Remy 36SI ALTERNATOR - Manual

Instruction Sheet
10500196
06SE13 C/P30502 REV7
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
33SI, 34SI, 35SI & 36SI ALTERNATOR INSTALLATION INSTRUCTIONS
Instructions include installing or upgrading 21SI, 22SI, 23SI, 24SI, 33SI & 34SI alternators to a 35/36SI HP with remote sense ™
technology for improved battery monitoring and charging performance.
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.
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 to the tools and surrounding parts.
FOLLOW ENGINE OR VEHICLE MANUFACTURER’S INSTRUCTIONS FOR REMOVING THE OLD ALTERNATOR FROM THE
ENGINE AND INSTALLING THE NEW ALTERNATOR.
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 in the horizontal position and do not
apply any pressure to end of the shaft. Internal damage will 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 these alternators. Hold
the shaft by placing
an 8.01 mm (5/16”) 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).
BELT TENSIONING INSTRUCTIONS: Improper belt tension can cause premature alternator failure. If the
belt must be tightened manually, place a wood block between the alternator and pry bar (See illustration).
Pry as close to the center of the unit as possible. Use a torque wrench to tighten mounting bolts to
specified torque. Follow vehicle or engine manufacturer’s specifications carefully for belt tension and
mounting bolts torque. DO NOT OVER TIGHTEN BELT!
REMOVAL & INSTALLATION INSTRUCTIONS (See illustrations, page 2):
 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.
 Some 21SI, 22SI and 24SI applications may require enlarging the ring terminals. Others will require cutting and terminating wiring for
one or all of the “I”, “R” and “Remote Sense” leads.
 Cut lead, strip insulation 1/2”, insert wire into an A 3 Amp or equivalent ring terminal, crimp and solder the wire.
 Insure all leads are hooked back up or contained where they can not ground.
 Torque all fasteners to values labeled on the illustration (page 2).
 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.
NOTE: There may be applications where it is necessary to add a jumper wire between the remote sense terminal and the
battery (+) terminal on the alternator to lower the output voltage for 34SI, 35SI & 36SI alternators. If necessary, use an 18 AWG
minimum wire size terminated with ring terminals to fit remote sense and battery (B+). Securely crimp and solder the connections.
TYPICAL WIRING DIAGRAM
LOWER OUTPUT VOLTAGE: VOLTAGE CAN
BE REDUCED BY INSTALLING A JUMPER
WIRE BETWEEN THE REMOTE SENSE AND
OUTPUT TERMINALS. (SEE NOTE ABOVE)
RELAY TERMINAL OUTPUT
IS SYSTEM VOLTAGE AT 1/2