HDB Series and M1 Series Heavy Duty Brushless Alternators Caterpillar

Assembly Procedure

Note: Before assembly, clean all parts in cleaning fluid. Allow the parts to air dry. DO NOT dry the parts with wiping cloths or with rags. Cloths and rags contain lint. Inspect all parts. Replace worn parts and replace damaged parts.

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Illustration 1	g00825771

1. Put field winding (24) into the rear frame. Install three bolts.

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Illustration 2	g00825773

2. Install "R" terminal (19). Put rectifier (23) into the rear frame. Install the four bolts. Tighten the "B+" terminal nut to the following torque: 29 ± 8 N·m (21 ± 6 lb ft) Tighten the "B-" terminal nut to the following torque: 4.4 ± 1 N·m (39 ± 9 lb in)

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Illustration 3	g00825774

3. Put rear frame (4) on stator (5). Align the marks on the stator and on the rear frame. Connect the stator leads to the rectifier.

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Illustration 4	g00825775

4. Install regulator (15) and capacitor (17). Install the two bolts.

5. Connect the field winding leads and connect the wire (14) to the regulator and to the capacitor. Connect the other end of the wire (14) and connect wire (16) to the rectifier.

6. Install the rear cover.

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Illustration 5	g00825750

7. Install two ball bearings (6) on the rotor. Install plate assembly (10), the rear spacer, the rear felt washer, plate (7), ball bearing (8), washer (11), front felt washer (12), and spacer (9) .

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Illustration 6	g00825777

8. Put rotor (26) into the front frame. Install the four bolts.

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Illustration 7	g00825778

9. The rotor remains connected to the front frame. The stator remains connected to the rear frame. Put front frame (3) into the rear frame (4). Align the marks on the front frame and on the rear frame. Install the four bolts.

10. Install the fan, the key, the pulley, the washer, and the pulley nut. Tighten the pulley nut to the following torque: 102 ± 7 N·m (75 ± 5 lb ft)

11. Restore the residual magnetism in the alternator. Refer to Testing and Adjusting, "Residual Magnetism - Restore".

End By: Install the alternator on the machine. Refer to Disassembly and Assembly, "Alternator - Install" for the machine that is being serviced.