FJ60 Alternator Wires

[Salem Cruiser]

Dredging up this thread as I am undergoing the same upgrade, but running into some issues. I see the OP hasn’t been on since 2020, so maybe others can chime in with advice.
I have installed the same 140amp alternator on my ‘87 FJ60. I have the upgraded wire running to the battery. I disconnected the green plug, but left the two white wires also attached to the alternator as they feed the starter and harness (I believe).
When I turn on the car, the alternator sounds a little whiny, and after 10 to 20 seconds, it starts to bog engine more (presumably output is increasing, backed up by voltage meter). Then it just runs rough and sounds like it is struggling to idle.
I turned the car off (fearing I might be doing damage), and can feel the pulley and fan on the alternator are already too hot to touch.

I am thinking that either Quality Power shipped me a unit with a pulley that is too large (meaning width, as the belt sits deep within the pulley) which is causing the belt to slip, creating friction and thus heat…or incorporating the original fusible link wiring is somehow causing issues.
Looking at Quality Powers Website for their pulleys:

wide groove pulleys,alternators,starters, batterie

Having trouble finding a wide groove pulley for your alternator to use with the 1/2, 5/8 and 3/4 belts found on older vehicles? We have the wide groove pulley you need. You can also use them to replace the large diameter pulley on an OEM generator or when adapting an alternator to replace an...

www.qualitypowerauto.com

I see they have two options for 5/8” wide pulleys…I straight 5/8” and a 5/8” to 3/4” option. It appears I received the latter option which may account for how deep the belt sits, however they make it seem like you can run either size in this pulley? So maybe not the issue? I will say that after tensioning the belt, I could, under moderate force, rotate the alternator pulley! This seems like a sign something is off.

Anyway, if all of you super helpful alternator experts could lend me some advice, I would sure appreciate it.

Shahn

 

[Salem Cruiser]

Well I think I figured it out. After closely scrutinizing the pulley, I noticed the middle, flat section of the pulley was polished clean of coating. I guess the 99343-11570 Toyota belt had become more worn than I expected. I had a previous problem with the power steering pump failing causing the belt to deteriorate. I thought this belt had not had enough time to become damaged, but between the damage and the wider pulley, it was enough to bottom out.
Put on a new belt and all seems right in the world. Charging at 14.6 volts at 750rpm idle.

Self help for the win...this time!

 

[Umanad]

Hi - guys! need help!

I bought the high output alternator from Quality Powers too however I does not look like this alternator at all (mine has the fan inside the case).

I tried to test fitted today with the jay bracket and it is definitely a no go. Too much interaction with the upper bracket. I'm working with the support guys.

Mine looks like this

with lots of interactions here

Any body else bought from them? is it possible that I receive the wrong unit? share pictures of yours

I forgot I had started this thread. My original alternator finally bit the dust a couple of weeks ago so I guess it’s finally time to get off my butt and install my upgraded unit. It was easy enough to install, came with the mounting adapters and “one-wire” install. I capped off the old plug since it’s no longer used. I upgraded all of my wires from the alt to the batt, batt gnd, batt to starter, starter gnd, a couple other gnds I found and went with a SMD distribution block for all of my accessories. I went with 2 gauge welding wire that I sourced from a guy on eBay who builds them in any length you want with different size terminals to suit your needs. I now have strong starts, bright lights, no more pulsing headlights when I run my tunes. I’m reading 13.5 volts at idle. Definitely worth the money!

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