check F1 to Ground stud resistance and
verify it is within spec. (Figure 45) (See
Table 1 – A)

Figure 43 – Front Bearing Bore and Journal

Figure 45 – F1 to Ground Resistance

© 2012 EMP, Inc. 21

 Troubleshooting
3. Check AC to Ground stud resistance and 6. Measure both front and rear exciter leads
verify it is within spec. (Figure 46) (See and verify they are within spec. (See Figure
Table 1 – B) 49 and 50) (See Table 1 – D,E)

Figure 46 – AC to Ground Resistance

4. Check Positive to Ground stud resistance

and verify it is within spec. (Figure 47) (See
Table 1 – C)
Figure 49 Figure 50

NOTE: Make sure you are measuring

resistance across the red and white leads from
each exciter. (See Figure 49 and 50)

7. Remove stator leads from the rectifier

assembly, 12 in total – these leads need to
be completely separated from the rectifier
assembly or the measurements will not be
valid, diode damage may also occur.
Figure 47 – Positive Stud to Ground Stud
(Figure 51)
Resistance

5. Remove rear cover assembly (See ‘Remove

the Rear Cover’ and Figure 48) and remove
exciter leads from rectifier assembly.
(Figure 48)

Figure 51

Figure 48

© 2012 EMP, Inc. 22

 Troubleshooting
8. Measure Stator Leads and verify they are within spec. Use a Fluke 1587 or equivalent megohmmeter to
test the insulation resistance on all twelve stator leads. Connect the meter’s positive lead to the stator
lead and the meter’s negative lead to the stator’s steel frame. Set the meter at 250V and measure the
resistance. Resistance must exceed 1 mega ohm at 250V. Repeat on all twelve stator leads. (Figure
52) (See Table 1 – F)

Figure 52

9. Measure the Exciter Coil and verify it is within spec. Use a Fluke 1587 or equivalent megohmmeter to
test the insulation resistance on the exciter coil. Connect the meter’s positive lead to either exciter lead
and the meter’s negative lead to the exciter’s steel frame. Set the meter at 250V and measure the
resistance. Resistance must exceed 1 mega ohm at 250V. (Figure 53) (See Table 1 – G)

Figure 53

© 2012 EMP, Inc. 23

 Troubleshooting
NOTE: When a diode is bad: You’ll hear a continuous tone with a readout of 0.000 or the readout
will indicate any number value other than 0.400-0.600 or the readout with “OL."

10. Test rectifier diodes, with meter on diode setting (See Table 1 – H,I):
a. Negative lead on positive post and positive lead on stator lead Repeat for all twelve stator leads.
Verify measured value is within spec. (0.500±0.1V)

Figure 54

b. Positive lead on negative post and negative lead on stator lead Repeat for all twelve stator
leads. Verify measured value is within spec. (0.500±0.1V)

Figure 55

11. If all measurements are within spec then re-assemble alternator and verify its operation on a calibrated
test stand.

© 2012 EMP, Inc. 24

 Troubleshooting
Component Inspection Values
Table 1
Measurement P450 Specs
A F1 to Ground Stud 4.1±0.2 ohms
B AC to Ground Stud > 1 kilo ohm
C Positive Stud to Ground Stud > 1 kilo ohm
D Front Exciter Resistance 8.2±0.4 ohms
E Rear Exciter Resistance 8.2±0.4 ohms
F Stator Insulation Test @ 250V > 1 mega ohm
G Exciter Insulation Test @ 250V > 1 mega ohm
H Rectifier, Positive Stud to Stator Lead 0.5±0.1V
I Rectifier, Ground Stud to Stator Lead 0.5±0.1V
J Rear Bearing Bore 72.000 - 72.030 mm
K Front Bearing Bore 90.000 - 90.035 mm
L Front Rotor Bearing Journal 40.002 - 40.013 mm
M Rear Rotor Bearing Journal 35.002 - 35.013 mm

© 2012 EMP, Inc. 25

 Routine Maintenance/Technical Help
Routine Maintenance CAUTION: Ensure that all system power
and ground connection points are torqued to EMP
The following service intervals are
specifications to prevent system damage. Failure
recommended. Vehicle maintenance records must
to follow specified torque requirements at any
be maintained and consulted to provide information
point of the vehicle system power and ground
about alternator service interval data for your fleet. can result in loose connections which can damage
Frequency Action electronic components on the system and will
Every engine If using flexible ducting, inspect void EMP warranty.
oil change + air intake ducting for damage
(chafing or holes). Repair or
replace if damage is noted. WARNING: Use a backer wrench on all
Correct support devices to ensure studs before tightening nuts to prevent damage
damage will not reoccur. Clean air to the alternator.
intake screen if necessary.
Every 6 For solid or flexible ducting,
months + inspect air intake ducting for Technical Help
damage and clean air intake Contact EMP Customer Service for technical help
screen if necessary. at 1-906-789-7497 or service@emp-corp.com.
Every year + Inspect main power cables for
wear or frayed insulation and Additional information about this product is located
nylon bushings. Ensure under the support tab of the EMP official website:
connections are tightened to www.emp-corp.com
proper torque rating. Inspect F1
and AC harness for wear or
damaged insulation. Ensure all
wires and pin connections are
intact. Alternator cables must be
supported with a strain relief to
prevent relative motion of the
cable to the alternator
terminals; inspect cable support
structures for any damage or
loose hardware.
Every 2 Perform bearing replacement
years service.
EMP Power 450™ brushless
alternators used in transit
applications operating on a 16-18
hour day, 6 days a week, should
have bearings replaced at 2-year
intervals. For vehicles operating
more or in operating
environments with prolonged high
engine compartment
temperatures a shorter bearing
change interval may be the
preferred choice. See service
bulletin 9910028225.

+ Inspections should also be conducted after any service

to the unit.

© 2012 EMP, Inc. 26

 Wiring Schematics

Wiring Schematics

© 2012 EMP, Inc. 27

 Wiring Schematics

Figure 56 – Schematics for 3590028257and 3590028277

Alternator Chassis

© 2012 EMP, Inc. 28

 Wiring Schematics

Figure 57 – Schematics for 3590028267 and 3590028284

Alternator Chassis

© 2012 EMP, Inc. 29

 Wiring Schematics

Figure 58 - Schematics for 3590028041 and 3590028150

Alternator Chassis

© 2012 EMP, Inc. 30