HARNESS AS-ENGINE 4256526 - Caterpillar

Image1.1.1
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4. Crimp the splice on exciter rotor leads (see image 1.2.1).
5. Cut 3 pieces (#6 awg wire) six inches, and strip one end (see image 1.2.2).
6. Crimp wires to the splices, on exciter rotor leads (see image 1.2.2).
Image1.2.1
Image1.2.2
7. Solder the splices on exciter rotor leads (see image 1.3.1).
8. Wrap the splices, with rubber silicone tape, extending 1" on each side of the splice overlapping 1/2 wrap on exciter rotor leads (see image 1.3.2).
9. Cut heat shrink sleeving and install over the taped splices on the exciter rotor leads (see image 1.3.3).
Image1.3.1
Image1.3.2
Image1.3.3
10. Cut sleeve insulation to cover and overlap existing main rotor leads (see image 1.4.1).
11. Install leads through rectifier assembly, careful not to trap insulation between rectifier assembly and shaft. Ensure pins align in rectifier assembly (see image 1.4.2).
12. Pull exciter rotor sleeving, to extend 2" from lead opening (see image 1.4.3).
Image1.4.1
Image1.4.2
Image1.4.3
13. Rotate rectifier, so that field leads are facing + and ? terminals (see image 1.5.1).
Note: If the main rotor leads are not long enough to reach the + and ? terminals, loosing the main rotor clamp and pulling the main rotor leads may give you the required length (see image 1.5.2). Secure the clamp making sure the sleeve remains in place to avoid damage to the leads. If the leads are still too short after loosing the clamp please contact Roberto Vivas for additional instructions. Refer to the Action Required for contact information.
14. Install rectifier assembly screws and tighten to 23 foot lbs, using cross-pattern tightening sequence (see image 1.5.3 and image 1.5.4).
15. Cut exciter rotor leads, by positioning leads to terminal connection to determine length to cut (see image 1.5.4).
Image1.5.1
Image1.5.2
Image1.5.3
Image1.5.4
16. Strip exciter rotor leads (see image 1.6.1).
17. Crimp terminals to exciter rotor leads (see image 1.6.2)
18. Secure leads with nylon tie (see image 1.6.3)
Image1.6.1
Image1.6.2
Image1.6.3
19. Remove nut and small washer on rectifier terminals and the + and - terminals (see image 1.7.1)
20. Connect exciter rotor leads to rectifier terminals and main rotor leads to the + and - terminal, install small washer and locking nut (see image 1.7.2).
21. Tighten the terminals to 13 foot pounds (see image 1.7.3).
Image1.7.1
Image1.7.2
Image1.7.3