BODY AS-PISTON 4W7402 - Caterpillar

Assembly Procedure
Table 1
Tooling that is needed    A    B    
    Soldering iron (180 watt)            
    Vise or clamping support with vee blocks            
    Press            
8H-8581     Feeler Gauges     3        
1P-0510     Driver Set         1    
1P-0466     Plate         1    
1P-0529     Handle         1    
6L-5897     Bolt         1    
Illustration 1 g00871248
Install the roller bearing (1) with tooling (B) .Note: If necessary, apply grease to the bearing.
Illustration 2 g00871460
Install the ring (2) in the rear frame.
Illustration 3 g00871252
Install the insulators for terminal "B+" and terminal "D+".
Illustration 4 g00871347
Install the "R" terminal, if the "R" terminal was replaced.
Install the rectifier (3) in the rear frame.
Install the two screws. Solder the sleeve (4) over terminal "R".
Install the following components on terminals: "D+", "B+" and B-: terminal insulators, washers and nuts.
Illustration 5 g00871376
Position the stator frame (7) on the rear frame (5). Use the marks on the alternator that were made in the disassembly procedure for alignment.
Illustration 6 g00871382
Solder the leads for the stator winding (8) to the terminals for the rectifier (6) .
Illustration 7 g00871385
Install the bearing (9) in the rear frame.Note: The bearing is a loose fit.
Illustration 8 g00871389
Install the intermediate ring (10) .
Illustration 9 g00871402
Install the field winding (11). The leads for the winding must fit in the deep groove. Install the six screws on the reverse side of the frame.
Apply the epoxy putty 5P-3321 Adhesive over the lead and the groove.
Illustration 10 g00871407
Install the spacer ring (12) .
In the next step you must support the spacer ring. The spacer ring is supported in order to support the bearing inner race.
Illustration 11 g00871415
Install the rotor assembly (13) in the drive end frame (14).
Illustration 12 g00871417
Heat the bearing race (15) to 135 °C (275 °F). Install the bearing race on the shaft.
Illustration 13 g00871447
Connect the drive end and the rotor (16) to the rear housing and the stator frame (17). The marks that were made during the disassembly procedure will help align the alternator. Install the four hex socket screws. Do Not Tighten the hex socket screws.
Illustration 14 g00871452
Insert three 0.3 mm (0.01 inch) feeler gauges (18) between the rotor and the stator. Tighten the screws to a torque of 4.8 .7 N m (3.5 .5 lb ft).
Illustration 15 g00871457
Connect the lead for the field coil to the regulator (21). The screw is large in diameter (19) .
Connect the lead for the rectifier and the remaining lead for the field coil (20) to the regulator terminal.Note: In order to maintain the proper polarity, one lead for the field coil has a hole that is small in diameter.
Illustration 16 g00871458
Install the regulator (21) on the rear frame assembly. Install the two screws for the regulator.
Install the lead for the suppression capacitor on the "D+" terminal (22) .
Illustration 17 g00871459
Install the regulator cover (23). Install the screws for the regulator cover.