Vehicles Equipped with Delco-Remy Alternators:
- Jensen-Healey (1973)
- Lotus Europa (1973)
- Triumph TR6 (1971-73)
CHANGES, CAUTIONS, CORRECTIONS
BATTERY INSTALLATION, BATTERY CHARGING, OR USING A BOOSTER BATTERY FOR ENGINE START - Reversed polarity or excessive voltage will result in extensive damage to alternator system. Note the following to prevent damage.
Battery Installation - Negative battery terminal must be connected to ground and positive terminal must be connected to starter. DO NOT reverse polarity.
Battery Charging - If a Quick Charger is used, both battery cables must be disconnected from the battery. DO NOT use a Quick Charger to provide starting voltage.
Circuit Interruption - Battery must NEVER be disconnected while alternator is running.
Alternator Removal - Always disconnect battery ground before removal and replacement of alternator.
High Voltage - DO NOT use a high voltage source to test diodes.
Battery Booster (For Engine Start) - Booster battery must be connected with proper polarity alignment with battery connections. DO NOT reverse battery leads.
DESCRIPTION
Conventional three-phase, self-rectifying type alternator. Alternator has a single field winding on rotor shaft which is encased between two multi-overlapping iron pole pieces assembled on rotor shaft. Field winding is connected to two slip rings assembled on, but insulated from rotor shaft. Alternator also has a state regulator which is mounted inside the slip ring end frame. The voltage regulator is not adjustable.
APPLICATION
Model Type No.
Jensen-Healey (1973).......................DN 460
Lotus Europa (1973)........................DN 460
Triumph TR6 (1971-73)...................DN 460*
* - Same model use Lucas alternators
SPECIFICATIONS
Application Data
Nominal Output................................................35 Amps
Control Voltage.........................................................14
Max. Output Speed.......................................5000 RPM*
Field Winding (Rotor) Resistance.............2.65-2.95 Ohms
Brush Replacement Length............................0.2" (5 mm)
Brush Spring Pressure....................................8.13 oz.**
* - Alternator RPM
** - At nominal working position
TESTING
ON CAR FUNCTIONAL TEST
1) Check adjustment of alternator belt. Detach harness connectors and hook up test circuit as illustrated. CAUTION - Observe polarity of system when installing, in order to prevent reversed polarity.
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| DELCO-REMY ALTERNATOR TEST CIRCUIT |
2) NOTE - Do not connect variable resistor into the test circuit until instructed and do not connect if across battery for longer than necessary to perform test. Start engine, if voltmeter reading fluctuates with speed and exceeds 15.5 volts indication is that regulator should be replaced.
3) If voltmeter reading is steady below 15.5 volts, connect the variable resistor into test circuit as shown. Hold speed at approximately 5000 alternator RPM (1800-2400 engine RPM). Adjust variable resistor to obtain maximum ammeter reading. Ammeter should now register within 10% of specified nominal output. If not, alternator requires replacement or overhaul.
OVERHAUL
DISASSEMBLY
1) Scribe a line across drive end frame, stator, and slip ring end frame to facilitate assembly. Remove three through bolts. Separate drive end frame and rotor assembly from slip ring end frame and stator assembly. As rotor is withdrawn, brushes will be pushed up by brush springs. Exact brushes.
2) Remove three nuts. Withdraw stator, noting three wire tags. NOTE - It is essential that all components be sufficiently marked for proper reinstallation in original position, including screws and washers, to ensure proper alternator operation.
3) Remove single screw, washer and insulation washer (with insulation sleeve), then lift out diode trio. Extract components retaining brush box and withdraw box. Remove short, red grounding screw and extract regulator.
4) Detach and remove rectifier bridge insulation piece attached to rectifier bridge may remain in position, unless replacement is necessary.
5) Mark pulley and fan, then detach from shaft. Withdraw rotor shaft from drive and frame bearing. Remove spacer.
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| DELCO-REMY (DN 460) ALTERNATOR |
REASSEMBLY
1) Position spacer. Ensure rotor shaft is clean, then insert shaft through drive end frame bearing. Position fan, pulley, spring, washer, and nut.
2) Ensure insulation piece is properly fitted to rectifier bridge live side slot (so that flange will be assembled against slip ring end frame). Position rectifier bridge and attach with proper screws placed in original position.
3) Position diode trio, attaching with proper screws. Using a suitable probe, hold back brushes (insert probe through slip ring end frame), then insert stator, noting three wire tags for proper position. Fit three nuts.
4) Ensure rotor shaft and slip rings are clean. Carefully position drive end frame and rotor assembly to slip ring end frame and stator assembly. Align housing scribe marks and join housing halves with through bolts. Withdraw probe and allow brushes to drop onto slip rings.
