Procedure for Replacing Regulator Kit on All Engines {1405} Caterpillar

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Introduction

This special instruction provides the installation procedure of replacing 100-6534 Regulator Kit on all engines.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Important Safety Section

Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If the tools, the procedure, the work method, or your actions are not recommended by Caterpillar, ensure that the tools and your actions are safe for you and for others.

Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures.

Follow all safety warnings. Most accidents that involve product operation, maintenance, or repair are caused by failure to observe safety warnings. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. Personnel should be properly trained to perform maintenance, repair, or operate any machine. Safety precautions and warnings are provided this instruction and on Caterpillar products. These warnings should be observed before performing any procedures. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are not all inclusive.

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

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When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.

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Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.

Note: Always use proper eye protection when performing any mechanical repairs to a vehicle including, but not limited to, any installation and or repairs to the starter. Failure to use proper eye protection can lead to serious and permanent eye damage.

Note: Only perform the mechanical functions that you are properly qualified to perform. Mechanical repairs that are beyond your technical capabilities should be handled by a professional installation specialist.

Note: To avoid injury or damage, always disconnect the negative cable at the battery before removing or replacing the alternator. The alternator output terminal is always lived ("hot"). If the battery is not disconnected, a tool accidentally touching this terminal and ground can quickly get hot enough to cause skin burn or damage to the tool and surrounding parts.

Installation Procedure

The Integrated Circuit (IC) voltage regulator, base plate, diode trio, and attaching hardware in this package are used to replace discrete component regulators used in earlier designs of 25SI alternators.

The earlier regulators have separate transistors, diodes and other components mounted on a circuit board covered with an RTV-type coating. Both the new diode trio and the new regulator must be installed to replace this former type regulator.

New mounting holes must be drilled into the alternator housing to attach the new components.

Use the below procedure to replace 100-6534 Regulator Kit to the earlier design discrete component regulator. In addition to the items supplied in the package and the usual hand tools, a drill with 9/64 inch diameter bit will be needed to complete the installation.

Install regulator and diode trio as follows:

1. Remove four thru-bolts from alternator and separate drive end assembly (with rotor) from rectifier end assembly. This is necessary to allow complete removal of metal shavings created by drilling holes. Cover the open end of the rectifier end bearing with tape to keep shavings from getting into the bearing grease.

2. Remove end plate and rectifier cover from rectifier end assembly by removing attaching screws.

3. Remove nuts from rectifier bridge terminals and inside of "R" terminal to disconnect three long, identically colored leads to regulator. Some units may have a separate lead between the "R" terminal and a rectifier bridge terminal if so, remove this lead also. Place nuts loosely back on "R" terminal and on rectifier bridge terminals to hold other leads in place during repair.

   Note: If old regulator has a sense lead connected to the heat sink attaching screw, remove screw, flat washer and insulator to disconnect lead. Place insulator, washer, and heat sink screw loosely back into unit for later attachment of new sense lead. Disconnect two field coil leads from regulator and remove two regulator-mounting screws. Lift regulator and long leads with grommet from generator housing.

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   Illustration 1	g06389571
   Locating new mounting holes and installing diode trio (1) Diode Trio (2) Base plate (3) New trio mounting hole (4) New regulator mounting hole (5) Mounting screw (A) Mounting hole (B) Mounting hole (C) Mounting hole (D) Mounting hole

4. Refer to Illustration 1. Place new diode trio (1) and regulator base plate (2) in position. Locate base plate by positioning mounting hole (A) over existing mounting hole in casting. Temporarily install the 1/2 inch long mounting screw in hole (A) to hold plate, aligning edges to be straight with sides of casting. Mark three new hole locations ( (B), (C), and (D)), then remove diode trio and base plate from housing. Use 9/64 inch drill bit to make new mounting holes in housing. Holes (C) and (D) will go through housing wall. Hole (D) is positioned in thicker cross section and will not go through drill 3/4 inch deep, straight into housing material. Remove all traces of metal shavings from both inside and outside of housing when drilling is complete.
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   Illustration 2	g06389572
   Diode trio and sense lead connections (6) Diode trio (7) Diode trio mounting screw (8) Heat sink attaching screw diode trio lead (9) Rectifier bridge terminals (10) Inside "R" terminal connection (11) Trio lead to regulator (12) Regulator stud (13) Sense lead (14) Insulator (15) Plain Washer (16) Heat sink attaching screw for sense lead

5. Refer to Illustration 1 and 2. Place diode trio into position in housing. Coat threads on 1/2 inch long screw (in package), with high temperature adhesive/sealant (Loctite^® 620, in package). Secure diode trio to housing with screw at mounting hole (D). Tighten screw in newly drilled mounting hole to 3.4 N·m (30.1 lb in).

   Note: When reinstalling screw in hole previously used, tighten to 3 N·m (27 lb in). This is a grounding screw and must be secure.

6. Refer to Illustration 2. Locate heat sink attaching screw for connecting red diode trio lead (8). Remove screw, plain washer (15), and insulator (14). Place connector of red lead over hole, then reinstall insulator, plain washer and screw. Connector of red lead must be under insulator. Tighten screw to 3 N·m (27 lb in).

7. Refer to Illustration 2. Locate three yellow leads coming out of diode trio on same side as red lead. Connect each lead to a different rectifier bridge terminal, using three nuts removed and left loosened earlier. Ensure all leads to each of these terminals are properly reconnected. Tighten nuts to 3 N·m (27 lb in).

8. Install remaining yellow lead coming out of diode trio (on same side as blue lead) to inside of "R" terminal with existing attaching nut refer to Illustration 2. It may be necessary to hold hex shoulder on outside of terminal as anti-turn while tightening nut. Tighten nut to 2.3 N·m (20.3 lb in). Ensure that terminal lead does not touch housing after tightening.
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   Illustration 3	g06389573
   Attaching regulator to base plate (17) Apply Di-electric grease (18) Regulator (19) Base Plate (20) Diode trio lead (Blue) (21) Field coil lead (22) 1 inch insulated screw (23) Nut/lockwasher assembly (E) Mounting hole (F) Mounting hole (G) Mounting hole (H) Mounting hole

9. Refer to Illustration 3. Coat back (metal side) of new regulator with silicone dielectric grease (Loctite^® 5840, in package). Place regulator onto base plate, aligning three mounting holes ( (F), (G), and (H)) in each. Position blue lead from diode trio and one field coil lead over mounting hole (F) (refer to Illustration 3), then insert 1 inch long insulated screw through regulator and base plate. Install nut/lockwasher assembly (23). Ensure the three regulator and base plate mounting holes are still aligned. Hold screw at hex cap and tighten nut to 3 N·m (27 lb in).
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   Illustration 4	g06389574
   Installing regulator/Base plate assembly (24) Regulator/Base plate assembly (25) Spacer (26) Apply Di-electric grease (27) 1/2 inch mounting screw (28) field coil lead (29) 2 inch insulated screw (30) 1 inch mounting screw (J) Mounting hole (K) Mounting hole (L) Mounting hole

10. Refer to Illustration 4. Coat areas on back of base plate (side away from regulator) that will touch rectifier housing with silicone dielectric grease (Loctite^® 5840, in package). Coat ends of spacer with same grease, then place spacer over newly drilled mounting hole (K). Place regulator/plate assembly (24) into housing and align to mounting holes. Blade terminals on regulator "MUST NOT" touch alternator housing-trim ends of terminals if necessary to avoid contact. Install 1/2 inch long screw (provided in package) to hole (J) in base plate and old mounting hole in housing (finger tighten).

11. Refer to Illustration 4. Insert 2 inch long insulated screw (in package) through remaining field coil lead then coat threads with high temperature adhesive/sealant (Loctite^® 620, in package). Without getting sealant on surface of regulator contact, insert screw through regulator, base plate, and spacer into newly drilled mounting hole (K) (hand tighten).

12. Refer to Illustration 4. Install 1 inch long screw (provided in package) through regulator and base plate, and into newly drilled mounting hole (L).

13. Tighten screw in existing mounting hole (J) to 3 N·m (27 lb in). Tighten screws in newly drilled mounting holes (K) and (L) to 3.4 N·m (30.1 lb in)). The screw in hole (L) is a grounding screw, ensure that regulator is held securely.

    Note: When reinstalling screws in previously used mounting holes (K) and (L), tighten to 3 N·m (27 lb in).

14. Refer to Illustration 2. Install yellow sense lead loosely to threaded stud on regulator with nut/lockwasher assembly, routing lead through grommet to heat sink attaching screw. Remove heat sink screw, plain washer, and insulator. Place sense lead connector over hole and reinstall insulator, washer, and screw. Sense lead must be under insulator. Tighten heat sink screw to 3 N·m (27 lb in).

15. Place rectifier cover back onto rectifier end assembly and reinstall attaching screws. Tighten screws to 5.3 N·m (47.0 lb in).

16. Install end plate to rectifier end assembly and reinstall attaching screws. Tighten screws to 3 N·m (27 lb in).

17. Check inside of rectifier and assembly for new metal shavings that may have been created by installation of self-tapping screws into newly drilled mounting holes. Remove all traces of metal shavings.

18. Remove protective tape from open end of bearing in rectifier end assembly. Assemble drive-end assembly (with rotor) to rectifier end assembly. Install thru-bolts and tighten to 6 N·m (53 lb in).