Remy 55SI™ ALTERNATOR - Manual

GROUND SCREWS (-) (Three Locations)
40SI 6.8 - 10.2 Nm (60 - 90 lb in)
55SI 5.8 - 6.8 Nm (50 - 60 lb in)
Grd
®
40SI
™
& 55SI
™
ALTERNATOR INSTALLATION INSTRUCTIONS
WARNING!!!!
ALWAYS USE PROPER EYE PROTECTION WHEN PERFORMING ANY MECHANICAL REPAIRS TO A
VEHICLE – INCLUDING, BUT NOT LIMITED TO, ANY INSTALLATION AND OR REPAIRS TO THE DELCO REMY ®
ALTERNATORS. FAILURE TO USE PROPER EYE PROTECTION CAN LEAD TO SERIOUS AND PERMANENT EYE
DAMAGE.
Only perform the mechanical functions that you are properly qualified to perform. Mechanical repairs that are beyond your
technical capabilities should be handled by a professional installation specialist.
DANGER!!! To avoid injury or damage, always disconnect the negative cable at the battery before removing or replacing
the alternator. The alternator output terminal is always live (“hot”). If the battery is not disconnected, a tool accidentally
touching this terminal and ground can quickly get hot enough to burn skin or damage tools and surrounding parts.
FOLLOW ENGINE OR VEHICLE MANUFACTURER’S INSTRUCTIONS FOR REMOVING THE OLD ALTERNATOR
FROM THE ENGINE AND INSTALLING THE NEW ALTERNATOR.
NOTICE! These are extremely high amperage output Alternators. Always ensure your application is
equipped with the appropriate size and gauge of cable. See “Recommendation for Determining
Appropriate Cable Size
” with the wiring diagram in Figure 2 to determine if installation is acceptable.
REMOVAL & INSTALLATION INSTRUCTIONS
 Disconnect the negative (-) cable at the batteries.
 Identify and tag all leads when removing the old alternator and install them on the same terminals of the new alternator.
 Insure all leads are reconnected or contained where they cannot ground.
 Torque all fasteners to values labeled in Figure 1 below.
 This alternator may have more terminals than the one being replaced had or used. It will charge properly with only the
battery and ground leads connected. Use of the other terminals is optional based on need
. See “TERMINAL
DESCRIPTIONS ”, Page 2.
FIGURE 1 - 40SI ™ & 55SI™ Alternator Torque Values
PULLEY INSTRUCTIONS: Use pulley from old alternator if this alternator does not have a pulley or pulley supplied is
different from the one on alternator being replaced. NOTICE! When changing the pulley, keep the alternator shaft in a
horizontal position and do not apply any pressure to end of the shaft. Internal damage may occur if the shaft is
pushed back and turned. If there were spacers when the fan and pulley were removed, make sure all spacers are replaced
when installing the fan and pulley on this alternator. Hold the shaft by placing a hex wrench in the hexagonal hole in the shaft
while removing or installing the pulley. Tighten the pulley nut to 95-108 Nm (70-80 lb ft).
INSTRUCTION SHEET
10523421
09OC13 REV 5
HIGH OUTPUT FEATURES WITH REMOTE SENSE
™
TECHNOLOGY
40SI
™
: 12 Volt 240 - 275 - 300 Ampere Ratings Three Mounting Options: Pad, Delco Remy
®
Standard Hinge
198mm (7.8 inch) & Long Hinge 216mm (8.5 inch)
55SI
™
: 12 Volt 420 Ampere Rating 24 Volt 250 - 275 Ampere Ratings Mounting Option: Pad
BATTERY (+)
9.0 –13.5 Nm
(80 –120 lb in)
USE PULLEY FROM OLD ALTERNATOR
(SEE PULLEY INSTRUCTIONS BELOW)
REMOTE SENSE
™
INDICATOR/IGNITION
RELAY
(3 Terminals)
1.7 –2.8 Nm (15–25 lb in)
198 mm (7.8”)
or
216 mm (8.5”)
40SI AVAILABLE IN DELCO
REMY
®
STANDARD HINGE &
LONG HINGE MOUNTING SIZES
Grd
NOTICE - Only licensed Remy International, Inc. product and component parts should be used, and the use of other parts or modifications not approved
by Remy International, Inc. will void all applicable warranties. The failure to carefully follow these Installation Instructions, set forth above, will void all
applicable warranties. DELCO REMY is a registered trademark of General Motors Corporation, licensed to Remy International, Inc. Pendleton, IN 46064.
©
2012 Remy International, Inc. All rights reserved 1