D400E ARTICULATED TRUCK
Product: ARTICULATED TRUCK
Model: D400E ARTICULATED TRUCK 2YR
Configuration: D400E Articulated Truck 2YR00001-UP (MACHINE) POWERED BY 3406 Engine
Disassembly and Assembly
26SI Series Alternator
Media Number -RENR1252-01
Alternator - Assemble
SMCS - 1405-016
Assembly Procedure
-01/10/1999
-09/10/2001
i01167078
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) .
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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
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7. Press housing (31) on rotor (39) and bearing (40) .
8. Install 4 screws (38) in housing (31) .
Illustration 5
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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) .
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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
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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
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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.
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
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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
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20. Install the screw and insulator (16). Connect capacitor lead (17) .
Illustration 15
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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.
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) .
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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.
Product: ARTICULATED TRUCK
Model: D400E ARTICULATED TRUCK 2YR
Configuration: D400E Articulated Truck 2YR00001-UP (MACHINE) POWERED BY 3406 Engine
Disassembly and Assembly
26SI Series Alternator
Media Number -RENR1252-01
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
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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
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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) .
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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
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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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Product: ARTICULATED TRUCK
Model: D400E ARTICULATED TRUCK 2YR
Configuration: D400E Articulated Truck 2YR00001-UP (MACHINE) POWERED BY 3406 Engine
Disassembly and Assembly
3406C ENGINE FOR CATERPILLAR BUILT MACHINES
Media Number -SENR1029-01
Publication Date -01/06/2001 Date Updated -25/01/2016
Automatic Timing Advance
SMCS - 1405-016
Remove Automatic Timing Advance 1272-011
1. Remove nuts (1), cover (2), and the gasket.
SENR10290007
2. Remove four bolts (3) and automatic timing advance (4). Remove O-ring seals from the automatic timing advance.
3. Remove gear (6) from fuel injection pump camshaft (5).
Install Automatic Timing Advance 1272-012
1. Remove the plug from the timing pin hole in the fuel injection pump housing, and install Tool (A) in the timing pin hole.
2. Install two 7/16" -20 NF x 4" long bolts in fuel injection pump camshaft (1). Slowly rotate the fuel injection pump until Tool (A) goes into the groove in the fuel injection pump camshaft. Remove the bolts from the camshaft.
3. Put No. 1 piston at the top center compression position (TC) with the following procedure:
a. Remove plug (3), timing bolt (4) and cover (2) from the flywheel housing.
b. Install Tool (B) in the flywheel housing. Use Tool (B) to slowly rotate the engine in the direction of normal rotation (counterclockwise as seen from the flywheel end of the engine) until timing bolt (4) can be installed in the flywheel housing and into the hole in the flywheel.
c. Remove the valve cover from the valve cover base. Check to see if both rocker arms (5) for the No. 1 cylinder can be moved backward and forward.
NOTE: The No. 1 piston is at the top center compression position (TC) when the timing bolt is installed in the flywheel and both rocker arms for the No. 1 cylinder can be moved backward and forward. If both rocker arms cannot be moved, the No. 1 piston is not at the top center compression position (TC). Remove the timing bolt from the flywheel and rotate the engine in the direction of normal rotation (counterclockwise as seen from the flywheel end of the engine) one full turn 360 degrees, and install the timing bolt again.
4. Remove the timing bolt, and use Tool (B) to rotate the engine in the opposite direction of normal rotation (clockwise as seen from the flywheel end of the engine) a minimum of 30 degrees.
5. Put gear (6) in position on the fuel injection pump camshaft.
6. Put two O-ring seals (8) in position on automatic timing advance (7).
7. Put automatic timing advance in position on the fuel injection pump camshaft, and install the four bolts. Tighten the bolts to a torque of 3 N·m (27 lb in).
8. Use Tool (B) and slowly rotate the engine in the direction of normal rotation until the timing bolt can be installed in the flywheel.
9. Tighten the bolts that hold the automatic timing advance to the fuel injection pump camshaft to a torque of 55 ± 7 N·m (41 ± 5 lb ft).
10. Remove Tool (A) from the fuel injection pump housing, and remove the timing bolt from the flywheel.
11. Check the timing as follows:
a. Rotate the engine in the direction of normal rotation (counterclockwise as seen from the flywheel end of the engine) two full turns, and install Tool (A) and the timing pin again.
b. The timing is correct if Tool (A), and the timing bolt can be installed at the same time. The timing procedure must be done again if the timing bolt and Tool (A) can not be installed at the same time.
c. Remove tool (A), and install the plug in the fuel injection pump housing. Remove the timing bolt and Tool (B), and install the plug and cover on the flywheel housing.
12. Put the gasket and cover (9) in position on the timing gear cover, and install the nuts.
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