Technical Service Parts Breakdown

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Refer to TSB-3012 for models not requiring the capacitor. Refer to TSB-1 for Solid Leadframe changeout procedure.

1 Parts Breakdown Group: 4000 J10 6 Diode Notes: Form: SP1013 Refer to SP1013 -DWG for major component drawing. Date: December 1, 2009 Refer to TSB-30 for hardware kit breakdown for File: Alternator Parts List Section models requiring the R03036S capacitor. Refer to TSB-3012 for models not requiring the capacitor. Refer to TSB-1 for Solid Leadframe changeout procedure. This service parts list covers 6 diode rectified alternators less than 15 Amps and either remote rectified or remote regulated models. * This indicates the revision letter on the label. If your unit is this revision or later, use this service component. Rev. B In addition to identifying the part number from the part label it is also required that you identify the REV level. It is probable that no REV level is present; if so, utilize the part number only to identify the appropriate part. However, if a REV level is present, choose the applicable part for that REV level which is listed below the part number. 55 Empire Drive Page 1

2 Parts Breakdown Group: 4000 J10 6 Diode Notes: Form: SP1013 Refer to SP1013 -DWG for major component drawing. Date: December 1, 2009 Refer to TSB-30 for hardware kit breakdown for File: Alternator Parts List Section models requiring the R03036S capacitor. Refer to TSB-3012 for models not requiring the capacitor. Refer to TSB-1 for Solid Leadframe changeout procedure. Component View Front Housing Spacer, bearing, retainer Rotor Rear Housing, bearing Stator Rectifier Negative Rectifier Positive Brush Box & gasket Model * A0041AA A01019S A S A S A S N/A N/A A S Rev. B A0041JB A01019S A S A01034S A S N/A N/A A S Rev. B A00420JB A01019S A S A01034S A S N/A N/A A S A002AA A009630S A S A01056S A S N/A N/A A S Rev. C A002AB A009630S A S A01056S A S N/A N/A A S Rev. C A002JB A009630S A S A01056S A S N/A N/A A S Rev. L A002JB A S A S A S A S N/A N/A A S A0029LC A S A S A0105S A S N/A N/A A S A0005AA A009009S A S A S A S N/A N/A A S A0005JB A009009S A S A S A S N/A N/A A S Rev. K A0006AA A009630S A S A S A S A S A S A S Rev. F A0006JB A01049S A S A S A S A S A S A S Rev. C A0026AA A009009S A S A S A S N/A N/A A S Rev. E A0026JB A009630S A S A01056S A S N/A N/A A S A002JB A009630S A S A S A S A S A S A S A0029JB A009009S A S A S A S N/A N/A A S Rev. J Component View Brush Kit * See SP1013-DWG for details on items. Model All Models K S 55 Empire Drive Page 2

3 Parts Breakdown Group: 4000 J10 6 Diode Notes: Form: SP1013 Refer to SP1013 -DWG for major component drawing. Date: December 1, 2009 Refer to TSB-30 for hardware kit breakdown for File: Alternator Parts List Section models requiring the R03036S capacitor. Refer to TSB-3012 for models not requiring the capacitor. Refer to TSB-1 for Solid Leadframe changeout procedure. Component View Fan Regulator or Cover, with mounting screws Rectifier Solid Lead Frame Pos/ Neg Overhaul Kit Bearings, brushes, seal & spacer Hardware Kit Capacitor Assy. Capacitor Trio Model A0041AA A S A S A S K S K S N/A N/A N/A Rev. B A S N/A A0041JB A S R S* A S K S K S N/A N/A N/A Rev. B A030522S N/A A00420JB A S R S A S K S K S N/A N/A N/A A002AA A040296S A S A S K S K S N/A N/A N/A Rev. C A S N/A A002AB A040296S A S A S K S K S N/A A S N/A Rev. C A S N/A A002JB A S R S A S K S K S N/A A S A S Rev. L A040296S A S A002JB A040296S R S A S K S K S N/A A S A S A S A0029LC A040296S R S A S K S K S N/A A S A S A S A0005AA A S A S A S K S K S N/A A S N/A A S N/A A0005JB A040296S R S A S K S K S A S N/A Rev. K A S N/A A0006AA A S A S N/A K S K S R03036S A030121S N/A Rev. F N/A A0006JB A040296S R S N/A K S K S R03036S A030121S N/A Rev. C N/A A0026AA A S A S A S K S K S N/A A S N/A Rev. E A S N/A A0026JB A S R S A S K S K S N/A A S A S A S A002JB A040296S R S N/A K S K S R03036S A030121S N/A A0029JB A040296S R S A S K S K S N/A A S N/A Rev. J A S * Use R S for 56V setpoint. 55 Empire Drive Page 3

4 Parts Breakdown Group: 4000 J10 Notes: Form: SP1013-DWG Refer to SP diode for parts breakdown. Date: January 2, 2009 Refer to TSB-30 for hardware kit breakdown for models File: Alternator Parts List Section requiring the R03036S capacitor. Refer to TSB-3012 for models not requiring the capacitor. This service parts list covers 6 diode rectified alternators less than 15 Amps and either remote rectified or remote regulated models See TSB-30 and TSB-3012 for Hardware Kit breakdowns Actual appearances of some components may differ from the actual product. This document is intended to be for generic referral only. 55 Empire Drive Page 1

5 Source: Date: January 2, 2009 No: Models: Subject: Technical Service Division - Arcade, NY USA TSB Series 6 Diode Rectifier Alternators Hardware Kit for Diode Series Alternators K S This series covers 6 diode rectified alternators less than 15 Amps and either remote rectified or remote regulated models requiring the R03036S capacitor. NOTE: All of these components are part of the hardware kit and not available for individual purchase. * * Solid lead frame rectifier See page 2 for brush box details Main Street Arcade, NY 009 Page 1

6 Date: January 2, 2009 No: TSB Empire Drive Page 2

7 Date: January 2, 2009 No: TSB-30 Description Qty. Key Where used NUT, 5/-1, LOCK 1 1 Fan Nut WASHER, FLAT# Thru-Bolt flat washer KEY, WOODRUFF # 1 3 Shaft key SCREW, THREAD FORMING 4 4 Front housing retainer plate holding screw NUT 4 5 Internal stator nuts to AC-taps THROUGH BOLT 3 6 Thru-Bolt Hold Alternator Together SCREW TERMINAL 5/16-1 x 3 1/4 2 Positive and Negative Output Studs SCREW, TAP #6-32X/32 4 Hold regulator sense leads and capacitor to rectifier rings SCREW #10-32 X 1 1/2 2 9 Holds rectifier ring to rear housing SCREW #10-32 X 1 1/2 2 9 Holds rectifier ring to rear housing WASHER, LOCK # Lock washer for bolt (Key 9) WASHER, FLAT #10 2 Flat washer for bolt (Key 9) WASHER INSULATING 2 12 Insulates bolt (Key 9) from rectifier rings BUSHING, INSULATING 2 13 Insulates bolt (Key 9) from rectifier rings BUSHING, INSULATING 2 Insulates output studs and rectifier rings from rear housing BUSHING, INSULATING 4 Insulates rectifier ring from rear housing NUT, CON LOCK, 5/ Holds positive and negative studs into rear housing WASHER GUARD, 5/ Washer used on negative output stud WASHER, LOCK 5/ Lock washer for positive and negative output stud HEX NUT, 5/16-1 UNC 1 19 Jam nut used on negative output stud HEX NUT, 5/16-1 UNC 2 20 Nut used to attach customer cables to alternator output studs NUT, #10-32 FLANGE LOCK 3 21 Thru Bolts nuts WASHER, LOCK, 5/ Lock washer for (Key ) SCREW 5/16-1 X 3/4 HEX HD 2 Attaches capacitor to alternator CLAMP 1 24 Secure capacitor wires to alternator WASHER LOCK, # Lock washer for (Key 26) SCREW #10-32 X 1/2 RD HD 1 26 Attaches clamp (Key 24) to alternator SPACER 2 2 Spacer for external capacitor WASHER, LOCK 1/4 2 2 Lock washer for bolt (Key 29) SCREW 1/4-20 X 2 HEX HD 2 29 Attaches capacitor to alternator SCREW #-32 X 3/ 4 30 Attaches regulator to brush box SCREW #-32 X / Attaches regulator to brush box HEX NUT, #10-32 UNF 4 31 Holds AC studs into brush box SCREW #10-32 X 5/ SQ HD 1 32 Ignition stud STUD, TERMINAL 3 33 AC Studs NUT, CON LOCK, 1/ AC Stud Nuts 55 Empire Drive Page 3

8 Source: Date: January 2, 200 No: Models: Subject: Technical Service Division - Arcade, NY USA TSB Series 6 Diode Rectifier Alternators Hardware Kit for Diode Series Alternators K S This series covers 6 diode rectified alternators less than 15 Amps and either remote rectified or remote regulated models not requiring the R03036S capacitor. NOTE: All of these components are part of the hardware kit and not available for individual purchase. * * Solid rectifier lead frame See page 2 for brush box details Main Street Arcade, NY 009 Page 1

9 Date: January 2, 200 No: TSB A 2 24B 2 55 Empire Drive Page 2

10 Date: January 26, 200 No: TSB-3012 NOTE: All of these components are part of the hardware kit and not available for individual purchase T-Mount * * Solid rectifier lead frame A Main Street Arcade, NY 009 Page 3

11 Date: January 2, 200 No: TSB-3012 Description Qty. Key Where used NUT, 5/-1, LOCK 1 1 Fan Nut WASHER, FLAT# Thru-Bolt flat washer KEY, WOODRUFF # 1 3 Shaft key SCREW, THREAD FORMING 4 4 Front housing retainer plate holding screw NUT 4 5 Internal stator nuts to AC-taps THROUGH BOLT 3 6 Thru-Bolt Hold Alternator Together THROUGH BOLT 3 6 Thru-Bolt Hold Alternator Together SCREW TERMINAL 5/16-1 x 3 1/4 2 Positive and Negative Output Studs SCREW, TAP #6-32X/32 4 Hold regulator sense leads and capacitor to rectifier rings SCREW #10-32 X 1 1/2 2 9 Holds rectifier ring to rear housing SCREW #10-32 X 1 1/2 2 9 Holds rectifier ring to rear housing WASHER, LOCK # Lock washer for bolt (Key 9) WASHER, FLAT #10 2 Flat washer for bolt (Key 9) WASHER INSULATING 2 12 Insulates bolt (Key 9) from rectifier rings BUSHING, INSULATING 2 13 Insulates bolt (Key 9) from rectifier rings BUSHING, INSULATING 2 Insulates output studs and rectifier rings from rear housing BUSHING, INSULATING 4 Insulates rectifier ring from rear housing NUT, CON LOCK, 5/ Holds positive and negative studs into rear housing WASHER GUARD, 5/ Washer used on negative output stud WASHER, LOCK 5/ Lock washer for positive and negative output stud HEX NUT, 5/16-1 UNC 1 19 Jam nut used on negative output stud HEX NUT, 5/16-1 UNC 2 20 Nut used to attach customer cables to alternator output studs NUT, #10-32 FLANGE LOCK 3 21 Thru Bolts nuts SCREW #-32 X 3/ 4 22 Regulator attachment screws HEX NUT, #10-32 UNF AC Tap Nuts STUD TERMINAL 3 24A AC Studs STUD TERMINAL 3 24B AC Studs SCREW, #10-32 X 5/, SQ HD 1 25 Ignition stud TERMINAL, 1/4, Ignition terminal NUT, CON LOCK, 1/ AC nuts 55 Empire Drive Page 4

Technical Service Parts Breakdown

Technical Service Parts Breakdown Parts Breakdown Group: 4000 T-Mount Notes: Form: SP1010 Refer to SP1010 -DWG for major component drawing. Refer to TSB-300, 3012, and TSB-3014 for hardware kit File: Alternator Parts List Section breakdown.