KIT-ENGINE OVERHAUL 3909370 - Caterpillar

Disassembly Procedure
Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     6V-7070     Digital Multimeter     1    
B         Variable Power Supply     1    Start By:
Remove the alternator. Refer to Disassembly and Assembly, "Alternator - Remove" for the machine that is being serviced.Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.
Remove the pulley nut, the washer, the pulley, and the fan.
Illustration 1 g00627790
Remove 4 screws (1). Remove plate (2) .
Illustration 2 g00627792
Remove 7 screws (3). Remove cover (4) .
Illustration 3 g00627794
Remove gasket (5) .
Illustration 4 g00627796
Remove 2 insulated screws (6). Remove the 3 leads.Note: The regulator and the mounting plate are coated with dielectric grease. If the grease is removed, reapply the grease.
Remove nut (7) .
Illustration 5 g00627804
Remove grounded mounting screw (8) .
Remove regulator (9) .
Illustration 6 g00627808
Remove mounting plate (10). The mounting plate may be stuck to the regulator.
Illustration 7 g00627810
Note: The 3 output diodes (11) are located in heat sink (12). These diodes are identical in polarity. Diode (11) has red insulation on the wire. The 3 ground diodes (13) are located in housing (14). These diodes are identical in polarity. Diode (13) has black insulation on the wire.
Remove 3 nuts (15). Disconnect 3 stator phase leads. Disconnect 3 phase leads. Disconnect 6 diode leads.
Table 2
Alternator Ground    Current Flow of the Output Diodes    Current Flow of the Ground Diodes    
Negative     Lead to the Heat Sink     Housing to the Lead    
Red Wire Black Wire    
Illustration 8 g00627820
Remove the screw and insulator (16). Disconnect capacitor lead (17) .
Illustration 9 g00627832
Remove the 3 screws and insulators (18). Disconnect wire (19) .
If the "R" terminal is used, remove the following components: nut (20), lead (21), the washer and terminal (21) .
Illustration 10 g00627840
Remove screw (23) and remove diode trio (24) .
Remove the nut and washer (25). Remove insulator (26). Remove alternator output terminal (27) .
Remove separator (28) .
Illustration 11 g00627853
Note: Many of the alternator's internal components are covered with dielectric grease. If the grease is removed, reapply the grease.
Illustration 12 g00627855
Remove the heat sink and diode assembly (12) from housing (14). Insulator (29) may be stuck to heat sink (12) .
Illustration 13 g00628035
Note: Do not damage exposed stator windings or field windings. Bumping the windings or scraping the windings may break the insulation. Broken insulation may create a short circuit or a ground.
Remove 4 bolts (30). Carefully separate housing (31) from housing (14) .
Illustration 14 g00628037
Pull apart stator (32) and housing (14). Guide the stator leads and the grommet through the hole as the stator is removed from housing (14) .
Illustration 15 g00628041
Remove 3 screws (33). Remove the coil and support (34) from housing (14). Guide the field leads and the grommet through the hole as the coil is removed from housing (14) .
Illustration 16 g00628043
Position a small screwdriver in slot (35). Pry cap (36) from housing (14) .
Illustration 17 g00628057
Note: Do not strike the bearing. Shocks