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still not exactly understand. There is no relay in the drawing. But more important, I cannot see in your pic of the installed alternator that you connected the terminal 1 + 2. I just see a thin red wire in parallel to the positive wire to the battery.

ground is ground, no matter 12 or 24 volts. So that's fine. what do you mean by switching the alternator on and off? How do you want to do that?

Now certainly you will. You need to remove the HH again. Make sure that the plunger button is there. Turn the engine until you have #1 cylinder in compression, align the damper marking and install the HH. Now the notch has to align with a valley right next to the scribed tooth. The scribed tooth...

Sure. If you haven't turned the engine in the time it was off. If the scribed tooth was exactly under the notch install it that way. If you have turned it, different topic.

Actually that is easier than you might think. Stand on the front bumper and turn the engine with the fan blades with one hand while using the other hand to tension the belts. You will be only able to turn it in one direction. For removing the HH I would turn the red tooth exactly under the...

I would say a bad lower o-ring in the HH could cause that