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	g00825148

1. Install ball bearing (28) into the front frame. The installation of this component requires force.

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Illustration 2	g00825149

2. Install retainer (27). Install three bolts (26) .

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Illustration 3	g00825154

3. Install spacer (25) onto the rotor.

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Illustration 4	g00825155

4. Install rotor (24) onto the front frame. The installation of this component requires force.

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Illustration 5	g00825156

5. Install stator (23) onto the front frame. Align the mark on the stator to the mark on the front frame.

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Illustration 6	g00825158

6. Install roller bearing (22) into the rear frame. The installation of this component requires force. Apply grease to the roller bearing, if necessary.

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Illustration 7	g00825168

7. Install field coil (21) onto the rear frame. The leads must fit through the rear frame. Install three bolts (20) .

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Illustration 8	g00825170

8. Attach rear frame (18) to front frame (19). Align the mark on the rear frame to the mark on the front frame. The stator leads must pass through the appropriate openings. Install four bolts (17) .

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Illustration 9	g00825173

9. Install rectifier (16). Install five bolts (14). Connect the stator leads to the rectifier and install four bolts (10). Tighten "B+" terminal (9) to the following torque: 18.2 ± 2.4 N·m (13.4 ± 1.8 lb ft)

10. Install "R" terminal (12). Install grommet (11). Install bolt (13) .

11. Install "B-" terminal (15). Tighten the "B-" bolt to the following torque: 4.4 ± 1 N·m (39 ± 9 lb in)

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Illustration 10	g00825175

12. Install regulator (8). Install the three bolts (7). Connect the field winding leads to the regulator. Install two bolts (6) .

    Note: The regulator terminal that is closest to the "B+" terminal goes on top of the rectifier terminal. The regulator terminal that is farthest from the "B+" terminal goes underneath the rectifier terminal.

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Illustration 11	g00825176

13. Install the rear cover. Install three bolts (5) .

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Illustration 12	g00825178

14. Install spacer (4), fan (3), washer (1), and pulley nut (2) to the rotor shaft. Tighten the pulley nut to the following torque: 127 ± 10 N·m (94 ± 7 lb ft)

15. 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.