DOWNLOAD LINK
For some reason if link does not work download this pdf and then click
Illustration 4
g00628063
7. Press housing (31) on rotor (39) and bearing (40) .
8. Install 4 screws (38) in housing (31) .
Illustration 5
g00628057
Note: Do not strike the bearing. Shocks from striking the housing can cause damage.
9. Install the inner race. Press bearing (37) into the housing.
Illustration 6
10. Press cap (36) in housing (14) .
g00628043
Illustration 7
g00628041
11. Install the coil and support (34) in housing (14). Guide the field leads and the grommet through the hole as the coil is installed in housing (14). Install 3 screws (33) .
Illustration 8
g00628037
12. Press the stator (32) and housing (14) together. Guide the stator leads and the grommet through the hole as the stator is installed in housing (14) .
Illustration 9
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.
13. Join housing (31) and housing (14). Install 4 bolts (30) .
Illustration 10
g00627853
Note: Many of the alternator's internal components are covered with dielectric grease. If the grease is removed, reapply the grease.
11
14. Install Insulator (29). Install the heat sink and diode assembly (12) in housing (14) .
12
15. Install separator (28) .
16. Install alternator output terminal (27). Install insulator (26). Install the nut and washer (25) .
17. Install diode trio (24) and install screw (23) .
Illustration
g00627855
Illustration
g00627840
Illustration 13
g00627832
18. Install the 3 screws and insulators (18). Connect wire (19) .
19. If the "R" terminal is used, install the following components: nut (20), lead (21), the washer and terminal (21) .
Illustration 14
g00627820
20. Install the screw and insulator (16). Connect capacitor lead (17) .
Illustration 15
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.
21. Connect 6 diode leads. Connect 3 phase leads. Connect 3 stator phase leads. Install 3 nuts (15).
Table 1
Alternator Ground
Negative
Current Flow of the Output Diodes
Lead to the Heat Sink
Current Flow of the Ground Diodes
Housing to the Lead Red Wire Black Wire
Illustration 16
22. Install mounting plate (10).
g00627808
Illustration 17
23. Install regulator (9) .
24. Install grounded mounting screw (8) .
g00627804
18
25. Install 2 insulated screws (6). Connect the 3 leads.
Note: The regulator and the mounting plate are coated with dielectric grease. If the grease is removed, reapply the grease.
26. Install nut (7) and connect the wire.
19
27. Install gasket (5) .
Illustration
g00627796
Illustration
g00627794
20
28. Position cover (4). Install 7 screws (3) .
21
29. Position plate (2). Install 4 screws (1) .
30. Install the fan, the pulley, the washer, and the pulley nut.
Illustration
g00627792
Illustration
g00627790
Product: EXCAVATOR
Model: 235D EXCAVATOR 8KJ
Configuration: 235D EXCAVATOR 8KJ00001-UP (MACHINE) POWERED BY 3306 ENGINE
Disassembly and Assembly
26SI Series Alternator Media
Alternator - Disassemble
SMCS - 1405-015
Disassembly Procedure
Table 1
Required Tools
Start By:
A. 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.
1. Remove the pulley nut, the washer, the pulley, and the fan.
i01167081
Illustration 1
2. Remove 4 screws (1). Remove plate (2) .
Illustration 2
3. Remove 7 screws (3). Remove cover (4) .
Illustration 3
4. Remove gasket (5) .
g00627790
g00627792
g00627794
Illustration 4
5. 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.
6. Remove nut (7) .
Illustration 5
7. Remove grounded mounting screw (8) .
8. Remove regulator (9) .
g00627796
g00627804
Illustration 6
g00627808
9. 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.
10. 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
11. Remove the screw and insulator (16). Disconnect capacitor lead (17) .
Illustration 9
g00627832
12. Remove the 3 screws and insulators (18). Disconnect wire (19) .
13. If the "R" terminal is used, remove the following components: nut (20), lead (21), the washer and terminal (21) .
Illustration 10
14. Remove screw (23) and remove diode trio (24) .
15. Remove the nut and washer (25). Remove insulator (26). Remove alternator output terminal (27) .
16. 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
17. 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.
18. Remove 4 bolts (30). Carefully separate housing (31) from housing (14) .
Illustration 14
g00628037
19. 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
20. 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
21. Position a small screwdriver in slot (35). Pry cap (36) from housing (14) .
Illustration 17
g00628057
Note: Do not strike the bearing. Shocks from striking the housing can cause damage.
22. Wipe the excess grease from the bearing well. Press bearing (37) into the housing. Remove the inner race.
Illustration 18
23. Remove 4 screws (38) from housing (31) .
g00628063
24. Lift rotor (39) and bearing (40) from housing (31) .
Illustration 19
25. Pull bearing (40) from rotor (39) .
26. Pull retainer (41) from rotor (39) .
27. Pull collar (42) from rotor (39) .
g00628067
Illustration 20
g00628068
Note: Do not strike the bushing. Shocks from striking the housing can cause damage.
28. Press bushing (43) from housing (14) .
Note: Do not strike the diodes. The shock of such an impact can damage the diodes. Use proper tools in order to press or pull the diodes from the mountings. As much as 890 N (200 lb) of force may be needed to remove a diode.
29. Remove 3 diodes (13) from housing (14) .
Illustration 21
30. Remove diode (11) from heat sink (12) .
g00628072
Copyright 1993 - 2024 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Sat Jul 20 01:52:08 UTC+0530 2024
Product: EXCAVATOR
Model: 235D EXCAVATOR 8KJ
Configuration: 235D EXCAVATOR 8KJ00001-UP (MACHINE) POWERED BY 3306 ENGINE
Disassembly and Assembly N3 Series Brushless Alternators
Media Number -SENR2082-01
i01688996
Alternator - Assemble
SMCS - 1405-016
Assembly Procedure Table 1
Tooling that is needed A B
Soldering iron (180 watt)
Vise or clamping support with vee blocks
Press
Illustration 1
1. Install the roller bearing (1) with tooling (B) .
Note: If necessary, apply grease to the bearing.
Illustration 2
2. Install the ring (2) in the rear frame.
g00871460
g00871248
Illustration 3 g00871252
3. Install the insulators for terminal "B+" and terminal "D+".
Illustration 4
4. Install the "R" terminal, if the "R" terminal was replaced.
5. Install the rectifier (3) in the rear frame.
6. Install the two screws. Solder the sleeve (4) over terminal "R".
7. Install the following components on terminals: "D+", "B+" and B-: terminal insulators, washers and nuts.
g00871347
Illustration 5
g00871376
8. Position the stator frame (7) on the rear frame (5). Use the marks on the alternator that were made in the disassembly procedure for alignment.
Illustration 6
g00871382
9. Solder the leads for the stator winding (8) to the terminals for the rectifier (6) .
7
10. Install the bearing (9) in the rear frame.
Note: The bearing is a loose fit.
Illustration 8
11. Install the intermediate ring (10) .
Illustration
g00871385
g00871389
