INJECTOR GP- 9Y4544 - Caterpillar

Image1.4.1
Detail view of the new hardware that is used to connect a Reverse diode negative flying lead, a Standard diode positive flying lead, and the white sheathed exciter armature lead to the plate. Three of these AC connection points are located on the Rotating Rectifier Assembly.
(15) Locknut 1/4-20 (2D-6235)
(16) Spring Washer (4N-3884)
(17) Flat Washer (8T-4205)
(14) Reverse Diode negative flying lead
(10) Standard Diode positive flying lead
(18) White sheathed exciter armature lead
(19) Flat Washer (8T-4205)
(20) Insulated hole in Rotating-Rectifier DC Plate
(21) Flat Washer (8T-4205)
(22) Spring Washer (4N-3884)
(23) Bolt 1/4"-20 (5P-2675)
Image1.5.1
Standard Diode - 488-9244 (Red Sleeve) replaces 390-2032 (Blue Sleeve)
Reverse Diode - 488-9245 (Black Sleeve) replaces 390-2031 (Red Sleeve)
The 390-2031 and 390-2032 Diodes will no longer be used in 390-2000 Generators.
1. Install a threaded 488-9246 Sleeve on each of the new diodes. The sleeve must bottom out on the base of the diode as shown in Image 1.5.2. The purpose of the sleeve is to center the smaller studded diode in the oversized hole.
Image1.6.1
Image1.6.2
2. Rotate the Rectifier to access one of the three AC connection points. Remove all of the 5/16" hardware that secures the two diode flying leads and armature lead to the rectifier plate. The 5/16" hardware will be replaced with 1/4" hardware.
Image1.7.1
3. Rotate the Rectifier to access the base connection of one of the diodes that has the flying lead disconnected.
4. Remove the M12 nut and washer from the diode base stud. Remove the diode from the mounting hole. All hardware will be replaced.
5. Install one of the new diodes of the same polarity as the removed diode. Insure the sleeve is in place as the stud is inserted thru the hole in the Rectifier plate. Orient the diode base so that the flying lead connection can be made with minimal twist. Secure the base of the diode to the plate using a 7X-0623 Hard Washer, 264-3617 Lock Washer, and 5B-9079 Half Nut. Tighten to 13.5 +/- 1.0 N.m (120 +/- 9 in-lb).
Image1.8.1
CAUTION: The stud on the diode is plated copper - do not over-tighten the nut or the diode can be damaged.
6. Rotate the Rectifier to access the base connection of the other diode that has the flying lead disconnected.
7. Repeat steps 4 & 5 to install a new diode of the opposite polarity.
8. Rotate the Rectifier to access the flying lead AC connection point for the new diodes.
9. Install a new 1/4 inch 5P-2675 Bolt with a 4N-3884 Spring Washer and 8T-4205 Hard Washer thru the insulated hole in the Rectifier plate from the rear. Install a 8T-4205 Hard Washer on the bolt on the other side of the plate, under the Exciter Armature AC lead lug. Check that the bolt passes through the AC lead lug.
10. Install one of the diode flying lead lugs on the bolt, oriented so it lays flat against the Exciter Armature AC lead lug.
Image1.9.1
11. Install the flying lead lug of the other diode on the bolt, oriented so it lays flat against the first diode flying lead lug. Proper diode flying lead orientation is shown in image 1.9.1.
Image1.10.1
12. Install a 8T-4205 Hard