Alternator, Leece-Neville 15.00

Transcription

1 Alternator, Leece-Neville 5.00 General Information General Description The Leece-Neville JB series alternator is a 4-volt self-load-limiting alternator equipped with a threestep adjustable voltage regulator. See Fig.. For voltage regulator adjustment procedures, see Subject 40. The LCF models have all the same improvements as the LC models. In addition, the front bearing is secured with five bolts instead of four. Mounting hardware and vehicle wiring require periodic inspection. See Group 5 of the Condor Maintenance Manual for instructions. Principles of Operation Current is produced by rotating a magnet inside a stationary winding. The rotating magnet is called a rotor and the stationary winding is called a stator. See Fig.. 09/0/95 f50554 N Fig., Three-Step Adjustable Voltage Regulator The optional SmartChek models feature a lightemitting diode (LED) that changes color to simplify troubleshooting. When the LED is green, the alternator is OK. When the LED is red, the alternator needs replacing. Six silicon diodes mounted in heat sinks convert alternating current from the delta-wound stator into direct current. A capacitor connected between the heat sinks helps suppress transient voltage spikes, which could possibly damage the diodes. The brushes and voltage regulator are located in a waterproof housing that may be removed for replacement or inspection. An external relay terminal is also provided for operation of a 7V battery isolator relay or other accessories that might require power from such a source. The voltage regulator is also equipped with transient voltage protection and will withstand instantaneous opening of the charging circuit under full load conditions. The LC models are identical to the JB models but are improved in the following ways: The rear rotor bearings are stronger and more durable; The diode post installation has been improved; The rectifier heat sink has a larger capacity. S 04//95 f5045a. Rotor. Stator Fig., Producing the Current The rotor is electrically magnetized by a small current flowing through the brushes, riding on smooth slip rings. See Fig.. Alternating current is then produced as the magnetic poles of the rotor pass the coil windings of the stator. 04//95 f5046a. Slip Rings. Brushes N S Fig., Magnetizing the Rotor Condor Workshop Manual, Supplement, June /

2 5.00 General Information Alternator, Leece-Neville These alternators have magnetic poles in the rotor. See Fig. 4. The stator has three separate windings. See Fig. 5. Since the rotor produces alternating current as it passes the coil windings of the stator, increased engine speed produces more current. 04//95 f50400a 04//95 f5047a Fig. 4, Rotor Fig. 6, Heat Sink When the headlights or accessories place a load on the battery, the regulator increases the current flow to the rotor, and alternator output increases, to maintain voltage. 04//95 f508a Fig. 5, Stator Rectifier assemblies convert alternating current to direct current for storage in the batteries. Rectifiers consist of silicon diodes that work as electrical switches and permit current flow in only one direction. They are mounted in an aluminum casting, which is finned to dissipate heat. This is called a heat sink. See Fig. 6. The voltage regulator controls the alternator output and the state of charge of the batteries. It is used in the charging system to regulate the battery voltage to the vehicle. See Fig.. The diode trio converts a small amount of alternating current from the stator into direct current which is used as a signal to turn on the regulator. When the battery is charged, the regulator reduces the field current flow to the rotor. Reducing the field current flow, in turn, reduces the alternator output. 050/ Condor Workshop Manual, Supplement, June 00

3 Alternator, Leece-Neville 5.00 JB Series Alternator Removal and Installation, Caterpillar 6/CFE Removal. Park the vehicle on a level surface, shut down the engine, apply the parking brakes, and chock the rear tires. 5. Insert a breaker bar in the belt tensioner and rotate the tensioner down and remove the belt from the alternator. See Fig.. DANGER Before tilting the cab or returning the cab to the normal operating position, read the instructions and the hazard notices in Section Failure to follow these instructions could cause the cab to fall and hit or crush a person, which will result in severe injury or death.. Tilt the cab. WARNING Before disconnecting the batteries, read the instructions and Danger and Warning notices in Section Keep sparks, flames, burning cigarettes, etc. away from batteries. Batteries generate explosive gases, which could cause a battery to explode, causing serious personal injury, including blindness.. Disconnect the batteries. 4. Mark all electrical leads and disconnect them from the alternator. See Fig.. 0/0/000 4 Rotate the belt tensioner down and off the belt.. JB Series Alternator. Alternator Mounting Capscrew, Top. Alternator Mounting Capscrew, Bottom 4. Refrigerant Compressor 5. Belt Tensioner 5 f506 Fig., Alternator Installation, Caterpillar 6/CFE Engine 6. Remove both alternator mounting capscrews. Remove the alternator from the vehicle. 7. Inspect the drive belt. For instructions, see Section 0.00, Subject /9/96 f Ground (G) Terminal. Output (BAT) Terminal Fig., Battery Lead Connections Installation. Install the alternator on the engine. Install the top and bottom alternator mounting capscrews, tighten both alternator mounting capscrews 65 lbf ft (88 N m).. Install the drive belt on the pulleys, as removed. If installing a new pulley or a new alternator, tighten the pulley nut 75 lbf ft (0 N m). For belt tightening procedures and specifications, see Section 0.00, Subject 0.. Verify that the edge of the tensioner arm is within the green zone on the decal. See Fig.. If within Condor Workshop Manual, Supplement 7, September /

4 5.00 JB Series Alternator Removal and Installation, Caterpillar 6/CFE Alternator, Leece-Neville the red zone, the tensioner will have to be replaced. For instructions, see the Caterpillar 6/ CFE Diesel Truck Engine Service Manual. 7. Before returning the vehicle to operation, test the alternator DC output voltage. For instructions, see "Alternator Voltage Test" in Troubleshooting, 00. DANGER Before tilting the cab or returning the cab to the normal operating position, read the instructions and the hazard notices in Section Failure to follow these instructions could cause the cab to fall and hit or crush a person, which will result in severe injury or death. 8. Return the cab to the normal operating position. 9. Remove the tire chocks. 0/8/96 A A. Belt Off, No Tension B. Belt On, Correct Tension. Decal. Edge of Tensioner Arm. Green Zone (operating range) B f0048 Fig., Belt Tensioner With Decal 4. Connect all leads to the back of the alternator as previously marked. Tighten the output terminal nut 00 lbf in (40 N cm). Tighten the ground terminal nut 65 lbf in (740 N cm). For other terminals, tighten thenut 0 lbf in (0 N cm). 5. Spray any exposed terminal connectors with dielectric red enamel. See Table. Protectant Material Spray-On Application Approved Brands MMM 60 IVI Spray Sealer, Red Electric Grade; order from the PDC Glyptal 0EW Low VOC, Brush-On Application Red; order at or -800-GLP-0 Table, Approved Dielectric Red Enamel 6. Connect the batteries. 00/ Condor Workshop Manual, Supplement 7, September 005

5 Alternator, Leece-Neville 5.00 JB Series Alternator Removal and Installation, Caterpillar C0/C Removal. Park the vehicle on a level surface, shut down the engine, apply the parking brakes, and chock the rear tires. 5. Insert a breaker bar in the belt tensioner and rotate the tensioner down and remove the belt from the alternator. See Fig.. DANGER Before tilting the cab or returning the cab to the normal operating position, read the instructions and the hazard notices in Section Failure to follow these instructions could cause the cab to fall and hit or crush a person, which will result in severe injury or death Tilt the cab. WARNING Before disconnecting the batteries, read the instructions and Danger and Warning notices in Section Keep sparks, flames, burning cigarettes, etc. away from batteries. Batteries generate explosive gases, which could cause a battery to explode, causing serious personal injury, including blindness.. Disconnect the batteries. 4. Mark all electrical leads and disconnect them from the alternator. See Fig.. 05/9/96 f Ground (G) Terminal. Output (BAT) Terminal Fig., Battery Lead Connections 06/06/ Remove both alternator mounting capscrews. Remove the alternator from the vehicle. 7. Inspect the drive belt. For instructions, see Section 0.00, Subject 00. Installation 0 f5057 Rotate the belt tensioner down and away from the belt.. JB Series Alternator. Alternator Mounting Capscrew, Top. Alternator Mounting Capscrew, Bottom 4. Fan Pulley 5. Refrigerant Compressor Drive Belt 6. Vibration Damper 7. Alternator Adjusting Strap 8. Adjusting Strap Mounting Capscrew 9. Belt Tensioner 0. Alternator Drive Belt Fig., Alternator Installation, Caterpillar C-0/C- Engine. Install the alternator on the engine. Install the top and bottom alternator mounting capscrews, tighten both alternator mounting capscrews 65 lbf ft (88 N m). 6 Condor Workshop Manual, Supplement 7, September 005 0/

6 5.00 JB Series Alternator Removal and Installation, Caterpillar C0/C Alternator, Leece-Neville. Install the drive belt on the pulleys, as removed. If installing a new pulley or a new alternator, tighten the pulley nut 75 lbf ft (0 N m). For belt tightening procedures and specifications, see Section 0.00, Subject 0.. Verify that the edge of the tensioner arm is within the green zone on the decal. See Fig.. If within the red zone, the tensioner will have to be replaced. For instructions, see the Caterpillar C0/ C Diesel Truck Engine Service Manual. Protectant Material Approved Brands Glyptal 0EW Low VOC, Brush-On Application Red; order at or -800-GLP-0 Table, Approved Dielectric Red Enamel 6. Connect the batteries. 7. Before returning the vehicle to operation, test the alternator DC output voltage. For instructions, see "Alternator Voltage Test" in Troubleshooting, 00. DANGER Before tilting the cab or returning the cab to the normal operating position, read the instructions and the hazard notices in Section Failure to follow these instructions could cause the cab to fall and hit or crush a person, which will result in severe injury or death. 8. Return the cab to the normal operating position. 9. Remove the tire chocks. 0/8/96 A A. Belt Off, No Tension B. Belt On, Correct Tension. Decal. Edge of Tensioner Arm. Green Zone (operating range) B f0048 Fig., Belt Tensioner With Decal 4. Connect all leads to the back of the alternator as previously marked. Tighten the output terminal nut 00 lbf in (40 N cm). Tighten the ground terminal nut 65 lbf in (740 N cm). For other terminals, tighten the nut 0 lbf in (0 N cm). 5. Spray any exposed terminal connectors with dielectric red enamel. See Table. Protectant Material Spray-On Application Approved Brands MMM 60 IVI Spray Sealer, Red Electric Grade; order from the PDC 0/ Condor Workshop Manual, Supplement 7, September 005

7 Alternator, Leece-Neville 5.00 JB Series Alternator Removal and Installation, Cummins ISC/ISL Removal. Park the vehicle on a level surface, shut down the engine, apply the parking brakes, and chock the rear tires. 5. Insert a breaker bar in the belt tensioner and rotate the tensioner up and remove the belt from the alternator. See Fig.. DANGER Before tilting the cab or returning the cab to the normal operating position, read the instructions and the hazard notices in Section Failure to follow these instructions could cause the cab to fall and hit or crush a person, which will result in severe injury or death. 6. Tilt the cab. WARNING Before disconnecting the batteries, read the instructions and Danger and Warning notices in Section Keep sparks, flames, burning cigarettes, etc. away from batteries. Batteries generate explosive gases, which could cause a battery to explode, causing serious personal injury, including blindness.. Disconnect the batteries. 4. Mark all electrical leads and disconnect them from the alternator. See Fig.. 05/9/96 f Ground (G) Terminal. Output (BAT) Terminal Fig., Battery Lead Connections 5 4 0/0/00 f508. Alternator Mounting Capscrew, Top. Alternator Drive Belt. Idler Pulley 4. Belt Tensioner 5. Alternator Mounting Capscrew, Bottom 6. JB Series Alternator Fig., Alternator Installation, Cummins ISC/ISL Engines 6. Remove both alternator mounting capscrews. Remove the alternator from the vehicle. Installation. Install the alternator on the engine. Install the top and bottom alternator mounting capscrews, tighten both alternator mounting capscrews 65 lbf ft (88 N m). Condor Workshop Manual, Supplement 7, September 005 0/

8 5.00 JB Series Alternator Removal and Installation, Cummins ISC/ISL Alternator, Leece-Neville. Install the drive belt on the pulleys, as removed. If installing a new pulley or a new alternator, tighten the pulley nut 75 lbf ft (0 N m).. Connect all leads to the back of the alternator as previously marked. Tighten the output terminal nut 00 lbf in (40 N cm). Tighten the ground terminal nut 65 lbf in (740 N cm). For other terminals, tighten the nut 0 lbf in (0 N cm). 4. Spray any exposed terminal connectors with dielectric red enamel. See Table. Protectant Material Spray-On Application Approved Brands MMM 60 IVI Spray Sealer, Red Electric Grade; order from the PDC Glyptal 0EW Low VOC, Brush-On Application Red; order at or -800-GLP-0 Table, Approved Dielectric Red Enamel 5. Connect the batteries. 6. Before returning the vehicle to operation, test the alternator DC output voltage. For instructions, see "Alternator Voltage Test" in Troubleshooting, 00. DANGER Before tilting the cab or returning the cab to the normal operating position, read the instructions and the hazard notices in Section Failure to follow these instructions could cause the cab to fall and hit or crush a person, which will result in severe injury or death. 7. Return the cab to the normal operating position. 8. Remove the tire chocks. 0/ Condor Workshop Manual, Supplement 7, September 005

9 Alternator, Leece-Neville 5.00 JB Series Alternator Removal and Installation, Cummins ISM Removal. Park the vehicle on a level surface, shut down the engine, apply the parking brakes, and chock the rear tires. 5. Insert a breaker bar in the belt tensioner and rotate the tensioner down and remove the belt from the alternator. See Fig.. DANGER Before tilting the cab or returning the cab to the normal operating position, read the instructions and the hazard notices in Section Failure to follow these instructions could cause the cab to fall and hit or crush a person, which will result in severe injury or death Tilt the cab. WARNING Before disconnecting the batteries, read the instructions and Danger and Warning notices in Section Keep sparks, flames, burning cigarettes, etc. away from batteries. Batteries generate explosive gases, which could cause a battery to explode, causing serious personal injury, including blindness.. Disconnect the batteries. 4. Mark all electrical leads and disconnect them from the alternator. See Fig.. 0/09/00 f505 Rotate the belt tensioner down and away from the belt.. Belt Tensioner. Idler Pulley. Alternator Mounting Capscrew 4. JB Series Alternator 5. Alternator Drive Belt Fig., Alternator Installation, Cummins ISM Engine 05/9/96 f Ground (G) Terminal. Output (BAT) Terminal Fig., Battery Lead Connections 6. Remove both alternator mounting capscrews. Remove the alternator from the vehicle. Installation. Install the alternator on the engine. Install the top and bottom alternator mounting capscrews, Condor Workshop Manual, Supplement 7, September 005 0/

10 5.00 JB Series Alternator Removal and Installation, Cummins ISM Alternator, Leece-Neville tighten both alternator mounting capscrews 65 lbf ft (88 N m).. Install the drive belt on the pulleys, as removed. If installing a new pulley or a new alternator, tighten the pulley nut 75 lbf ft (0 N m).. Connect all leads to the back of the alternator as previously marked. Tighten the output terminal nut 00 lbf in (40 N cm). Tighten the ground terminal nut 65 lbf in (740 N cm). For other terminals, tighten the nut 0 lbf in (0 N cm). 4. Spray any exposed terminal connectors with dielectric red enamel. See Table. Protectant Material Spray-On Application Approved Brands MMM 60 IVI Spray Sealer, Red Electric Grade; order from the PDC Glyptal 0EW Low VOC, Brush-On Application Red; order at or -800-GLP-0 Table, Approved Dielectric Red Enamel 5. Connect the batteries. 6. Before returning the vehicle to operation, test the alternator DC output voltage. For instructions, see "Alternator Voltage Test" in Troubleshooting, 00. DANGER Before tilting the cab or returning the cab to the normal operating position, read the instructions and the hazard notices in Section Failure to follow these instructions could cause the cab to fall and hit or crush a person, which will result in severe injury or death. 7. Return the cab to the normal operating position. 8. Remove the tire chocks. 0/ Condor Workshop Manual, Supplement 7, September 005

11 Alternator, Leece-Neville 5.00 Voltage Regulator Adjustment Adjustment NOTE: Before checking or adjusting the alternator voltage, check the wiring, connections, and belt tension.. Park the vehicle on a level surface, apply the parking brake and chock the rear tires.. Turn off all accessories. Run the engine at fast idle (approximately 00 RPM) and charge the batteries.. Connect an accurate voltmeter across the batteries to determine the charging voltage. If the voltage is below.8v, or above 4.V, adjust the voltage regulator. 4. Shut down the engine. 5. If needed, adjust the charging voltage. 5. Remove the small black cap on the regulator cover to expose the adjustment screw. 5. Using a small screwdriver, turn the adjusting screw until the voltage is between.8v and 4.V. To increase the voltage, turn the adjusting screw clockwise. To decrease the voltage, turn the adjusting screw counterclockwise. 6. Run the engine at fast idle (approximately 00 RPM) and check the voltage again to make sure it has been properly adjusted. Readjust as necessary. NOTE: If adjustment does not bring the voltage into the proper range, replace the voltage regulator. 7. Shut down the engine. 8. Replace the plastic cap on the access hole over the adjusting screw. 9. Remove the chocks from the tires. Condor Workshop Manual, Supplement, June 00 40/

12 Alternator, Leece-Neville 5.00 Troubleshooting Troubleshooting The following symptoms indicate that the batteries may be undercharged: The engine does not crank or only cranks slowly The vehicle lights are dim The turn signals flash more slowly than normal The voltmeter reads low The following symptoms indicate that the batteries may be overcharged: The battery smells bad The battery is swollen or spews electrolyte The lights are brighter than normal The lights are burned out, or burn out when the engine starts The voltmeter reads high To troubleshoot the SmartChek diagnostic alternator, do the following steps:. With the engine off, clean the top of the regulator using a shop cloth until you can see the Smart- Chek indicator.. Start the engine. If the SmartChek indicator glows red, replace the alternator. If the indicator glows green, go to the next step.. Turn on a number of vehicle accessories, such as lights and heater fans. If the green indicator changes to red, replace the alternator. If the indicator continues to glow green, the alternator is OK. Check the other components of the electrical system. Troubleshooting Tables Problem The Batteries Seem Undercharged Possible Cause The drive belt is loose. The drive belt is damaged or missing. The batteries cannot hold a charge. The wiring is not delivering sufficient voltage to fully charge the batteries. The wiring is undersized. Terminals are corroded, broken, loose, or dirty. The battery cables do not deliver sufficient voltage to the starter. The alternator is malfunctioning. Problem The Batteries Seem Undercharged Remedy Check the drive belt. See the drive belt subject in the appropriate engine section in Group 0 for instructions. If necessary, tighten to the manufacturer s specifications. Start the engine and do the "Alternator Troubleshooting Tests." Check the drive pulleys for locked bearings. Repair or replace any damaged components. Replace the drive belt and crank the engine. If the engine cranks OK, do the "Alternator Troubleshooting Tests." If the engine still cranks slowly, check the cranking circuit. Go to "Cranking Circuit Test" in Section 5.0, Subject 00 for instructions. Do a load test on the batteries. See Section 54.0, Subject 0 for instructions. Charge or replace batteries as needed. If the batteries were discharged, but are able to hold a charge, do the "Alternator Troubleshooting Tests." Check the wiring and repair or replace any broken wires. Ensure the proper size wire is being used. Replace any undersized wire. Clean, tighten, repair, and replace terminals as needed. Check the available cranking voltage. Go to "Available Cranking Voltage Test" in Section 5.0, Subject 00 for instructions. Replace the alternator. Condor Workshop Manual, Supplement, June 00 00/

13 5.00 Troubleshooting Alternator, Leece-Neville Problem The Batteries Seem Overcharged Possible Cause The batteries are overheated. The batteries need replacing. The voltage regulator is poorly adjusted or damaged. Problem The Batteries Seem Overcharged Remedy Check battery temperatures. If 0 F (49 C) or above, connect cool, fully charged batteries and do the "Alternator Troubleshooting Tests." If 9 F (48 C) or below, load test the batteries. See Section 54.0, Subject 0 for instructions. Check battery temperatures. If 9 F (48 C) or below, load test the batteries. See Section 54.0, Subject 0 for instructions. Do the "Alternator Troubleshooting Tests." If the voltmeter reads below.6v or above 4.V, adjust the voltage regulator. For instructions, see Subject 40. Do the "Alternator Troubleshooting Tests" again. If adjusting the voltage regulator did not bring the voltmeter reading within the range of.6v to 4.V, replace the alternator. Alternator Troubleshooting Tests IMPORTANT: Before starting these tests, make sure of the following: All belts are correctly tightened The wiring and terminals are clean and in good condition All terminal nuts are torqued and properly protected The alternator troubleshooting tests in this subject have been designed to clearly determine when the alternator needs replacement. See Fig. for a troubleshooting flow chart. Test #: Battery Open Circuit Voltage. Check the battery open circuit voltage (OCV). See Fig... Shut down the engine.. Using a digital volt-ohmmeter (VOM) set on the -0VDC (or similar) scale, check the battery open circuit voltage (OCV). Set up the voltmeter as shown in Fig... If the OCV is.4 volts or more, turn on the vehicle headlights for approximately minutes. If the OCV is less than.4 volts, charge the batteries properly. For instructions, see Section 54.0, Subject 0. IMPORTANT: Be sure to disconnect the batteries or remove them from the vehicle before charging.. Do "Test #: Alternator Voltage Output." Test #: Alternator Voltage Output. Check the alternator output without a load. See Fig... Start the engine and run it at 500 rpm.. Connect the positive lead of the digital voltmeter (still set on the high scale) to the alternator BAT (+) terminal. Connect the negative lead of the voltmeter to the alternator G ( ) terminal. See Fig... If the voltmeter reads from.8 to 4. volts, record this reading (V) and go to the next step. If the voltmeter reads less than.8 or more than 4. volts, try to adjust the regulator to 4.0V. If the regulator cannot be adjusted to a voltage within.8v and 4.V, replace the alternator. IMPORTANT: On Leece-Neville alternators with adjustable regulators, there may be 00/ Condor Workshop Manual, Supplement, June 00

14 Alternator, Leece-Neville 5.00 Troubleshooting TEST BATTERY OCV (See TEST #) OCV LESS THAN.4 V CHARGE BATTERIES OCV.4 V OR MORE TURN ON HEADLIGHTS FOR MINUTES START ENGINE SET TO 500 RPM REPLACE ALTERNATOR CHECK VOLTAGE AT ALTERNATOR.8 4. VOLTS (See TEST #) NO CONNECT CARBON PILE TESTER AND AMMETER (See TEST #) YES LOAD ALTERNATOR AMPS TURN OFF ALL VEHICLE LOADS RUN ENGINE AT MAX RPM CHECK VOLTAGE AT ALTERNATOR.6 4. VOLTS (See TEST #) YES NO REPEAT TEST NO ADJUST TESTER TO ALTERNATOR MAX CURRENT OUTPUT CURRENT READING WITHIN 85% OF RATED CURRENT YES NO YES ALTERNATOR IS OK CHECK SYSTEM WIRING (See TEST #) TEST COMPLETE 0/9/98 f04047 Fig., Alternator Troubleshooting sealant in the adjustment screw hole when the cap is removed. If so, do not attempt to Condor Workshop Manual, Supplement, June 00 00/

15 5.00 Troubleshooting Alternator, Leece-Neville 0/6/97 f Battery. Digital Voltmeter Fig., Test #: Battery Open Circuit Voltage 6 B G 5 0/6/98 f5098a A. Locate the ammeter at least 6 inches (5 cm) away from the alternator.. Battery 4. Alternator. Digital Voltmeter 5. Cranking Motor. Ammeter 6. Solenoid Fig., Test #: Alternator Voltage Output adjust the regulator; instead, put the cap back on and replace the alternator if the voltage output is not within spec.. Check the alternator output under load. See Fig... Attach a clamp-on induction ammeter around the alternator output (+) wire. See Fig.. NOTE: Locate the ammeter at least 6 inches (5 cm) away from the alternator. 4 A. With the engine still running at 500 rpm, turn on the following electrical accessories to load the alternator until the ammeter reads 60 to 75 amps. Both front and rear heater blowers (on HIGH) Headlights (high beams) Road lights Interior lights NOTE: As an alternate method of putting load on the alternator, connect a carbon pile tester and set it to 60 to 75 amps.. Keep the voltmeter connected as in the previous step (positive lead connected to the alternator BAT (+) terminal; negative lead to the alternator G ( ) terminal)..4 If the voltmeter reads from.6 to 4. volts, the alternator is not the problem. Record this reading (V) and go to the next step. If the voltmeter reads less than.6 volts, replace the alternator.. Do "Test #: Alternator Amperage Output." Test #: Alternator Amperage Output. Check the alternator amperage output.. Connect a carbon pile tester across the vehicle batteries as shown in Fig. 4.. Attach a clamp-on induction ammeter around the alternator output (+) wire. See Fig.. NOTE: Locate the ammeter at least 6 inches (5 cm) away from the alternator.. Start the engine and make sure all vehicle electrical accessories are turned off. Run it at 500 rpm, and adjust the tester to the alternator maximum current output. Record this output value. NOTE: Ensure that the alternator is turning at maximum available rpms, and then keep adjusting the tester until the ammeter reads its highest value. 00/4 Condor Workshop Manual, Supplement, June 00

16 Alternator, Leece-Neville 5.00 Troubleshooting 6 B G 5 4 0/5/98 f50948 A. Locate the ammeter at least 6 inches (5 cm) away from the alternator.. Battery 4. Alternator. Carbon Pile Tester 5. Cranking Motor. Ammeter 6. Solenoid A. Compare the two readings. If the reading at the batteries is within 0.5 volts of the reading at the alternator, the charging system is working correctly. Check other areas of the vehicle to locate the problem. If the reading at the batteries is more than 0.5 volts lower than the reading at the alternator, do the next step.. Check charging system connections, cables, and terminals.. Check all connections between the battery, starter, and alternator for tightness and signs of corrosion. Tighten and clean as necessary.. Check all cables for breaks or partial breaks. Repair or replace as necessary.. Check each ring terminal for breakage at the point where it attaches to its wire or cable. Fig. 4, Test #: Alternator Amperage Output.4 Turn off the tester and shut down the engine..5 If the output value recorded is less than 85% of the rated amperage output, repeat the test. If the output value recorded is still less than 85% of the rated amperage output, replace the alternator..6 Make sure that all test instruments are removed and that the vehicle wiring is returned to its operational state.. To identify other problem areas within the vehicle, check the operation of the charging system. NOTE: For any load at 500 rpm or more, battery voltage must be within 0.5 volts of the alternator voltage.. Check the battery open circuit voltage as shown in Fig.. Make a note of this reading.. Check the alternator voltage output as shown in Fig.. Make a note of this reading also. Condor Workshop Manual, Supplement, June 00 00/5

17 Alternator, Delco Remy 5.0 General Information General Description The Condor chassis may be equipped with either a Delco Remy SI series or a SI series alternator. See Fig. and Fig.. The SI alternator features a solid-state voltage regulator mounted inside the end frame. The only moving part is the rotor, which is mounted on a ball bearing at the drive end, and a roller bearing at the rectifier end. See Fig.. The SI alternator is similar in construction, differing only in output and regulator placement. The regulator of the SI alternator is mounted externally on the rear of the alternator body, for ease of replacement. See Fig.. All bearings are sealed so that no periodic maintenance is required. The regulator and diodes are enclosed in a sealed compartment. A fan located on the drive end provides air flow for cooling. In a one-wire system, the voltages at start-up are generated by residual magnetism within the rotor. In a three-wire system, rotor magnetism is boosted at start-up by field current entering through the # regulator terminal then flowing through the rotor windings. Normally only one wire connects the alternator to the battery at the starter, along with a ground return. Since the vehicle s system is a negative ground, the output terminal connects to the starter s positive terminal A 0/0/96 A. Rectifier End B. Drive End. Rectifier Bridge 5. Frame, Rectifier End. Relay ("R") Terminal 6. Stator. Output ("BAT") Terminal 7. Frame, Drive End 4. Indicator Light ("I") Terminal 8. Adjustment Lug B 9. Fan 0. Pulley. Mounting Lug f5049a Fig., Delco Remy -SI Alternator (exterior view) Condor Workshop Manual, Supplement 0, January /

18 5.0 Alternator, Delco Remy General Information /06/000 f505. Voltage Regulator. Indicator Light ("I") Terminal. Sense Terminal 4. Relay ("R") Terminal 5. Output ("BAT") Terminal 6. Rectifier Bridge Fig., Delco Remy -SI Alternator (exterior view) 07/0/94. Rotor. Roller Bearings. Brushes 4. Regulator 5. Field Windings 6. Ball Bearings f5050a Fig., Delco Remy -SI Alternator (cutaway view) 050/ Condor Workshop Manual, Supplement 0, January 000

19 Alternator, Delco Remy 5.0 Alternator Removal and Installation, Caterpillar Engines Removal. Park the vehicle on a level surface, shut down the engine, apply the parking brakes, and chock the rear tires. DANGER Before tilting the cab or returning the cab to the normal operating position, read the instructions and the hazard notices in Section of this workshop manual. Failure to follow these instructions could cause the cab to fall and hit or crush a person, which will result in severe injury or death.. Tilt the cab. 4 WARNING Before disconnecting the batteries, read the instructions and Danger and Warning notices in Section 54.0 of this workshop manual. Keep sparks, flames, burning cigarettes, etc. away from batteries. Batteries generate explosive gases, which could cause a battery to explode, causing serious personal injury, including blindness.. Disconnect the batteries. 4. Mark all electrical leads and disconnect them from the alternator. 5. Remove the drive belts and note the routing. For instructions, see Section Remove the alternator. See Fig.. 6. Remove the upper alternator mounting capscrew. 6. Remove the lower alternator mounting capscrews. 6. Remove the alternator from the vehicle. 7. Inspect the drive belt. Installation. Install a new pulley, if applicable, and tighten the shaft nut to 75 lbf ft (0 N m). 0/0/000. Upper Mounting Capscrew. Alternator. Lower Mounting Capscrew 4. Refrigerant Compressor 5. Belt Tensioner Fig., Alternator Mounting 5 f506. Install the alternator on the mounting bracket. See Fig... Install the lower mounting capscrews.. Install the upper mounting capscrew.. Tighten the mounting capscrews 65 lbf ft (88 N m).. Install the drive belt on the pulley as removed. For instructions, see Section NOTE: The belt tensioner automatically adjusts the drive belt to the correct tension. If the belt slips, repair or replace the tensioner. For instructions, see the engine manufacturer s service literature. 4. Connect all leads to the back of the alternator as previously marked and tighten. See Specifications Spray any exposed terminal connectors with dielectric red enamel. See Table for approved brands. Condor Workshop Manual, Supplement 7, September /

20 5.0 Alternator Removal and Installation, Caterpillar Engines Alternator, Delco Remy Protectant Material Spray-On Application Approved Brands MMM 60 IVI Spray Sealer, Red Electric Grade; order from the PDC Glyptal 0EW Low VOC, Brush-On Application Red; order at or -800-GLP-0 Table, Approved Dielectric Red Enamel 6. Connect the batteries. 7. Before returning the vehicle to operation, test the alternator DC output voltage. For instructions, see "Alternator Voltage Output Test" or use the Delco Intelli-Check Alternator Analyzer ( SI only) in Troubleshooting, 00. DANGER Before tilting the cab or returning the cab to the normal operating position, read the instructions and the hazard notices in Section of this workshop manual. Failure to follow these instructions could cause the cab to fall and hit or crush a person, which will result in severe injury or death. 8. Return the cab to the normal operating position. 9. Remove the tire chocks. 00/ Condor Workshop Manual, Supplement 7, September 005

21 Alternator, Delco Remy 5.0 Alternator Removal and Installation, Cummins Engines Removal. Park the vehicle on a level surface, shut down the engine, apply the parking brakes, and chock the rear tires. DANGER Before tilting the cab or returning the cab to the normal operating position, read the instructions and the hazard notices in Section Failure to follow these instructions could cause the cab to fall and hit or crush a person, which will result in severe injury or death.. Tilt the cab. WARNING Before disconnecting the batteries, read the instructions and Danger and Warning notices in Section Keep sparks, flames, burning cigarettes, etc. away from batteries. Batteries generate explosive gases, which could cause a battery to explode, causing serious personal injury, including blindness.. Disconnect the batteries. 4. Mark all electrical leads and disconnect them from the alternator. 5. Remove the drive belts and note the routing. 6. Remove the alternator. See Fig.. 6. Remove the alternator mounting capscrew (Ref. 8) from the link (Ref. 7). 6. Remove the nut and washer (Refs. 5 and 4) from the pivot bolt (Ref. ). 6. Securely hold the alternator to prevent it from falling, and remove the pivot bolt. 6.4 Remove the alternator from the vehicle. 7. Inspect the drive belt. Installation. Install a new pulley, if applicable, and tighten the shaft nut to 75 lbf ft (0 N m).. Install the alternator on the pivot bracket. See Fig /09/96 f5059. Pivot Capscrew. Mounting Lug. Pivot Bracket 4. Washer 5. Pivot Nut 6. Alternator Link Fastener 7. Alternator Link 8. Alternator Mounting Capscrew 7 Fig., Mounting Hardware. Position the alternator on the bracket.. Insert the pivot bolt (Ref. ) through the alternator and the bracket.. Install the washer and nut (Refs. 4 and 5) on the end of the pivot bolt.. Check the torque of the alternator bracket fasteners. If necessary, tighten, see Specifications Install the alternator mounting capscrew, and tighten it 65 lbf ft (88 N m). Tighten the pivot nut 65 lbf ft (88 N m). 5. Install the drive belt on the pulley as removed. NOTE: The belt tensioner automatically adjusts the drive belt to the correct tension. If the belt slips, repair or replace the tensioner. For instructions, see the engine manufacturer s service literature Condor Workshop Manual, Supplement 7, September 005 0/

22 5.0 Alternator Removal and Installation, Cummins Engines Alternator, Delco Remy 6. Connect all leads to the back of the alternator as previously marked and tighten. See Specifications Spray any exposed terminal connectors with dielectric red enamel. See Table for approved brands. Protectant Material Spray-On Application Approved Brands MMM 60 IVI Spray Sealer, Red Electric Grade; order from the PDC Glyptal 0EW Low VOC, Brush-On Application Red; order at or -800-GLP-0 Table, Approved Dielectric Red Enamel 8. Connect the batteries. 9. Before returning the vehicle to operation, test the alternator DC output voltage. For instructions, see "Alternator Voltage Output Test" or use the Delco Intelli-Check Alternator Analyzer ( SI only) in Troubleshooting, 00. DANGER Before tilting the cab or returning the cab to the normal operating position, read the instructions and the hazard notices in Section Failure to follow these instructions could cause the cab to fall and hit or crush a person, which will result in severe injury or death. 0. Return the cab to the normal operating position.. Remove the tire chocks. 0/ Condor Workshop Manual, Supplement 7, September 005

23 Alternator, Delco Remy 5.0 Troubleshooting Troubleshooting WARNING Keep sparks, flames, burning cigarettes, etc. away from batteries. Batteries generate explosive gases, which could cause a battery to explode, causing serious personal injury, including blindness. Before troubleshooting the alternator, make sure that the batteries are properly charged, neither overcharged or undercharged. The following symptoms indicate that the batteries may be undercharged: The engine does not crank or only cranks slowly The vehicle lights are dim The turn signals flash more slowly than normal The voltmeter reads low The following symptoms indicate that the batteries may be overcharged: The battery smells bad The battery is swollen or spews electrolyte The lights are brighter than normal The lights are burned out, or burn out when the engine starts The voltmeter reads high Alternator Troubleshooting Tests IMPORTANT: Before starting these tests, make sure of the following: All belts are correctly tightened The wiring and terminals are clean and in good condition All terminal nuts are torqued and properly protected Delco Remy has an alternator testing tool called the Intelli-Check Alternator Analyzer. See Fig.. This tool (DR , a single tester, or DR , a four-pack of testers) is to be used as a quick check of the alternator to see if it is working correctly. NOTE: If you do not have the Delco Intelli- Check Tester, the alternator rated output is above 45 amps (as is the case of the SI), or if a total vehicle charging system analysis is required, see "Alternator/Charging System Testing." Intelli-Check Alternator Analyzer IMPORTANT: The Intelli-Check Alternator Analyzer cannot be used with the SI alternator. The following information includes a pre-test procedure and operating instructions for the Delco tester, and is similar to the procedures provided with the Intelli-Check Tester. Pre-Test Procedure (Engine Off). Inspect the alternator connections to verify that all terminals are secured and tight. Verify that the sense wire is connected to the sense terminal on vehicles equipped with remote-sense alternators.. With the engine off, connect the red alligator clip to the output terminal of the alternator. Connect the black alligator clip to the alternator ground. An optional ground connection is to the body of the alternator. The tester LEDs will illuminate and then go off as it performs a self-test.. After 4 seconds the tester will activate. The following LEDs may illuminate depending on the condition of the batteries: GOOD (green) LED indicates the battery voltage is above.8 and has a surface charge. The surface charge must be removed before proceeding with the alternator test. To remove the surface charge, do the following: A. Turn on the headlights and blower motor for minutes without restarting the engine. B. Reset the tester by disconnecting, then reconnecting the tester alligator clips. The analyzer will again perform its self-test. C. Repeat the applicable steps of the Pre-Test Procedure. Condor Workshop Manual, Supplement 0, January /

24 5.0 Troubleshooting Alternator, Delco Remy 09/0/99 f5098. Red Alligator Clip. Black Alligator Clip. Hand-Held Alternator Analyzer Fig., Delco Remy Intelli-Check Alternator Analyzer NO CHARGE (red) LED indicates the battery voltage is below.8. This LED should illuminate for most tests. Proceed with the alternator test. LOW BATTERY VOLTAGE (blue) LED indicates the battery voltage is below.5. If the batteries will start the vehicle, proceed with the alternator test. However, after completing the Intelli-Check alternator test, perform the procedures under "Alternator/Charging System Testing" to determine the condition of the rest of the charging system. Tester Operating Instructions (Engine Running). Start the engine using onboard batteries only. If the batteries will not start the engine, they must be charged for hours. Start the test again after charging the batteries.. Verify the engine is at idle and all electrical loads are off.. Depress the accelerator to governed speed, hold for 0 seconds, then return to idle. If the GOOD (green) LED illuminates, proceed to the next step. If any LEDs illuminate indicating overcharge, partial charge or no charge (the three red lights in the DEFECTIVE section), replace the alternator and run the complete test again. If the LOW BATTERY VOLTAGE (blue) LED illuminates, evaluate the charging system using the instructions in "Alternator/Charging System Testing." 4. With the engine running, turn on all electrical loads. 5. Depress the accelerator to governed speed, hold for 0 seconds, then return to idle. 00/ Condor Workshop Manual, Supplement 0, January 000

25 Alternator, Delco Remy 5.0 Troubleshooting 6. If the GOOD (green) LED illuminates, the alternator is OK electronically and the test is complete. NOTE: If the alternator tests OK in the above tests, and the customer s complaint is reduced battery or headlight life, see "Alternator/ Charging System Testing" to completely analyze the charging system. 7. If any LEDs illuminate indicating overcharge, partial charge or no charge (the three red lights in the DEFECTIVE section), replace the alternator and run the complete test again. 8. If the LOW BATTERY VOLTAGE (blue) LED illuminates, evaluate the charging system using the instructions in "Alternator/Charging System Testing." Alternator/Charging System Testing The alternator troubleshooting tests in this subject have been designed to clearly determine when the alternator needs replacement. See Fig. for a troubleshooting flow chart. Test #: Battery Open Circuit Voltage. Check the battery open circuit voltage (OCV). See Fig... Using a digital volt-ohmmeter (VOM) set on the -0VDC (or similar) scale, check the battery open circuit voltage (OCV). With the engine shut down, set up the voltmeter as shown in Fig... If the OCV is.4 volts or more, turn on the vehicle headlights for approximately minutes. If the OCV is less than.4 volts, charge the batteries properly. For instructions, see Section 54.0, Subject 0. IMPORTANT: Be sure to disconnect the batteries or remove them from the vehicle before charging.. Do "Test #: Alternator Voltage Output." Test #: Alternator Voltage Output. Check the alternator output without a load. See Fig. 4.. Start the engine and run it at 500 rpm.. Connect the positive lead of the digital voltmeter (still set on the high scale) to the alternator BAT (+) terminal. Connect the negative lead of the voltmeter to the alternator G ( ) terminal.. If the voltmeter reads from.8 to 4. volts, record this reading (V) and go to the next step. If the voltmeter reads less than.8 volts, replace the alternator. If the voltmeter reads more than 4. volts, replace the alternator. NOTE: Delco alternators do not have adjustable voltage regulators.. Check the alternator output under load. See Fig. 4.. Attach a clamp-on induction ammeter around the alternator output (+) wire. See Fig. 4. NOTE: Locate the ammeter at least 6 inches (5 cm) away from the alternator. NOTE: The preferred method of putting a load on the alternator is to connect a carbon pile tester and set it to amps.. Keep the voltmeter connected as in the previous step (positive lead connected to the alternator BAT (+) terminal; negative lead to the alternator G ( ) terminal). NOTE: As an alternate method of loading the alternator, locate the ammeter at least 6 inches (5 cm) away from the alternator. With the engine still running at 500 rpm, turn on the following electrical accessories to load the alternator until the ammeter reads amps. HVAC blower (on HIGH) Headlights (high beams) Interior lights Condor Workshop Manual, Supplement 0, January /

26 5.0 Troubleshooting Alternator, Delco Remy TEST BATTERY OCV (See TEST #) OCV LESS THAN.4 V CHARGE BATTERIES OCV.4 V OR MORE TURN ON HEADLIGHTS FOR MINUTES START ENGINE SET TO 500 RPM REPLACE ALTERNATOR CHECK VOLTAGE AT ALTERNATOR.8 4. VOLTS (See TEST #) NO CONNECT CARBON PILE TESTER AND AMMETER (See TEST #) YES LOAD ALTERNATOR AMPS TURN OFF ALL VEHICLE LOADS RUN ENGINE AT MAX RPM CHECK VOLTAGE AT ALTERNATOR.6 4. VOLTS (See TEST #) YES NO REPEAT TEST NO ADJUST TESTER TO ALTERNATOR MAX CURRENT OUTPUT CURRENT READING WITHIN 85% OF RATED CURRENT YES NO YES ALTERNATOR IS OK CHECK SYSTEM WIRING (See TEST #) TEST COMPLETE 0/9/98 f04047 Fig., Alternator Troubleshooting Body accessories as needed. Keep the voltmeter connected as in the previous step (positive lead connected to 00/4 Condor Workshop Manual, Supplement 0, January 000

27 Alternator, Delco Remy 5.0 Troubleshooting Test #: Alternator Amperage Output. Check the alternator amperage output.. Connect a carbon pile tester across the vehicle batteries as shown in Fig. 5. 0/6/97 f Battery. Digital Voltmeter Fig., Test #: Battery Open Circuit Voltage 6 B A BAT G 6 B A BAT G G 5 4 G 5 0/5/98 f50947 A. Locate the ammeter at least 6 inches (5 cm) away from the alternator.. Battery 4. Ammeter. Digital Voltmeter 5. Cranking Motor. Alternator 6. Solenoid Fig. 4, Test #: Alternator Voltage Output the alternator BAT (+) terminal; negative lead to the alternator G ( ) terminal)..4 If the voltmeter reads from.6 to 4. volts, the alternator is not the problem. Record this reading (V) and go to the next step. If the voltmeter reads less than.6 volts, replace the alternator.. Do "Test #: Alternator Amperage Output." 4 0/5/98 f50946 A. Locate the ammeter at least 6 inches (5 cm) away from the alternator.. Battery 4. Ammeter. Carbon Pile Tester 5. Cranking Motor. Alternator 6. Solenoid Fig. 5, Test #: Alternator Amperage Output. Attach a clamp-on induction ammeter around the alternator output (+) wire. See Fig. 5. NOTE: Locate the ammeter at least 6 inches (5 cm) away from the alternator.. Start the engine and make sure all vehicle electrical accessories are turned off. Run the engine at 500 rpm, and adjust the carbon pile tester to the alternator maximum current output. Record this output value from the ammeter reading. NOTE: Ensure that the engine is turning at 500 rpm, and then keep adjusting the carbon pile tester dial until the ammeter reads its highest value. Condor Workshop Manual, Supplement 0, January /5

28 5.0 Troubleshooting Alternator, Delco Remy.4 Turn off the tester and shut down the engine..5 If the output value recorded is less than 85 percent of the rated amperage output, repeat the test. If the output value recorded is still less than 85 percent of the rated amperage output, replace the alternator..6 Make sure that all test instruments are removed and that the vehicle wiring is returned to its operational state.. To identify other problem areas within the vehicle, check the operation of the charging system. NOTE: For any load at 500 rpm or more, battery voltage must be within 0.5 volts of the alternator voltage.. Compare the two readings. If the reading at the batteries is within 0.5 volts of the reading at the alternator, the charging system is working correctly. Check other areas of the vehicle to locate the problem.. If the reading at the batteries is more than 0.5 volts lower than the reading at the alternator, do the next step.. Check charging system connections, cables, and terminals.. Check all connections between the battery, starter, and alternator for tightness and signs of corrosion. Tighten and clean as necessary.. Check all cables for breaks or partial breaks. Repair or replace as necessary.. Check each ring terminal for breakage at the point where it attaches to its wire or cable. Troubleshooting Tables Problem The Batteries Seem Undercharged Possible Cause The drive belt is loose. The drive belt is damaged or missing. The batteries cannot hold a charge. The wiring is not delivering enough voltage to fully charge the batteries. The wiring is undersized. Terminals are corroded, broken, loose, or dirty. The battery cables do not deliver sufficient voltage to the starter. Problem The Batteries Seem Undercharged Remedy Check the drive belt. See the drive belt subject in the appropriate engine section in Group 0 for instructions. If necessary, tighten to the manufacturer s specifications. Start the engine and do "Test #: Alternator Voltage Output." Check the drive pulleys for locked bearings. Repair or replace any damaged components. Replace the drive belt and crank the engine. If the engine cranks OK, do "Test #: Alternator Voltage Output." If the engine still cranks slowly, check the cranking circuit. Do a load test on the batteries. See Section 54.0, Subject 0 for instructions. Charge or replace batteries as needed. If the batteries were discharged, but are able to hold a charge, do the "Alternator Troubleshooting Tests." Do the "Alternator Troubleshooting Tests" and repair or replace any broken wires. Check for the correct wire sizes. Replace any undersized wires. Clean, tighten, repair, and replace terminals as needed. Check the available cranking voltage. 00/6 Condor Workshop Manual, Supplement 0, January 000