Converting Delco 28Si to external regulation

[mbath]

Hello all, my first post.

I am adding a second alternator to my D2-55 and have just installed the factory produced second alternator bracket (part number 21178401, part of kit 21384685). So the same as BlueHeeler used.

I have run into a problem in which the bracket won't fit with the hot water feed spigot installed and if I remove the spigot and install the bracket, the spigot can't align with the hole. Has anyone else experienced this and got a workable solution.

I am thinking about installing a 45 or 90 degree elbow. As I am not sure I can easily cut a section out of the bracket.

Many Thanks

Originally Posted by BlueHeeler

So I fired up the new d2-50 today with the DR 28SI mods finished and fitted on the Volvo Penta factory produced second alt mounting kit. Using the old external balmar MC614 and with battery SOC at about 82% the alternator kicked off at around 90 amps rapidly stabilizing at about 55amps at 1500 engine rpm. After about 20 min the alt was still cool enough to touch. The old motor was a Volvo md22 and had a large case balmar 94 series 210 amp fitted on top of the engine on a dodgy homemade mounting (fitted by previous owner). I tried to strengthen this mounting system several times after breaking various mounting points which seemed to just transfer stress to the next weak point every time. This was one reason on my decision to go with the factory mounting on the new engine. The factory mount is designed for the Volvo internal regulated 115 amp alternator which is significantly smaller than the delco remy 28SI.
Many thanks to evm1024 for showing me his detailed instructions on the regulator modification.

[BlueHeeler]

Hi,
I stuck with the straight threaded hose tail fitting and by grinding a little bit off the alternator bracket you can fit the hose ok. I also had to grind a bit of metal off the bracket to allow the bigger 28SI alternator casing to sit down snug to the engine block. Then Primed and Repainted the bracket In Volvo green.

[sailingharry]

Originally Posted by rom

My engines are 4JH4E and I can't tell for the optional second alternator as I only have one per engine. I replaced my hitachis with 28SI which are indeed much larger ! looking back it was much easier than I thought it would be, and rather inexpensive. I spent a lot of time on that project though, so if your time is more valuable than mine you may ask someone to do it for you. A local shop made the spacer and modified the tensioner, I found the rights bolts quite easily, the 6PK belt that"s right for me is 1250mm.
Attachment 208060
Attachment 208061

ROM and Q XOPA, you both have used 28SI on your 4JH4E original location.


Two questions:
* Where did you source your 28SI? What Amp rating? How much were they? I love the entire Delco line, but I've learned that there is a lot of variety within a single frame number.
* I have a 4JH2E. Slightly older, same engine. I look at the mounting, and it seems the 28SI gets all tied up with interferences behind it. Any thoughts on challenges there?


Thanks,

Harry

[Q Xopa]

Originally Posted by sailingharry

ROM and Q XOPA, you both have used 28SI on your 4JH4E original location.


Two questions:
* Where did you source your 28SI? What Amp rating? How much were they? I love the entire Delco line, but I've learned that there is a lot of variety within a single frame number.
* I have a 4JH2E. Slightly older, same engine. I look at the mounting, and it seems the 28SI gets all tied up with interferences behind it. Any thoughts on challenges there?


Thanks,

Harry

Hi Harry,


Sorry for the delayed reply, work and all that.
I've got 28si knock offs from alternatorparts.com . They have a number of different mount configurations voltages and Amperage models. I got #8717N which is the short ear, J180 mount style, 24v, 110A model. It cost me $258 when I got mine a year or so.

Clearance at the back. I assume you are talking in the Standard LH side? I had a look at my pics and dont have a real good pic showing the back of the Alt in the Standard position. Stuck at work in Pakistan ATM. The 1st attached pic shows this, kinda. Its actually more showing how I did my spacers. But you can see mine is clear. Actually in that pic I still have original still attached to the wires dangling from a string behind the new one. So on my 4JH4-TE there is no problem with interference at the back.

However if you are talking about in the Alternate/ Secondary/ RHS position, 2nd pic, then yes the engine Fuel filter housing has to go. This is no big deal and easy to relocate. I havent actually found mine its new home yet but its a minor detail. You can see in my pic the black fuel hose, Ive got some green tape over the end.

I hope this helps. Let me know if you want more.

Good luck.

[Federico993]

What pulley diameter are you using on the 28SI?

[Federico993]

Can someone says where is it possible to buy the Alternator's pulley?

Thanks

[Singularity]

Originally Posted by Federico993

Can someone says where is it possible to buy the Alternator's pulley?

Thanks

One source in California is S&W Diesel (very reputable company):

Custom Parts

[Federico993]

I am looking for an alternator pulley which can be bought in Europe easily, but I have just found this one from US: https://store.alternatorparts.com/pa...ovepulley.aspx.
It is a 2,37" (60mm) pulley, it should work perfectly and guaranteeing more alternator speed and cooling at engine idle speed.
Will it work?

[Q Xopa]

Originally Posted by Federico993

I am looking for an alternator pulley which can be bought in Europe easily, but I have just found this one from US: https://store.alternatorparts.com/pa...ovepulley.aspx.
It is a 2,37" (60mm) pulley, it should work perfectly and guaranteeing more alternator speed and cooling at engine idle speed.
Will it work?

Yes that's the one I use. IMHO it works great.

They run the Alternator faster to keep more cooling air flowing, more Alternator output and puts a bit of load on the engine (which is good).

The 8 groove belts really help when you have reduced the circumference contactct length. I have used Gates KD08.... 'FleetRunner' Heavy duty Micro V belts. They are green.

Obviously you need a 8 groove Crank pulley. My machine shop guy did a couple and a water pump pulley for me. Ideally go as large as you can fit here to up your ratio some more.

I dont know what motor you have but I fit 178mm pullies on the crank and 153mm for the water pump pulley. If you increase your crank pulley it is better to proportionally increase the water pump pulley to keep it the original speed ratio. Ie keep it from running too quick and cavitating.

When you have the pullies all sitting on your motor use a Straight edge and digital calipers to measure the spacers you need to get them all aligned up nice.

Then get a tape measure to measure the belt length you need. Do this with the Alternator swung fully in, ie smallest belt size. PM me if you want the specific belt PNs I got.

In the scheme of costs for big alternators they are relatively inexpensive. I got doubles so I had spares. They are not exactly difficult to track down, but not as easy to find as garden variety belts.

I got nice solid spacers with good bearing faces and a good sized hole etc machined. That keeps the mounting nice and solid so it doesnt flop around and keeps alignment good.

I assume you have your mounts all sorted out.

Another thing that keeps everything rock solid is the Adjuster mechanism. You can use spring loaded idler pulley. The proper ones are dampened which reduces belt wear by dampening torsional power pulses and turning a heavy alternator rotor.

I just used the threaded adjuster, with a lock nut style.

Let me know if you need any other help.

Good luck.

[offpist]

Here is how I did my Yanmar 4JH4AE.

Ome Delco 28SSI and one Balmar AT200.
Both with external regulators.

I added an ekstra roller to the belt allowing for larger alternator in original space.

[Federico993]

What wire size are you using on the Delco Remy alternator?

[Q Xopa]

Oops my bad, answering wrong question

[Federico993]

Originally Posted by Q Xopa

Im not sure who you are asking?

Sorry, I meant the electric wire size to the battery.
I was asking to everyone

[offpist]

Originally Posted by Federico993

What wire size are you using on the Delco Remy alternator?

Well its 200A, so for me I chose 50mm2.
(Both for + and -)

I guess 35mm2 of good quality would also be ok.

It also depends in the lengts, for me its only 1,5 meter.
Then double 70 MM2 from main busbars to battery.

[Federico993]

Where did you find a screw for the upper installation hole?
I can see it is a 1/2-13 UNS screw but I can't find it.
Where can I find this screw?

Thanks!