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Swapping the Prestolite alternator on a John Deere 550G for a Motorola-style unit may seem straightforward due to part number cross-references, but in practice it often requires electrical troubleshooting, mechanical modification, and a deep understanding of alternator configurations.
John Deere 550G Background and Electrical System
The John Deere 550G crawler dozer was introduced in the early 1990s as part of Deere’s mid-size earthmoving lineup. Designed for grading, land clearing, and site preparation, the 550G featured a 70–80 hp diesel engine, hydrostatic transmission, and a robust undercarriage. Its electrical system included a Prestolite alternator with external voltage regulation, a common setup in industrial equipment of that era.
Prestolite alternators were known for durability but became harder to source over time. Many operators turned to Motorola-style replacements, which are widely available and often listed as direct crossovers to the original Deere part number.
Terminology Note
Despite matching part numbers, the Motorola-style alternator presented several issues:
Recommendations for Future Swaps
In Illinois, a technician swapped a Prestolite alternator on a Deere 450C with a Delco 10SI one-wire unit. The installation was simpler due to internal regulation and universal mounting, but required rerouting the charge wire and disabling the warning light circuit.
In Missouri, a retired operator noted that many older Deere machines used Motorola alternators with external regulators. He recommended switching to internally regulated units for simplicity, especially in field repairs.
Conclusion
Replacing the alternator on a John Deere 550G is more than a plug-and-play operation. Even with matching part numbers, differences in wiring, shaft size, and regulation type can complicate the process. Success depends on mechanical skill, electrical knowledge, and patience. For operators without access to machining tools or wiring diagrams, consulting a specialist or choosing a truly universal alternator may be the better path.
John Deere 550G Background and Electrical System
The John Deere 550G crawler dozer was introduced in the early 1990s as part of Deere’s mid-size earthmoving lineup. Designed for grading, land clearing, and site preparation, the 550G featured a 70–80 hp diesel engine, hydrostatic transmission, and a robust undercarriage. Its electrical system included a Prestolite alternator with external voltage regulation, a common setup in industrial equipment of that era.
Prestolite alternators were known for durability but became harder to source over time. Many operators turned to Motorola-style replacements, which are widely available and often listed as direct crossovers to the original Deere part number.
Terminology Note
- Prestolite Alternator: A brand of heavy-duty alternators often used in off-road and military equipment.
- Motorola-Style Alternator: A generic term for alternators with a specific case and terminal layout, often used in automotive and industrial applications.
- Internal Regulator: A voltage control circuit built into the alternator, eliminating the need for an external regulator.
- Pulley Bore: The diameter of the hole in the pulley that fits over the alternator shaft.
- Warning Light Post: A terminal used to trigger the dashboard charge indicator.
Despite matching part numbers, the Motorola-style alternator presented several issues:
- Wiring confusion due to mislabeled terminals. The decal on the back of the unit was installed upside down, leading to misinterpretation of the connections.
- Lack of technical support from the manufacturer and distributor. Even the tech hotline and headquarters were unable to clarify wiring functions.
- No warning light post, which required bypassing or modifying the dashboard indicator circuit.
- Pulley incompatibility, as the original Prestolite pulley had a smaller bore than the new alternator shaft. This required boring out the pulley on a lathe to fit.
Recommendations for Future Swaps
- Verify terminal layout and regulator type before purchase. Internal vs. external regulation affects wiring and dashboard integration.
- Request pulley specifications when ordering. A mismatched shaft diameter can delay installation or require machining.
- Use a multimeter to trace original wiring and confirm voltage paths before connecting to the new unit.
- Consult experienced rebuilders or electrical technicians if manufacturer support is lacking.
- Ensure return policy is in place in case the unit proves incompatible or defective.
In Illinois, a technician swapped a Prestolite alternator on a Deere 450C with a Delco 10SI one-wire unit. The installation was simpler due to internal regulation and universal mounting, but required rerouting the charge wire and disabling the warning light circuit.
In Missouri, a retired operator noted that many older Deere machines used Motorola alternators with external regulators. He recommended switching to internally regulated units for simplicity, especially in field repairs.
Conclusion
Replacing the alternator on a John Deere 550G is more than a plug-and-play operation. Even with matching part numbers, differences in wiring, shaft size, and regulation type can complicate the process. Success depends on mechanical skill, electrical knowledge, and patience. For operators without access to machining tools or wiring diagrams, consulting a specialist or choosing a truly universal alternator may be the better path.
