21460908 Volvo.Penta Converter

Table 1
Revision Table
Revision Summary of Changes
02 Added serial numbers. Important Safety Section
Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If the tools, the procedure, the work method, or your actions are not recommended by Caterpillar, ensure that the tools and your actions are safe for you and for others.Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures.Follow all safety warnings. Most accidents that involve product operation, maintenance, or repair are caused by failure to observe safety warnings. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. Personnel should be properly trained to perform maintenance, repair, or operate any machine. Safety precautions and warnings are provided this instruction and on Caterpillar products. These warnings should be observed before performing any procedures. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are not all inclusive.
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.
ELECTROCUTION HAZARD - The electrical system contains hazardous voltage levels.DO NOT remove any covers that will expose energized hazardous-voltage electrical components without shutting down and discharging the electrical system.DO NOT perform any maintenance on the electrical system until after the electrical system has been shut down and the voltage has been discharged by qualified personnel.Read and understand the instructions and warnings found in the Operation and Maintenance Manual to properly shut down the electrical system and discharge hazardous-voltage electrical components.Failure to follow these instructions could result in personal injury or death.
Note: Always use proper eye protection when performing any mechanical repairs to a vehicle including, but not limited to, any installation and or repairs to the starter. Failure to use proper eye protection can lead to serious and permanent eye damage.Note: Only perform the mechanical functions that you are properly qualified to perform. Mechanical repairs that are beyond your technical capabilities should be handled by a professional installation specialist.Note: To avoid injury or damage, always disconnect the negative cable at the battery before removing or replacing the alternator. The alternator output terminal is always lived ("hot"). If the battery is not disconnected, a tool accidentally touching this terminal and ground can quickly get hot enough to cause skin burn or damage to the tool and surrounding parts.Installation Procedure
The Integrated Circuit (IC) voltage regulator, base plate, diode trio, and attaching hardware in this package are used to replace discrete component regulators used in earlier designs of 25SI alternators.The earlier regulators have separate transistors, diodes and other components mounted on a circuit board covered with an RTV-type coating. Both the new diode trio and the new regulator must be installed to replace this former type regulator.New mounting holes must be drilled into the alternator housing to attach the new components.Use the below procedure to replace 100-6534 Regulator Kit to the earlier design discrete component regulator. In addition to the items supplied in the package and the usual hand tools, a drill with 9/64 inch diameter bit will be needed to complete the installation.Install regulator and diode trio as follows:
Remove four thru-bolts from alternator and separate drive end assembly (with rotor) from rectifier end assembly. This is necessary to allow complete removal of metal shavings created by drilling holes. Cover the open end of the rectifier end bearing with tape to keep shavings from getting into the bearing grease.
Remove end plate and rectifier cover from rectifier end assembly by removing attaching screws.
Remove nuts from rectifier bridge terminals and inside of "R" terminal to disconnect three long, identically colored leads to regulator. Some units may have a separate lead between the "R" terminal and a rectifier bridge terminal if so, remove this lead also. Place nuts loosely back on "R" terminal and on rectifier bridge terminals to hold other leads in place during repair.Note: If old regulator has a sense lead connected to the heat sink attaching screw, remove screw, flat washer and insulator to disconnect lead. Place insulator, washer, and heat sink screw loosely back into unit for later attachment of new sense lead. Disconnect two field coil leads from regulator and remove two regulator-mounting screws. Lift regulator and long leads with grommet from generator housing.
Illustration 1 g06389571
Locating new mounting holes and installing diode trio
(1) Diode Trio
(2) Base plate
(3) New trio mounting hole
(4) New regulator mounting hole
(5) Mounting screw
(A) Mounting hole
(B) Mounting hole
(C) Mounting hole
(D) Mounting hole
Refer to Illustration 1. Place new diode trio (1) and regulator base plate (2) in position. Locate base plate by positioning mounting hole (A) over existing mounting hole in casting. Temporarily install the 1/2 inch long mounting screw