Technical Service Bulletin - Prestolite · PDF fileRemove blocking diode from regulator ... rectifier + terminals to the battery isolator start battery post. Fig 9 5) Install new 8RD

Important: The information contained in this bulletin is intended for use by trained, professional technicians who have the proper tools, equipment, and training to perform the required maintenance described above. This information is NOT intended for ‘do-it-yourselfers’, and you should not assume that this information applies to your equipment. If you have any questions regarding this information please visit our website at www.prestolite.com, or contact our technical service department at:

Page 1

Leece-Neville Heavy Duty Systems400 Main StreetArcade, NY 14009

Technical ServiceBulletin

Phone: (844) [email protected]

Source: Leece-Neville Heavy Duty Systems Division - Arcade, NY USA

Date: JULY 7, 2017

Bulletin No: TSB-1144

Models: 5078R, 5042R, 6014R and 6026R

Subject: Regulator retrofit procedure

This procedure was created to help convert vehicles that used our 5078R(12V) and 5042R(24V) remote regulators to our newer 8RD2041S(12V) and 8RD3043S(24V) regulators.

8RD2041S (12V)8RD3043S (24V)

8RD2041S8RD3043S

Remote regulated systems procedure: 1) Disconnect vehicle batteries.

2) Identify and label vehicles wires connecting to voltage regulator and relay as indicated in Fig 1.

3) Remove , , wires from relay and , , wires from regulator terminals. Remove both regulator and relay from vehicle. Fig 1

Note: Relay will not be needed when using the replace-ment regulator.

4) Install new 8RD style regulator.

5) Wiring, please refer to steps below. Fig 2

A) Splice wires and together and apply shrink tubing to prevent shorting. B) Connect wire to (Blue / A Pin) on voltage regulator. C) Connect wire to (Green / C Pin) on voltage regulator. D) Connect wire to (Red / D Pin) on voltage regulator. E) Connect wire to (Black / B Pin) on voltage regulator. Note: Regulator pin identifications can be found in Fig 3

6) Connect batteries and test for proper operation.

1 2

3

F

+

-

BL

G

R

B

1 2 3 + - F

Fig 2

+-

F+

F-

8RD2041S (12V)8RD3043S (24V)

B+Ign.

+ - F 32 1R B G BL

ALT

+-

F+

F-

F-+

5078R(12V)5042R (24V) Regulator

6014R (12V)6026R (24V) Relay

123

B+Ign.

Fig 1

+ - F 3 2 1

ALT

Fig 3


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Leece-Neville Heavy Duty Systems7585 Empire DriveFlorence, KY 41042



Date: JULY 7, 2017


Remote regulated systems with battery isolator procedure:. 1) Disconnect vehicle batteries.


3) Remove , , wires from relay and , , wires from regulator terminals. Remove blocking diode from regulator terminal and relay terminal. Fig 4 Remove regulator, relay and blocking diode from vehicle.

Note: Relay and blocking diode will not be needed when using the replacement regulator.

4) Remove short jumper wire connecting alternator F+ and B+ terminals. Install a new (14 AWG min.)wire from the alternator F+ terminal to the battery isolator start bat-tery post. Fig 5



A) Splice wires and together and apply shrink tubing to prevent shorting. B) Connect wire to (Blue / A Pin) on voltage regulator. C) Connect wire to (Green / C Pin) on voltage regulator. D) Wire is not needed. Insulate wire or remove to prevent shorting. E) Connect wire to battery isolator start battery post. regulator. F) Connect wire to (Black / B Pin) on voltage regulator. Note: Regulator pin identifications can be found on page one Fig 3 of this document.7) Connect batteries and test for proper operation.

1 2

3

F

+

-

BL

G

R

B

1 2 3 + - F+-

F+

F-

F-+


6014R (12V)6026R (24V) Relay

123

Batt 1 (+)House

Ign.

Fig 4

+ - F 3 2 1

ALT

BatteryIsolatorA

1

2Batt 2 (+)Start

+3

+-

F+

F-

Batt 1 (+)House

Ign.

Fig 5

+

- F3

2 1

ALT

BatteryIsolatorA

1

2Batt 2 (+)Start

8RD2041S (12V)8RD3043S (24V)

BLGB

R

14 AWG.Min.

X

X

Short jumperwire.

Blocking Diode


Page 3




Date: JULY 7, 2017


AC

F+F-

ACAC

F-+


6014R (12V)6026R (24V) Relay

123

B+

Ign.

Fig 6

+ - F 3 2 1

ALT

ACACAC

+

-

1111CA1112CARecti�er

Fig 7

AC

F+F-

ACAC

8RD2041S (12V)8RD3043S (24V)

B+

Ign.

+ - F 32 1R B G BL

ALT

ACACAC

+

-


Remote regulated and rectified systems procedure. 1) Disconnect vehicle batteries.


3) Remove , , wires from relay and , , wires from regulator terminals. Remove both regulator and relay from vehicle. Fig 6

Note: Relay will not be needed when using the replace-ment regulator.

4) Install new 8RG style regulator.


A) Splice wires and together and apply shrink tubing to prevent shorting. B) Connect wire to (Blue / A Pin) on voltage regulator. C) Connect wire to (Green / C Pin) on voltage regulator. D) Connect wire to (Red / D Pin) on voltage regulator. E) Connect wire to (Black / B Pin) on voltage regulator.

Note: Regulator pin identifications can be found on page one Fig 3 of this document.

6) Connect batteries and test for proper operation.

1 2

3

F

+

-

BL

G

R

B

1 2 3 + - F


Page 4




Date: JULY 7, 2017


Fig 9

AC

F+F-

ACAC

8RD2041S (12V)8RD3043S (24V)

Ign.

+ - F 32 1B G BL

ALT

ACACAC

+

-


BatteryIsolatorA

1

2Batt 1 (+)Start

Batt 2 (+)House

R

X

Fig 8

AC

F+F-

ACAC

F-+


6014R (12V)6026R (24V) Relay

123

Ign.

+ - F 3 2 1

ALT

ACACAC

+

-


BatteryIsolatorA

1

2Batt 1 (+)Start

Batt 2 (+)House

Remote regulated and rectified systems with battery isolator procedure:. 1) Disconnect vehicle batteries.


3) Remove , , wires from relay and , , wires from regulator terminals. Remove blocking diode from regulator terminal and relay terminal. Fig 8 Remove regulator, relay and blocking diode from vehicle.

Note: Relay and blocking diode will not be needed when using the replacement regulator.

4) Move wire originally connecting alternator F+ and rectifier + terminals to the battery isolator start battery post. Fig 9



A) Splice wires and together and apply shrink tubing to prevent shorting. B) Connect wire to (Blue / A Pin) on voltage regulator. C) Connect wire to (Green / C Pin) on voltage regulator. D) Wire is not needed. Insulate or remove wire to prevent shorting. E) Connect wire to battery isolator start battery post. regulator. F) Connect wire to (Black / B Pin) on voltage regulator. Note: Regulator pin identifications can be found on page one Fig 3 of this document.7) Connect batteries and test for proper operation.

1 2

3

F

+

-

BL

G

R

B

1 2 3 + - F

+3

XBlockingDiode

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Technical Service Bulletin - Prestolite · PDF fileRemove blocking diode from regulator ... rectifier + terminals to the battery isolator start battery post. Fig 9 5) Install new 8RD