Service Repair Manual Alternator Disassembly

Service Repair Manual
Models
D4E TRACK TRACTOR

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Product: TRACK-TYPE TRACTOR
Model: D4E TRACK-TYPE TRACTOR 77W
Configuration: D4E TRACTOR / POWER SHIFT / 77W01664-UP (MACHINE) POWERED BY 3304 ENGINE
Disassembly and Assembly
Alternator - Bosch K1/N1
Media Number -SENR3685-02 Publication Date -01/09/2013 Date Updated -16/09/2013
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 is being serviced.
Note: The Disassembly and Assembly that follows is of a K1, 12V 7T-2876 Charging Alternator Gp.
The other alternators are similar.
Illustration 1 g03228038
(1) Regulator
(2) Capacitor lead
(3) Capacitor
1. Remove the two screws and regulator (1) .
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2. Disconnect capacitor lead (2) from the back of the alternator. Remove the screw and capacitor
(3) .
(4) Pulley
(5) Fan
3. Remove the pulley nut, washer, pulley (4), fan (5), and the key from the rotor shaft.
(6) Screws
4. Mark the front and rear frame assemblies for proper assembly. Remove four screws (6) (one
has a 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.
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(7) Screws
(8) Rotor
6. Remove four screws (7), and rotor (8) from the front frame.
(9) Bearing cover
(10) Spacer
(11) Front bearing
7. Remove spacer (10), and front bearing (11), with a suitable puller. Remove bearing cover (9)
from the rotor (8) .
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(12) Rear bearing
(13) Slip ring
8. Remove the rear bearing (12) with a suitable puller. Unsolder both rotor winding leads from
slip ring (13). Remove slip ring (13) with a suitable puller.
(14) terminal nuts
(15) terminal nuts
(16) terminal nuts
9. Remove terminal nuts (14), (15), and (16). Remove all of the washers and insulators.
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(17) Screws
10. Remove three screws (17). Remove the stator and rectifier assembly from the rear frame.
Remove the remaining insulators from the terminal studs.
(18) Rectifier
(19) Stator
11. Unsolder the three stator leads and separate rectifier (18) from stator (19) .
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K1 Alternator
(1) Regulator
(4) Pulley
(5) Fan
(6) Screws
(8) Rotor
(9) Bearing cover
(11) Front bearing
(12) Rear bearing
(13) Slip ring
(18) Rectifier
(19) Stator
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Alternator - Bosch K1/N1
i05064230
Alternator - Assemble
SMCS - 1405-016
Assembly Procedure
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 problems in the future. Inspect all parts. If
any parts are worn or damaged, use new parts for replacement.
(1) Rectifier
(2) Stator
1. Connect and solder the stator leads to the positive (+) diodes of rectifier (1) .
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(1) Rectifier
(2) Stator
(3) Position wave 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.
(4) Rear bearing
(5) Slip ring
3. Install slip ring (5) on the rotor. Connect and solder the rotor leads to the slip ring (5). Install
rear bearing (4) .
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(6) Bearing cover
(7) Spacer
(8) Front bearing
4. Install bearing cover (6), front bearing (8), and spacer (7) on the rotor.
(9) Rotor
5. Install rotor (9) and the four screws into the front frame.
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(10) Stator assembly
(11) Rotor assembly
6. Assemble front frame and rotor assembly (11) into rear frame and stator assembly (10).
Make sure that the wave washer is fixed in the rear frame bearing bore. Align the front and
rear frame marks made at disassembly for correct assembly. Install the four screws.
(12) Pulley
(13) Fan
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)
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(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 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Thu Sep 5 17:35:40 UTC+0800 2019
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3304B and 3306B Engines for Caterpillar Built Machines
i00984196
Fuel Priming Pump - Remove and Install
SMCS - 1258-010
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the machine. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop
Products Guide", for tools and supplies suitable to collect and contain
fluids in Caterpillar machines.
Dispose of all fluids according to local regulations and mandates.
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1. Turn the fuel supply line valve to the OFF position.
2. Remove the bolts and the washers that secure fuel priming pump (1) to base (5). Remove
gasket (4) .
3. Disconnect tube assembly (3) .
4. Remove two bolts (2), the washers and base (5) from the cylinder block.
Installation Procedure
NOTICE
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1. Install base (5), the washers and two bolts (2) .
2. Connect tube assembly (3) to base (5) .
Note: Check the condition of the gaskets. If the gaskets are worn or damaged, use new parts
for replacement.
3. Install gasket (4). Install fuel priming pump (1) and the bolts that secure the fuel priming
pump to base (5) .
4. Turn the fuel supply line valve to the ON position.
Thu Sep 5 15:59:09 UTC+0800 2019
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i00917143
Fuel Filter Base - Remove and Install
SMCS - 1262-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 2P-8250 Strap Wrench Assembly 1
NOTICE
NOTICE
containing fluids.
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1. Use Tool (A) to remove fuel filter (4) .
2. Disconnect fuel line (1) from fuel filter base (2) .
3. Remove two bolts (3), the washers, fuel filter base (2) and the gasket from the fuel injection
pump housing.
Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A 2P-8250 Strap Wrench Assembly 1
NOTICE
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Note: Check the condition of the gaskets. If the gaskets are worn or damaged, use new parts
for replacement.
1. Install the gasket, fuel filter base (2), the washers and two bolts (3) on the fuel injection
pump housing.
2. Connect fuel line (1) to fuel filter base (2) .
3. Use Tool (A) to install fuel filter (4) .
Thu Sep 5 15:59:57 UTC+0800 2019
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i00905874
Fuel Transfer Pump - Remove
SMCS - 1256-011
Removal Procedure
NOTICE
NOTICE
containing fluids.
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1. Turn the fuel supply line valve to the OFF position.
2. Remove tube assembly (2) and tube assembly (4) from fuel transfer pump (3) .
3. Remove bolts (1) and (5) from fuel transfer pump (3). Remove fuel transfer pump (3) and
the O-ring seal.
Thu Sep 5 16:00:44 UTC+0800 2019
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i01003268
Fuel Transfer Pump - Disassemble
SMCS - 1256-015
Disassembly Procedure
Start By:
A. Remove the fuel transfer pump. Refer to Disassembly and Assembly, "Fuel Transfer Pump -
Remove".
NOTICE
NOTICE
containing fluids.
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Personal injury can result from parts and/or covers under spring
pressure.
Spring force will be released when covers are removed.
Be prepared to hold spring loaded covers as the bolts are loosened.
1. Remove bolts (2) and cover (1) from the fuel transfer pump housing.
2. Remove spring (4) from housing (3) .
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3. Remove O-ring seals (5) and (6) from cover (1) .
4. Remove valve assembly (7) from cover (1) .
5. Remove piston (12) from sleeve (10). Remove washer (15), valve assembly (14) and seal
(13) from piston (12) .
6. Remove sleeve (10) from housing (3). Remove O-ring seal (11) from sleeve (10) .
7. Remove guide and tappet assembly (9) and seal (8) from housing (3) .
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8. Remove two bolts (16), cover (17) and the seal from housing (3) .
9. Remove valve assembly (18) from housing (3) .
Thu Sep 5 16:01:32 UTC+0800 2019
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i01003269
Fuel Transfer Pump - Assemble
SMCS - 1256-016
Assembly Procedure
NOTICE
containing fluids.
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Suggest:
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1. Install valve assembly (18) in housing (3) .
2. Put clean diesel fuel on seal (16). Install seal (16) on cover (17), as shown. Install the two
bolts that hold cover (17) to housing (3) .
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