CAT + Caterpillar 307 Excavator Service Repair Manual

307 EXCAVATOR

Product: EXCAVATOR

Model: 307 EXCAVATOR 2WM

Configuration: 307 Excavator 2WM00500-UP (MACHINE) POWERED BY 3054 Engine

Disassembly and Assembly

JF Series Starting Motor

Media Number -SENR3550-01 Publication Date -01/09/2000

General Information

SMCS - 1453

Updated -09/10/2001

The following diagrams are intended to aid in the disassembly and assembly of the starting motor.

Illustration 1

Starting motor

(15) C washer

(16) Shims

(18) Brushholderassembly

(19) Armature assembly

(20) Field winding assembly

(21) Screws

Illustration 2

Starting motor

(1) Armature assembly

(2) Pinion drive assembly

(3) Solenoid assembly

(4) Shift leverassembly

(5) Brush holder

(6) Brush springs

(7) Brushes

(8) Excitation winding Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Sun Sep 27 13:50:21 UTC+0530 2020

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Product: EXCAVATOR

Model: 307 EXCAVATOR 2WM

Configuration: 307 Excavator 2WM00500-UP (MACHINE) POWERED BY 3054 Engine

Disassembly and Assembly

Starting Motor - Assemble

SMCS - 1453-016

Assembly Procedure

Illustration 1

g00718908

1. Position the field winding assembly (20) within the starter motor housing. Put Thread Lock Compound in the threads of the screws(21). Install the screws and tighten the screws to a torque of 36 to 53 N·m (27 to 39 lb ft).

2. Solder the two negative brush leadsto the brush holder assembly (18) if the brush leads were removed. Put the brush holder assembly (18) in position on the starting motor housing. Install the two positive brushes to the field winding leads. Solder the two positive brushes to the field winding leads.

Illustration 2 g00718909

3. Put the armature assembly (19) in position in the starting motor housing. Use the cotter pins (22) to hold the brushes against the brush springs until the commutator is under the brushes.

Illustration 3 g00719542

4. Install the bushing (17) into the end cover with the driver group.

Illustration 4

5. Put the end cover assembly (14) in position on the starting motor housing.

6. Install the shims (16). Install the C washer (15) .

7. Put Molybdenum Grease on the ends of the armature. Put Molybdenum Grease in the center cover. Install the seal and install the center cover. Put Thread Lock Compound on the threadsof the two screws. Install the screws. Tighten the screws to a torque of 9 to 11 N·m (80 to 97 lb in).

Illustration 5

8. Install the bushing into the bearing assembly with the driver group, if necessary. Install the seal (13) into the bearing assembly with the driver group.

Illustration 6

g00718911

9. Install the bearing assembly (12) over the armature.

10. Put the pinion drive assembly (10) in position on the armature.

Illustration 7

g00719548

11. Put the seal (11) on the armature shaft. Put the ring in the armature ring slot. Do not scratch the armature shaft. Use multiple position pliersto press the ends of the ring together in the slot. Push a suitable assembly sleeve (23) onto the armature shaft against the ring.

12. Turn the pinion drive assembly (10) and the seal (11) against the ring. Use multiple position pliers (24) to secure the assembly in position. Engage the ring under the seal (11) by hammering against the sleeve (23), asshown. Use a plastic hammer or a rubber hammer.

Illustration 8 g00719540

13. Install the bushing (9) into the drive housing with the driver group, if necessary.

Illustration 9 g00718897

14. Position one of the studs(8) into the starting motor housing. Put the shift lever assembly (7) in position on the pinion drive housing.

15. Put the seal and the other stud into the drive housing assembly (6). Put the drive housing assembly over the pinion drive assembly by aligning the marks. At the same time, feed the shift lever assembly (7) into the drive housing.

16. Install stud (8) into the drive housing. Push everything together with studs through the holes in the end cover assembly.

10

17. Put Thread Lock Compound on the threads of the studs. Install the washersand the nuts (5). Tighten the nuts to a torque of 9.1 to 12.2 N·m (80.5 to 108 lb in).

18. Put Thread Lock Compound on the shift lever screw. Install the screw through the drive housing and through the shift lever. Install the washer and install the nut (4). Tighten the nut to a torque of 3.2 to 4.0 N·m (28 to 35 lb in).

11

19. Compress the spring (25) against the shift lever until the shift lever goes into the slot of the solenoid plunger (3) .

Illustration 12

20. Put solenoid assembly (1) in position over the solenoid plunger. Put Thread Lock Compound on the threads of the three solenoid screws. Install the solenoid screws through the drive housing assembly and into the solenoid assembly (1). Tighten the screws to a torque of 4.6 to 6.0 N·m (41 to 53 lb in) .

21. Connect the field winding strap (2) to the solenoid assembly. Tighten the motor terminal nut to a torque of 28 ± 4 N·m (21 ±3 lb ft) .

22. Check the armature end play.

Product: EXCAVATOR

Model: 307 EXCAVATOR 2WM

Configuration: 307 Excavator 2WM00500-UP (MACHINE) POWERED BY 3054 Engine

Disassembly and Assembly

Starting Motor - Disassemble

SMCS - 1453-015

Disassembly Procedure

Remove the starting motor from the machine. The procedure for removal of the starting motor may vary slightly with a different series of starting motor.

Illustration 1 g00718892

1. Disconnect the field winding strap (2) from the solenoid assembly (1) .

2

2. Disconnect the solenoid plunger and remove the solenoid plunger (3) from the shift lever. To remove the plunger, lift the plunger slightly.

Illustration 3

g00718894

3. Scribe a line on the drive and the starting motor housings for proper alignment at assembly. Remove the end cover nuts (5) and the washers. Remove the shift lever nut (4), the washer, and the screw.

4

4. Separate the two halves of the starting motor. It may be necessary to remove one stud (8) from the drive housing in order to remove the shift lever assembly (7) and drive housing assembly (6). Do not damage the seal.

Illustration 5 g00719540

5. If necessary, remove the bushing (9) from the drive housing.

Illustration 6

g00718898

6. Remove the seal (11) from the ring with a suitable sleeve. Remove the ring, the seal (11), and the pinion drive assembly (10) from the armature.

7. Remove the bearing assembly (12) .

Illustration 7

g00718899

8. Remove the seal (13) and remove the bushing from the bearing assembly, if necessary.

Illustration 8 g00718901

9. Remove the two screws and the center cover from the end cover assembly. Remove the seal.

10. Remove the C washer (15) from the end of the armature. Remove the shims(16) from the end of the armature.

11. Remove the end cover assembly (14) .

Illustration 9 g00719542

12. Remove the bushing (17) from the end cover, if necessary.

Illustration 10

13. Remove the armature assembly (19) from the starting motor housing and the brush holder assembly (18) .

Illustration 11

g00718908

14. Unsolder the field winding leads from the positive brush leads. Remove the brush holder assembly (18). Unsolder the negative brushesfrom the brush holder, if necessary.

15. Remove the screws (21) from the starting motor housing. Remove the field winding assembly (20) from the starting motor housing. Use an impact driver to remove the screws (21), if necessary.

NOTICE

Do not use a liquid cleaning agent to cleanthe armature assembly, field winding (coil) assembly, or pinion drive assembly. Liquids can damage these parts. Use only compressedair to clean them.

Personal injury can result from air pressure.

Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.

Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.

16. Clean the following items with compressed air:

armature assembly

field winding assembly

pinion drive assembly housings

solenoid assembly

To prevent personal injury or death from a possible explosion, make sure that all parts are thoroughly dry inorder to eliminate formation of gas withinthe starter.

17. Wash parts such as screws, hardware, and the shaft of the armature with a commercially available cleaning agent. Dry all parts thoroughly.

18. Inspect all partsfor wear and for damage.

Product: EXCAVATOR

Model: 307 EXCAVATOR 2WM

Configuration: 307 Excavator 2WM00500-UP (MACHINE) POWERED BY 3054 Engine

Disassembly and Assembly

Alternator - Bosch K1/N1

i05064230

Alternator - Assemble

SMCS - 1405-016

Assembly Procedure

Cleanliness is an important factor. Before assembly, all partsshould be thoroughly cleaned in cleaning fluid. Allowthe partsto air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause problems in the future. Inspect all parts. If any partsare worn or damaged, use new parts for replacement.

Illustration 1 g03230839

(1) Rectifier

(2) Stator

1. Connect and solder the stator leads to the positive (+) diodes of rectifier (1) .

Illustration 2

(1) Rectifier

(2) Stator

(3) Positionwave washer

2. Position the insulators on the rectifier terminal studs. Position rectifier (1), and stator (2) into the rear frame, and install the three screws. Install the terminal insulators, washers, and nuts. Position wave washer (3) into the bearing bore of the rear frame.

Illustration 3

(4) Rear bearing

(5) Slip ring

g03230842

3. Install slip ring (5) on the rotor. Connect and solder the rotor leadsto the slip ring (5). Install rear bearing (4) .

Illustration 4

(6) Bearingcover

(7) Spacer

(8) Front bearing

g03230845

4. Install bearing cover (6), front bearing (8), and spacer (7) on the rotor.

Illustration 5 g03230846

(9) Rotor

5. Install rotor (9) and the four screws into the front frame.

Illustration 6

(10) Stator assembly (11) Rotor assembly

g03230848

6. Assemble front frame and rotor assembly (11) into rear frame and stator assembly (10). Make sure that the wave washer isfixed in the rear frame bearing bore. Align the front and rear frame marks made at disassembly for correct assembly. Install the four screws.

Illustration 7

(12) Pulley (13) Fan

g03230896

7. Install the key, fan (13), pulley (12), washer, and pulley nut. Tighten the nut to a torque of: 3E-7295 Charging Alternator Gp, and 9X-0341 Charging Alternator Gp ... 70 ±5 N·m (52 ± 4 lb ft)

8C-5535 Charging Alternator Gp, 7T-2876 Charging Alternator Gp, 2Y-4212 Charging Alternator Gp, and 2Y-8310 Charging Alternator Gp ... 35 ± 10 N·m (26 ±7 lb ft)

9W-3043 Charging Alternator Gp ... 50 ± 5 N·m (37 ±4 lb ft)

Illustration 8 g03230899 (14) Capacitor lead (15) Regulator

8. Install the capacitor and connect capacitor lead (14) to the back of the alternator.

9. Install regulator (15) .

End By: Install the alternator on the machine. Refer to Disassembly and Assembly, "Alternator - Install"for the machine that is being serviced. Copyright 1993 - 2020 Caterpillar Inc.

Network For SIS Licensees. Sun Sep 27 13:55:16 UTC+0530 2020

Product: EXCAVATOR

Model: 307 EXCAVATOR 2WM

Configuration: 307 Excavator 2WM00500-UP (MACHINE) POWERED BY 3054 Engine

Disassembly and Assembly

Alternator - Bosch K1/N1

i05060896

Alternator - Disassemble

SMCS - 1405-015

Disassembly Procedure

Start By:

A. Remove the alternator. Refer to Disassembly and Assembly, "Alternator - Remove" for the machine that isbeing serviced.

Note: The Disassembly and Assembly that follows is of a K1, 12V7T-2876 Charging Alternator Gp. The other alternators are similar.

Illustration 1

(2) Capacitor lead

(3) Capacitor

1. Remove the two screws and regulator (1) .

2. Disconnect capacitor lead (2) from the back of the alternator. Remove the screwand capacitor (3) .

Illustration 2

(4) Pulley (5) Fan

3. Remove the pulley nut, washer, pulley (4), fan (5), and the key from the rotor shaft.

Illustration 3

(6) Screws

4. Mark the front and rear frame assembliesfor proper assembly. Remove four screws (6) (one hasa nut on it on the back of the alternator).

5. Separate the front frame and rotor assembly from the rear frame and stator assembly. Watch for the wave washer, at the back of the rear frame assembly, to fall out.

Illustration 4

g03228058 (7) Screws (8) Rotor

6. Remove four screws (7), and rotor (8) from the front frame.

Illustration 5 g03228059 (9) Bearingcover (10) Spacer

This is the sample of the manual click on the download link for complete manual

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