Owners manual

7501 Strawberry Plains Pike
Knoxville, TN 37924
[phone] option 7
FAX: [phone]
e-mail: [e-mail]
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INSTRUCTION SHEET
GM CS Series Performance Alternators
17802, 17861, 37802, 37861, 48206, 48208, 48229
INS093 Revised January 2005
INSTALLATION
These instructions are provided as supplementary
information to the factory service manual instructions
for alternator replacment.
DISCONNECT THE BATTERY.
REMOVE THE OLD ALTERNATOR. See the fac-
tory service manual for more details. Remove the belt
noting its routing and then remove the alternator. Be
sure to label all wires before removing to assure proper
reinstallation and location. Compare the new alterna-
tor to the old alternator. The “clocking” or the location of the back housing of the alternator when compared to the front housing
should be the same. If not, refer to the clocking instructions on the reverse side of this form.
INSTALL THE NEW ALTERNATOR.
♦ If the belt system on the vehicle is not compatible with the Powermaster alternator, change pulleys per the instructions on the
reverse side of this form. For optimum performance use the pulley that is installed on the Powermaster. In many cases the OE
pulley can be reused on the Powermaster alternator if necessary.
♦ Mount the alternator and check for interference with the brackets or other engine components. Tighten all the bolts.
♦ Check for proper belt alignment. Proper alignment is critical for serpentine belts. In cases where the supplied alternator pulley has
more grooves than necessary, seat the belt as close as possible to the alternator.
♦ Install the belt per the factory service manual instructions.
♦ Reconnect all wires and check labeling for correct location. If the Powermaster alternator is of a higher amperage that the
alternator that came OE on the vehicle then Powermaster recommends upgrading the battery output cable from the alternator. Your
local speed shop has optional charge wires for this purpose.
CONNECT THE BATTERY.
Up to 4' 4' - 7' 7' - 10' 10' - 13' 13' - 16'
125-150 66422
175-200 44220
AMPS
Recommended Charging Cable Gauge Size
PLEASE KEEP IN MIND...
• ALWAYS wear eye protection when working around batteries.
• ALWAYS disconnect battery ground terminal and cable assembly be-
fore replacing electrical components.
• NEVER disconnect a battery cable or alternator cable and wires when
engine is running. Transient voltages (spikes) are produced when this
occurs and some of these voltages exceed 200 volts. This can cause
alternator voltage regulator or engine computer failure.
• AVOID short circuits. When working with live circuits, never jumper
between terminals or from terminals to ground, nor try to trouble shoot
by "sparking" terminals. Always use a quality voltmeter to check the
operation of live circuits.
• CHECK the battery. Alternators and batteries work together. It is
important that the battery be in good condition and fully charged when
replacing the alternator. Do use an alternator to charge a dead battery.