Volvo Trucks North America, Inc.

Greensboro, NC USA
TSI
Date Group No. Supp. Page
This Bulletin replaces Service Manual V776–321–620SM,
“Alternator, 30SI – Delco Remy” from 11.1993 9.2003 321 013 1(13)

Alternator
30SI Delco Remy

Alternator
This service bulletin describes how to troubleshoot and repair the Delco Remy 30SI
alternator

Contents
• “Alternator” page 2
• “Alternator Fault Tracing” page 4
• “System Repair” page 8
• “Charging Regulator, Check and Adjustment” page 9
• “Alternator, Overhaul” page 11

PV776-TSP196180 USA14275
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Design and Function

Alternator

W3000224

Alternators 4) 12-Volt output terminal

1) Grounding screw 5) 24-Volt output terminal
2) Output terminal 6) Transformer rectifier (TR unit)
3) End plate

Delcotron® Integral Charging System (30-SI and 30-SI/TR Series)

Description
The Integral Charging Systems (generators) feature a
solid state regulator mounted inside the end frame. The
regulator voltage setting may be adjusted externally by
repositioning a voltage adjustment cap in the rectifier
end frame. On some models, a relay terminal provides
approximately half system voltage to which accessories
may be connected. The 30-SI Series uses one wire with
an adequate ground return to charge the vehicle battery
in the usual manner. The 30-SI/TR is a standard 30-SI
with a transformer-rectifier (TR unit) mounted on the end
frame. The TR unit provides a separate voltage to charge
a cranking battery. The cranking battery is connected in
series with the system battery to provide 24-volt cranking.
When the engine is running, the cranking battery is
charged at a low rate to maintain its full state of charge.
The vehicle electrical system, except for the cranking
motor, is 12 volts. The 30-SI/TR eliminates the need for a
series-parallel switch and associated wiring. W3000190

Typical circuit, negative ground 30-SI

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Operating Principles 30-SI

W3000189

Typical circuit, negative ground 30-SI/TR

The basic operating principles are explained as follows: As the speed and voltage increase, the voltage between
R2 and R3 increases to the value where zener diode D1
The base-transistor TR3 is connected to the battery conducts. Transistor TR2 then turns on and TR1 and TR3
through resistor R5. This connection turns on the turn off. With TR1 off, the field current and system voltage
transistors. Resistors R2 and R3 are connected to the decrease and D1 then blocks current flow causing TR1
battery through the voltage adjustment, but the discharge and TR3 to turn back on. The field current and system
current of the battery is very low because of the resistance voltage increase, and this cycle repeats many times per
values of R2, R3, R5, TR1 and TR3. second to limit the voltage to the adjusted value.
With the generator operating, AC voltages initially are If the voltage adjustment cube should become an
generated in the stator windings by residual magnetism open-circuit. TR3 and TRI will turn off, preventing high
in the rotor. The diodes in the rectifier bridge change system voltage.
the stator AC voltages to a DC voltage between ground
and the ”BAT” terminal. Increasing speed provides the Capacitor Cl smooths out the voltage across R3. Resistor
current for charging the battery and operating electrical R4 prevents excessive current through TR1 at high
accessories. temperature. Diode D2 prevents high-induced voltages in
the field windings when TRl turns off.
The stator also supplies DC field current through the
diode trio, the field coil, TR1 and through the diodes in the
rectifier bridge back to the stator.

Operating Principles 30-SI/TR

The lower portion of each circuit, with the system or ’S’ transformer is connected to the delta stator. The AC
battery, is the same as the circuits in page 2 and page 3. voltages in the stator cause an AC current to flow in the
primary. This changing, or AC current, creates magnetic
A transformer-rectifier (TR unit) is mounted on the rectifier fields which induce voltages in the transformer secondary
end frame, and is connected to the cranking, (”C”) battery. winding. The secondary then provides current through
the rectifier bridge to charge the ”C” battery.
The two batteries are connected in series to provide 24
volts for cranking or starting. The delta primary of the
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Troubleshooting
Alternator Fault Tracing
30–SI

W3006052

Cross Sectional View 6) Front seal

1) Relay terminal 7) Regulator
2) Output terminal 8) Roller bearing
3) Rectifier bridge 9) Stator
4) Grease reservoir 10) Rotor
5) Stationary field coil 11) Roller bearing

Energizing speed Rated voltage

The energizing speed is the rpm which turns on the On 12, 24 and 32-volt systems, the Integral Charging
regulator to energize the field coil. This speed is higher System output preferably should be checked at the ”Rated
than some speeds at which output can be obtained. Voltage” in the table below. However, the output may be
Therefore, when checking output at low speeds, increase checked in amperes at any voltage within the ”Operating
the speed until the regulator turns on, then reduce the Range” listed in the table, since the current output will
speed to check the output. An output may not be obtained be quite close to the value that would be obtained at the
until the regulator turns on. Once the regulator turns on, it ”Rated Voltage.” The voltage should never be allowed to
will remain turned on until the engine is stopped. rise above the ”Operating Range” for any length of time.

SYSTEM RATED OPERATING

VOLTAGE VOLTAGE RANGE
12 14.0 13.0-15.0
24 28.0 26.0-30.0
32 37.5 33.0-39.0

It should be noted that the voltage may be below the

”Operating Range” if the battery is in a low state of
charge. However, as the battery accumulates a charge,
the alternator voltage will rise to some value within the
”Operating Range.”
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Magnetizing the rotor

The rotor normally retains magnetism to provide voltage b. Connect an ammeter in the circuit at the output
build-up when the engine is started. After disassembly or terminal of the generator.
servicing, however, it may be necessary to re-establish
the magnetism. To magnetize the rotor connect the c. Reconnect the battery ground cable.
Integral Charging System to the battery in a normal
d. Turn on the accessories. Connect a carbon
manner, then momentarily connect a jumper lead from
pile across the battery.
the battery positive post to the Integral Charging System
relay terminal. On the 30-SI/TR series, be sure to jump e. Operate engine at moderate speed, usually
from the positive post of the system battery so that 12 4000 generator rpm or more, and adjust the
volts will be applied to the relay terminal. On generators carbon pile to obtain maximum current output.
without a relay terminal, remove the end plate and jumper
from the battery positive post to one of the stator lead Note: Initial voltage build-up is by residual
terminals on the rectifier bridge. magnetism in the rotor. Increase the speed as
required to obtain maximum current output.

Note: The following information concerning the

Voltage Adjustment Cap applies to older style
units only. The new style alternator does not use a
Voltage Adjustment Cap.

W3000188

Typical 30 SI Wiring
1) Integral charging system
2) Vehicle load
3) “S” battery

1 Be sure that an undercharged condition has not

been caused by accessories having been left on for
extended periods.
2 Check the drive belt for proper tension.
3 If a battery defect is suspected, refer to manual W3000234
V776-311-600WM. Voltage Adjustment Cap
4 Inspect the wiring for defects. Check all connections
for tightness and cleanliness, including the battery f. If the ampere output is within 10 amperes of
connectors. the rated output as stamped on generator frame,
the generator is not defective. In this case, an
5 Connect a voltmeter from output or ”BAT” terminal on adjustment of the voltage setting may correct the
Integral Charging System to ground. A zero reading condition. Raise or lower the setting by removing
indicates an open between voltmeter connection and the voltage adjusting cap, rotating in increments
battery. of 90 , and then re-inserting the cap in the
6 Turn off all accessories, increase engine speed as connector body.
required to obtain maximum voltage reading. g. The cap is normally set for low voltage. With
7 If voltage exceeds 15 volts on a 12-volt system, 30 position 2 aligned with the arrow, the setting is
volts on a 24-volt system or 39 volts on a 32-volt medium low; position 3 is medium high; and
system, remove Integral Charging System for repair as position HI is the highest regulator setting.
covered under heading of ”System Repair.” h. If the ampere output is not within 10 amperes of
8 If previous Steps 1 through 6 check satisfactorily check the rated output as stamped on Integral Charging
generator as follows: System frame, remove the Integral Charging
System for repair as covered in ”System Repair”
a. Disconnect the battery ground cable. repair.
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30-SI/TR
Read troubleshooting procedures on the 30-SI before 5 If a defect is found, repair it as required and reinstall
proceeding.. the TR unit.

6 If a defect is not found, check the rectifier bridge on the

TR unit as follows:
a. Disconnect the transformer leads from rectifier
bridge.

b. Connect the ohmmeter to a heat sink and one of

the three terminals (connection A, page 7). Then
reverse the lead connections to the same terminal.

c. If both readings are the same, replace the

rectifier bridge by detaching the necessary screws
W3006053 and nuts. A good rectifier bridge will give one high
Typical 30 SI/TR Circuit and one low reading.
1) 12/24 Integral charging system alternator
2) “C” cranking battery d. Repeat this same test between the same heat
3) Start switch sink and the other two terminals, and between the
4) Magnetic switch other heat sink and each of the three terminals.
5) Vehicle loads combined
e. This makes a total of six checks, with two
6) “S” system battery
readings taken for each check.
7) 24 volt cranking motor
f. If the rectifier bridge is constructed with flat metal
The 30-SI and system battery (S) battery operate together clips at the three studs, press down very firmly
in the normal manner in the 12-volt vehicle electrical onto flat metal clips and not onto threaded stud.
system. The transformer rectifier (TR unit), is an ’add
Note: When replacing rectifier bridge, note
on’ unit on the 30-SI generator. It charges the cranking
the stack-up of parts so unit may be properly
battery (C) battery which is connected in series with the
reassembled. For negative ground systems, the
”S” battery to provide 24 volts to the cranking motor.
bridge is assembled with long cooling fins next to
When the engine is running, the ”C” battery receives a low
end frame, and short fins next to transformer.
charge rate from the TR unit to maintain its full state of
charge. If either battery is undercharged or overcharged,
observe the following procedure:
1 DO NOT ALLOW LEADS OR TERMINALS TO TOUCH
GROUND.

2 Completely remove the TR unit from the 30-SI

generator as follows:
a. Remove the attaching screw.

b. Pull the TR unit away from the 30-SI generator

to expose lead connections.

c. Detach the three transformer leads from

the three studs on the 30-SI rectifier bridge.
Reassemble the nuts onto the 30-SI rectifier
bridge studs.

d. If there is a remaining TR single lead connected

from the TR rectifier bridge heat sink to the 30-SI
rectifier bridge heat sink, detach this lead from
the 30-SI 12-volt heat sink. (Some models may
not use this lead).

3 The circuit is now a regular 12-volt 30-SI charging

system connected to the ”S” battery.

4 Check the 30-SI as covered in the ”Trouble Shooting

Procedure” section.
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connection B, connection C and connection D. Each

reading should be very high (infinite). If not, replace
transformer.
8 Reinstall the TR unit onto the 30-SI generator.
9 Detach the 24-volt lead from the generator. DO NOT
ALLOW LEAD TO TOUCH GROUND.
10 Connect the ammeter between the 24-volt TR terminal
and the disconnected lead.
11 Connect a 5-20 ampere load (such as one or two
12-volt headlamps) across the 12-volt cranking (”C”)
battery.
12 Operate the generator at speeds sufficient to produce
maximum output.
13 The TR unit output to the ”C” battery and the load
should be five amperes or more. If less than five
W3005991 amperes, replace transformer.
Ohmmeter Checks of Transformer/Rectifier
Bridge and Diodes in TR Unit 14 If the output is five amperes or more, the TR unit is not
1) Ohmmeter defective. It will charge ”C” battery when the engine is
2) Long fins run a sufficient length of time.
3) Rectifier bridge
4) Connector lead
5) Transformer
WARNING
6) Rectifier bridge connections
As a safety precaution, inspect the fan blade assembly
7) 24 Volt output terminal
for cracks or loose mountings before starting the
engine with the hood or cab in the raised position.
7 Check the transformer on the TR unit by connecting NEVER stand along side of a rotating fan assembly,
an ohmmeter three ways as shown in page 7, particularly at high engine speeds.
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Service Procedures
System Repair

W3000226

Typical 30 SI Negative Ground 7) Field leads

1) Stator leads 8) Ground screw
2) Output terminal 9) Regulator
3) Diode trio 10) “R" terminal
4) Capacitor 11) Regulator stud
5) Output terminal 12) “R" terminal connector
6) lnsulated screws 13) Rectifier bridge

Component parts and connections are shown in the

illustrations. Note that the diode trio and the end plate
have been removed.
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Connector Body Check

W3000233

Ohmmeter connections to connector body

Remove the connector body from the regulator and check

it with an ohmmeter using the middle range scale.
Connect the ohmmeter to each adjacent pair of terminals,
making four checks in all. If any one check is infinite,
replace the connector body.

3221-08-04-01
Charging Regulator, Check and Adjustment
See also “System Repair” page 8

The regulator cannot be checked with an ohmmeter. Use

an approved regulator tester available from various test
equipment manufacturers.
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W3000227

Connection Points for Testing

Rectifier Bridge Check

(Omit for overcharged battery)
To check the rectifier bridge, connect the ohmmeter to a
heat sink and one of the three terminals (connection 1
above). Then reverse the lead connections to the same
heat sink and same terminal.

If both readings are the same, replace the rectifier bridge

by detaching the necessary screws and nuts. A good
rectifier bridge will give one high and one low reading.
Repeat this same test between the same heat sink and
the other two terminals, and between the other heat sink
and each of the three terminals. This makes a total of
six checks, with two readings taken for each check
on each rectifier bridge.

Note: If the rectifier bridge is constructed with flat metal

clips at the three studs, press down firmly onto flat metal
clips. Do not press onto the threaded stud.

Stator Check
(Omit for overcharged battery)

Most stators are delta wound and a check for grounds

may be made only with an ohmmeter. Connect from
either lead to the frame (connection 4). The reading
should be infinite. If it is not, replace the stator. See
“Alternator, Overhaul” page 11. If the regulator is ok and
the generator fails to supply rated output, replace the
stator if it is badly discolored.
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Diode Trio Check

W3000228

Diode Trio Check

To check the diode trio, remove it from the end frame

assembly by detaching the nuts and attaching screw.
Note that the insulating washer on the screw is assembled
over the top of the diode trio connector. Using the lowest
range scale, connect an ohmmeter having a 1-1/2 volt cell,
to the single connector and to one of the three connectors.
Observe the reading. Reverse the ohmmeter leads to the
same two connectors. If both readings are the same,
replace the diode trio. A good diode trio will give one high
and one low reading. Repeat this same test between the
single connector and each of the other two connectors.

3211-04-04-01
Alternator, Overhaul
See also “System Repair” page 8.

1
Remove the screws and end plate.

2
Remove the fan and pulley.

3
Remove the four thru-bolts.

4
Separate the Drive End frame and rotor from the Rectifier
End frame and stator.

5
Press the rotor from the end frame.

6
Remove the collar from the end frame.
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7
Remove the collar from the shaft.

To replace Drive End frame bearing:

1
Remove the four retaining plate attaching screws.

2
Remove the retainer plate and gasket.

3
Push on the inner race to remove the bearing.

4
Pull out the seals from the end frame and from the
retainer.

5
Press in the new seals with the lip toward the bearing.

6
Press in the new bearing against the outer race.

7
Fill the retainer cavity half full with Delco Remy Lubricant
Part No. 1948791 so part of the lubricant will touch the
bearing when it is assembled.

8
Assemble the retainer with the thru-bolts.

9
Assemble inside the collar over the shaft.

10
Assemble the outer collar under the seal next to the
bearing while supporting the outer collar.

11
Press the rotor into the drive end frame.

To replace Rectifier end frame bearing:

1
Pull the inner race from the shaft and bearing from the
end frame.

2
Assemble the new inner race and the bearing with the
bearing seal away from the grease reservoir.
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3
Use Delco Remy lubricant Part No. 2948791 and fill
reservoir half full. Arrange lubricant so a portion will touch
bearing when assembled.

To replace field coil:

1
Remove the attaching bolts.

2
Install the new field oil and torque bolts to 6 N•m (55
in.-lb.).