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ACDelco 26 SI manual

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Table of contents for the manual

  • Page 1

    26-SI ALTERNATOR 1G/287 4/96 PAGE 1G-28 7 HE A VY DUT Y BRUSHLESS AL TERN A T O R SER VICE MANU AL © 1 998 Delco Remy Inter national Inc. All Rights R eser ved. PRODUCT INFORMA TION 1/98 26 SI[...]

  • Page 2

    PAGE 1G-287 4/96 26-SI ALTERNATOR FEA TURES 302.5 mm 198.0 mm SPECIFICATIONS: MAXIMUM SPEED: Continuous: 10,000 rpm Intermittent: 12,000 rpm AMBIENT TEMPERATURE LIMITS: -40°C to +85°C (-40°F to + 185°F) TRANSIENT VOLTAGE LIMITS: 100V - 300 ms (12-volt) 250V - 300 ms (24-volt) POLARITY: Negative Ground ROTATION: Clockwise or Counterclockwise WEI[...]

  • Page 3

    26-SI ALTERNATOR 1G/287 4/96 PAGE PR ODUCT INFORMA TION AND SER VICE MANU A L 26-SI HEA VY DUTY BR USHLESS AL TERNA T O R CONTENTS INTRODUCTION The 26-SI series alternator is a brushless, heavy-duty integral charging system with built-in diode rectifier and voltage regulator, producing DC current for battery electrical systems. The 26-SI series is [...]

  • Page 4

    PAGE 1G-287 4/96 26-SI ALTERNATOR FEATURES The 26-SI alternator is designed for a “one-wire” charging system configuration. “One-wire” refers to the minimum number of lead wire connections necessary at the alternator for operation and requires only that the alternator output terminal be connected to the battery insulated (positive for a neg[...]

  • Page 5

    26-SI ALTERNATOR 1G/287 4/96 PAGE be passed through this circuit to aid in alternator turn-on. An “I” terminal is normally a threaded stud type with a 10- 24 thread. A threaded 1/4" hole (with screw and lockwasher) in the rectifier end housing between the output and “R” or “I” terminal is provided to connect a ground lead if used; [...]

  • Page 6

    PAGE 1G-287 4/96 26-SI ALTERNATOR TROUBLESHOOTING Trouble in the charging system will normally be indicated by one of the following: • Indicator light “on” with engine running. • Indicator light “off” with key on, engine not running. • Undercharged or overcharged battery. • Short life of light bulbs or other electric equipment cause[...]

  • Page 7

    26-SI ALTERNATOR 1G/287 4/96 PAGE - If indicator light does not come on with jumper lead in place, verify that alternator is properly grounded by touching jumper lead to another ground source. If lamp still does not light, locate and correct open circuit in indicator light circuit. Circuit fuse may be open or light bulb may be burned out. Correct a[...]

  • Page 8

    PAGE 1G-287 4/96 26-SI ALTERNATOR E. NO OUTPUT TEST EQUIPMENT NEEDED: • Voltmeter • Jumper Lead (18 ga. min; no fuse) Note that 26-SI alternators must be connected to a battery for the voltage sensing circuit to allow initial turn on (refer to section on Features). When properly connected and system checks indicate a “no output” condition, [...]

  • Page 9

    26-SI ALTERNATOR 1G/287 4/96 PAGE 8. Recheck voltage at insulated battery terminal. Voltage should be higher than previous reading, but below 15 volts on 12-volt system (31 volts on 24 volt system). - If reading is lower than previous reading (Step 6), refer to section on No Output. - If reading is higher than 15 volts on 12-volt system (31 volts o[...]

  • Page 10

    PAGE 1G-287 4/96 26-SI ALTERNATOR ALTERNATOR UNIT REPAIR CAUTION: Disconnect grounded cable at battery before removing or attaching battery cable at alternator output terminal. Otherwise, a tool shorted to the battery cable at the output terminal can quickly heat enough to cause a skin burn or damage the tool or cable. NOTICE: Always reinstall fast[...]

  • Page 11

    26-SI ALTERNATOR 1G/287 4/96 PAGE FIELD COIL 3 . Disconnect 2 field leads from regulator (9) by removing 2 insulated regulator attachment screws (36). (See Fig. 12) Use ohmmeter to check resistance of field coil. Compare to Field Check ohms in Specifications at the end of this manual or from Service Specification Bulletin. If outside specifications[...]

  • Page 12

    PAGE 1G-287 4/96 26-SI ALTERNATOR 6. Use ohmmeter or diode check function on multimeter to check diode trio (15). (See Fig. 15) Place negative ohmmeter lead on regulator lead (A) and use positive ohmmeter lead to check for continuity to each of the three phase leads (B, C, D). All three readings should indicate continuity. Reverse the ohmmeter lead[...]

  • Page 13

    26-SI ALTERNATOR 1G/287 4/96 PAGE RECTIFIER DIODES 8. Disconnect the 6 diode leads from the 3 diode junction studs by removing nuts. (See Fig. 17) Find the three output side diodes (11), which are installed in the heat sink (12). These diodes will be identical in polarity and will commonly have the same color of insulation on the diode lead wire. U[...]

  • Page 14

    PAGE 1G-287 4/96 26-SI ALTERNATOR 11. NOTICE: Do not hit diodes or diode mountings with a hammer or other tool. The shock of such an impact can damage the diode or other diodes in the same mounting. Use proper tools to press or pull diodes from their mountings. Replacing one or more diodes requires the use of an arbor press or vise, and special dio[...]

  • Page 15

    26-SI ALTERNATOR 1G/287 4/96 PAGE housing (1) apart carefully. Guide stator leads and grommet (48) through hole as stator is pulled from housing. It may be necessary to push on grommet with a blunt instrument to unseat it from the housing. (See Fig. 24) 14. To remove field coil and support from rectifier end housing, (See Fig. 25) remove 3 field co[...]

  • Page 16

    PAGE 1G-287 4/96 26-SI ALTERNATOR 17. To replace rotor (4) or drive end bearing (7), (See Fig. 27) remove 4 bearing retainer attachment screws (28) from outside of housing (1). Lift rotor with bearing from housing, then pull bearing off of rotor shaft. If inside collar (22) appears rough or damaged, pull collar from shaft. 18. NOTICE: Do not drive [...]

  • Page 17

    26-SI ALTERNATOR 1G/287 4/96 PAGE ALTERNATOR ASSEMBLY ASSEMBLY OF DE FRAME AND ROTOR INSTALL OR CONNECT 1. Press inner race for rectifier end bearing (3) onto short end of rotor shaft. Stop when race is 3.7 mm (.15 in.) above end of shaft. (See Fig. 29) 2. Press inside collar (22) onto rotor shaft until collar is against shoulder on rotor (4). (See[...]

  • Page 18

    PAGE 1G-287 4/96 26-SI ALTERNATOR Lightly lubricate outside surface of hinge bushing (44). Press hinge bushing into hole in lug on rectifier end housing (1). Install bushing flush with inside of lug to allow maximum distance between two hinge lugs for mounting. Final position of hinge bushing will be adjusted during mounting. (See Fig. 31) 6 . Posi[...]

  • Page 19

    26-SI ALTERNATOR 1G/287 4/96 PAGE 9. Push square plastic retainers for diode junction studs (13) into square holes in heat sink. Insert metal studs into holes in retainers and push in until shoulder on stud is seated against retainer. This spreads the retainer legs and secures the retainers in the holes. (See Fig. 34) 10. ! IMPORTANT Avoid getting [...]

  • Page 20

    PAGE 1G-287 4/96 26-SI ALTERNATOR 11. Place insulator (17b) on output terminal (17a) and install through hole in housing (1). (See Fig. 36) Install flat insulator washer (17c), aligning flat shoulders on terminal with slot in heat sink to fully seat terminal. Install nut/washer assembly (17d) onto threaded portion of terminal inside housing. Tighte[...]

  • Page 21

    26-SI ALTERNATOR 1G/287 4/96 PAGE FINAL ALTERNATOR ASSEMBLY 15. CLEAN Inner race of rectifier end bearing (on rotor shaft) to prevent contamination of grease. 16. Align mounting lugs and assemble two halves of alternator (See Fig. 39), inserting rectifier end bearing inner race (on rotor shaft) into rectifier end bearing in rectifier housing. Do no[...]

  • Page 22

    PAGE 1G-287 4/96 26-SI ALTERNATOR 20. Place clip of red diode trio lead over hole in heat sink, then install insulator (51), flat washer (39), and heat sink attachment screw (31). (See Fig. 40) TIGHTEN Heat sink attachment screw to 3 N.m (26 lb. in.). 21. Place “R” or “I” terminal (18) into hole in rectifier housing (1). Place insulating wa[...]

  • Page 23

    26-SI ALTERNATOR 1G/287 4/96 PAGE 25. TIGHTEN Regulator and mounting plate screws (holes A, B, C, and D) to 3 N.m (26 lb. in.). 26. Insert regulator lead support (57) into slots in housing (1). (See Fig. 43) Place one end of lead to diode heat sink lead (sense lead) over mounting hole in heat sink. Add insulator (51), flat washer (39), and heat sin[...]

  • Page 24

    PAGE 1G-287 4/96 26-SI ALTERNATOR center hole. Replace gasket with a new one if at all questionable. Wipe edges of rectifier end housing and end cover gasket clean of foreign material. Place gasket and cover (19) onto housing (1) and install 7 rectifier cover attachment screw/washer assemblies (32 & 33). (See Fig. 45) TIGHTEN Rectifier cover at[...]

  • Page 25

    26-SI ALTERNATOR 1G/287 4/96 PAGE ALTERNATOR BENCH TEST TEST EQUIPMENT NEEDED: • Alternator Test Stand (5000 rpm capability at least 5 HP) • Battery or Battery Set (fully charged) • Variable Carbon Pile Load Test • Ammeter (current capability at least 15 amps higher than alternator rating) • Voltmeter • Ohmmeter The bench test procedure[...]

  • Page 26

    PAGE 1G-287 4/96 26-SI ALTERNATOR - If voltage increases above 15 volts on 12-volt system (or above 31 volts on 24-volt system), voltage is uncontrolled. Turn carbon pile load off and stop test stand. Recheck alternator for proper assembly. If alternator has been assembled properly, replace regulator as described under Unit Repair. Also check field[...]

  • Page 27

    26-SI ALTERNATOR 1G/287 4/96 PAGE ALTERNATOR MOUNTING CAUTION: Failure to disconnect grounded battery cable at battery before removing or attaching alternator “BAT” terminal lead may result in an injury. If a tool is shorted to the battery cable connector at the output terminal, the tool can quickly heat enough to cause a skin burn or to damage[...]

  • Page 28

    PAGE 1G-287 4/96 26-SI ALTERNATOR 5. Alternator belt to pulley. 6. If engine uses automatic belt tensioner (idler), skip to Step 7. NOTICE: Do not pry directly against rectifier end housing to adjust belt tension. Force must be applied to DE frame as described. Prying only against rectifier end housing may damage alternator. If belt tension is adju[...]

  • Page 29

    26-SI ALTERNATOR 1G/287 4/96 PAGE INSTALL OR CONNECT 11. Ground lead, if used, to ground hole in rectifier end housing, with ground screw/lockwasher assembly. (See Fig. 53) If ground lead is not used, be sure screw/ lockwasher is installed in ground hole and properly tightened to prevent entry of water or dirt. TIGHTEN 1/4" ground screw to 6 N[...]

  • Page 30

    PAGE 1G-287 4/96 26-SI ALTERNATOR 28 SERVICE PARTS Illus. No. Name Qty. 1. Housing, Rectifier End 1 2. Bearing, Rectifier End Outer Race 1 3. Bearing, Rectifier End Inner Race 1 4. Rotor Assembly 1 5. Stator Assembly 1 6. Frame, Drive End (DE) 1 7. Bearing, DE 1 8. Field Coil and Support 1 9. Regulator 1 10. Diode, In Frame 3 11. Diode, Heat Sink 3[...]

  • Page 31

    26-SI ALTERNATOR 1G/287 4/96 PAGE 29 27 46 48 5 49 29 8 4 21 22 7 6 43 28 23 42 52 26 34 20 33 32 19 47 35 36 38 40 41 9 25 15 16 30 24 18 45 56 2 3 44 1 17 50 10 57 55 12 13 25 11 14 53 51 39 31 37 26-5054[...]

  • Page 32

    PAGE 1G-287 4/96 26-SI ALTERNATOR Delco Remy International, Inc. 2902 Enterprise Drive Anderson, IN 46013 For further information and specifications on these and other Delco Remy Products call: 1-800-DRA-0222 © Copyright DRI, 1G-500 10/97 Delco Remy is a registered trademark licensed by General Motors Corporation.[...]