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
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 1 2 3 4 5 6 * A0041AA A01019S A02010192S A0102203S A02210100S N/A N/A A0090902S Rev. B A0041JB A01019S A02010192S A01034S A02210100S N/A N/A A0090902S Rev. B A00420JB A01019S A020101991S A01034S A02210100S N/A N/A A0090902S A002AA A009630S A02009659S A01056S A0221021S N/A N/A A0090902S Rev. C A002AB A009630S A02009659S A01056S A0221021S N/A N/A A0090902S Rev. C A002JB A009630S A02009659S A01056S A0221021S N/A N/A A0090902S Rev. L A002JB A0101355S A02009659S A0105242S A0221021S N/A N/A A0090902S A0029LC A0103456S A02010345S A0105S A0221021S N/A N/A A0090902S A0005AA A009009S A0201041S A0105242S A022103504S N/A N/A A0090902S A0005JB A009009S A0201041S A0105242S A022103504S N/A N/A A0090902S Rev. K A0006AA A009630S A0201041S A0105242S A022103504S A0502220S A0502219S A0090902S Rev. F A0006JB A01049S A0201041S A0105242S A022103504S A0502220S A0502219S A0090902S Rev. C A0026AA A009009S A02009659S A0105242S A02210022S N/A N/A A0090902S Rev. E A0026JB A009630S A02009659S A01056S A02210022S N/A N/A A0090902S A002JB A009630S A02009659S A0105242S A0221040S A0502220S A0502219S A0090902S A0029JB A009009S A0201041S A0105242S A022103504S N/A N/A A0090902S Rev. J Component View Brush Kit * See SP1013-DWG for details on items. Model All Models K1510469S 55 Empire Drive Page 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 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 9 10 12 13 A0041AA A041099599S A03100265S A0505220S K1310445S K2121046S N/A N/A N/A Rev. B A0305229S N/A A0041JB A041099599S R24010345S* A0505220S K1310445S K2121046S N/A N/A N/A Rev. B A030522S N/A A00420JB A04109035S R24010540S A0505220S K1310445S K2121046S N/A N/A N/A A002AA A040296S A03100265S A0505220S K1310444S K2121046S N/A N/A N/A Rev. C A0305229S N/A A002AB A040296S A03100265S A0505220S K1310444S K2121046S N/A A031096545S N/A Rev. C A0305229S N/A A002JB A04109035S R24009652S A0505222S K1310444S K2121046S N/A A031096545S A051096603S Rev. L A040296S A0305229S A002JB A040296S R24009652S A0505220S K1310444S K2121046S N/A A031096545S A051096603S A0305229S A0029LC A040296S R24009652S A0505222S K1310445S K2121046S N/A A031096545S A051096603S A0305229S A0005AA A04109035S A03100265S A0505220S K1310444S K2121046S N/A A031096545S N/A A0305229S N/A A0005JB A040296S R24010325S A0505220S K1310444S K2121046S A031096545S N/A Rev. K A0305229S N/A A0006AA A04109035S A03100265S N/A K1310444S K2121043S R03036S A030121S N/A Rev. F N/A A0006JB A040296S R24010325S N/A K1310444S K2121043S R03036S A030121S N/A Rev. C N/A A0026AA A04109035S A03100265S A0505220S K1310444S K2121046S N/A A031096545S N/A Rev. E A0305229S N/A A0026JB A04109035S R24009652S A0505222S K1310444S K2121046S N/A A031096545S A051096603S A0305229S A002JB A040296S R24010322S N/A K1310444S K2121043S R03036S A030121S N/A A0029JB A040296S R24010326S A0505220S K1310444S K2121046S N/A A031096545S N/A Rev. J A0305229S * Use R24010540S for 56V setpoint. 55 Empire Drive Page 3
Parts Breakdown Group: 4000 J10 Notes: Form: SP1013-DWG Refer to SP1013-4000-6-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. 9 6 12 5 3 10 4 1 2 13 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
Source: Date: January 2, 2009 No: Models: Subject: Technical Service Division - Arcade, NY USA TSB-30 4000 Series 6 Diode Rectifier Alternators Hardware Kit for 4000 6 Diode Series Alternators K2121043S 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. * 1 16 20 21 22 26 25 24 19 1 16 1 20 2 2 29 * Solid lead frame rectifier 9 5 9 13 10 12 6 1 3 4 See page 2 for brush box details 2 400 Main Street Arcade, NY 009 Page 1
Date: January 2, 2009 No: TSB-30 30 30 31 31 10 5 32 31 33 33 34 34 55 Empire Drive Page 2
Date: January 2, 2009 No: TSB-30 Description Qty. Key Where used NUT, 5/-1, LOCK 1 1 Fan Nut WASHER, FLAT#10 3 2 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 #10 3 10 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, 5/16-1 2 16 Holds positive and negative studs into rear housing WASHER GUARD, 5/16 1 1 Washer used on negative output stud WASHER, LOCK 5/16 2 1 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, 5/16 2 22 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, #10 1 25 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 /16 4 30 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, 1/4-20 3 34 AC Stud Nuts 55 Empire Drive Page 3
Source: Date: January 2, 200 No: Models: Subject: Technical Service Division - Arcade, NY USA TSB-3012 4000 Series 6 Diode Rectifier Alternators Hardware Kit for 4000 6 Diode Series Alternators K2121046S 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. * 21 1 16 20 * Solid rectifier lead frame 19 16 1 1 20 9 5 9 13 10 12 6 1 3 4 See page 2 for brush box details 2 400 Main Street Arcade, NY 009 Page 1
Date: January 2, 200 No: TSB-3012 22 22 26 10 5 25 24A 2 24B 2 55 Empire Drive Page 2
Date: January 26, 200 No: TSB-3012 NOTE: All of these components are part of the hardware kit and not available for individual purchase. 4900 T-Mount * 16 1 20 21 * Solid rectifier lead frame 19 16 1 1 20 9 5 4 9 13 10 12 22 6 1 3 2 24A 2 400 Main Street Arcade, NY 009 Page 3
Date: January 2, 200 No: TSB-3012 Description Qty. Key Where used NUT, 5/-1, LOCK 1 1 Fan Nut WASHER, FLAT#10 6 2 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 #10 3 10 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, 5/16-1 2 16 Holds positive and negative studs into rear housing WASHER GUARD, 5/16 1 1 Washer used on negative output stud WASHER, LOCK 5/16 2 1 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, 45 1 26 Ignition terminal NUT, CON LOCK, 1/4-20 3 2 AC nuts 55 Empire Drive Page 4