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Product: TRUCK ENGINE
Model: 3208 TRUCK ENGINE 02Z
Configuration: 3208 TRUCK ENGINE 02Z00001-40744
Disassembly and Assembly
26SI Series Alternator
Alternator - Assemble
SMCS - 1405-016
Assembly Procedure
Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.
Note: Do not strike the diodes. The shock of such an impact can damage the diodes. Use proper tools in order to press the diodes in the mountings.
Illustration 1
1. Install 3 diodes (11) in heat sink (12) .
g00628072
Illustration 2
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Note: Do not strike the bushing. Shocks from striking the housing can cause damage.
2. Press bushing (43) in housing (14) .
3. Install 3 diodes (13) in housing (14) .
Illustration 3
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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
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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
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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 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).
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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) .
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.
1993 - 2024 Caterpillar Inc.
Rights Reserved.
Network For SIS Licensees. Tue Jun 4 22:23:42 UTC+0530 2024
Product: TRUCK ENGINE
Model: 3208 TRUCK ENGINE 02Z
Configuration: 3208 TRUCK ENGINE 02Z00001-40744
Disassembly and Assembly
26SI Series Alternator
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.
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) .
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) .
Illustration 6
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9. Remove mounting plate (10). The mounting plate may be stuck to the regulator.
Illustration 7
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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
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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
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Note: Many of the alternator's internal components are covered with dielectric grease. If the grease is removed, reapply the grease.
Illustration 12
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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
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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
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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
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21. Position a small screwdriver in slot (35). Pry cap (36) from housing (14) .
Illustration 17
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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) .
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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) .
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Copyright 1993 - 2024 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.
Tue Jun 4 22:23:19 UTC+0530 2024
Product: TRUCK ENGINE
Model: 3208 TRUCK ENGINE 02Z
Configuration: 3208 TRUCK ENGINE 02Z00001-40744
Disassembly and Assembly
3208 DIESEL TRUCK ENGINE
Media
Air Inlet Manifold (Later)
SMCS - 1058-11; 1058-12
Remove Air Inlet Manifold
start by:
a) remove turbocharger
-26/07/1991
1. Loosen clamps (1) and (2). Disconnect the hoses (3) from the manifold.
2. Remove seven bolts (6). Loosen one bolt (manifold has an opening [slot] in it for this bolt).
3. Disconnect fuel line (5).
4. Remove air inlet manifold (4) and its gaskets.
Install Air Inlet Manifold
1. Put the air inlet manifold (1) in position on cylinder block and install the seven bolts that hold the manifold in place. Tighten the one bolt (one in manifold slot).
2. Connect the fuel line (3) to the manifold.
3. Connect hoses (4) to the manifold and tighten clamps (2). end by:
a) install turbocharger Copyright 1993 - 2024 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.
Tue Jun 4 22:27:20 UTC+0530 2024
Product: TRUCK ENGINE
Model: 3208 TRUCK ENGINE 02Z
Configuration: 3208 TRUCK ENGINE 02Z00001-40744
Disassembly and Assembly
3208 DIESEL TRUCK ENGINE
Media
Air Inlet Manifold
SMCS - 1058-12; 1058-11
Remove Air Inlet Manifold
1. Loosen clamps (1) and (3). Disconnect the hoses.
2. Remove bolts (2) and elbow (4).
-26/07/1991
3. Loosen clamps (8) and then slide the hose on to the turbocharger.
4. Disconnect hose (9) from the manifold.
5. Remove fuel line (7) from the fuel ratio control.
6. Remove bolts (5). Loosen bolt (10).
NOTE: Manifold (6) has an opening (slot) in it for bolt (10).
7. Remove manifold (6) and its gaskets.
Install Air Inlet Manifold
1. Put gaskets (3) and manifold (1) in position and install the bolts that hold it.
2. Put hose (2) in position and tighten the clamps.
3. Install fuel line (4) on the fuel ratio control. Connect hose (5) to the manifold.
4. Put elbow (6) in position on the manifold and install the bolts that hold it.
5. Connect crankcase ventilator hoses (8) to the elbow and tighten the hose clamps.
6. Connect hose (7) to the manifold and tighten the hose clamp.
Tue Jun 4 22:26:58 UTC+0530 2024
This is the sample of the manual click on the download link for complete manual
DOWNLOAD LINK
For some reason if link does not work download this pdf and then click