2. Shutdown SIS
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Product: TRACK-TYPE TRACTOR
Model: D8K TRACK-TYPE TRACTOR 76V
Configuration: D8K TRACTOR / DIRECT DRIVE / 76V00505-UP (MACHINE) POWERED BY 342 ENGINE
Disassembly and Assembly
N3 Series Brushless Alternators
Media Number -SENR2082-01 Publication Date -01/03/2002 Date Updated -12/03/2002
i01688999
Alternator - Disassemble
SMCS - 1405-015
Disassembly Procedure
Start By:
A. Remove the alternator from the machine. Refer to Disassembly and Assembly, "Alternator -
Remove" for the machine that is being serviced.
Note: Before disassembly, clean the exterior of the alternator in order to prevent dirt from entering
the unit.
Table 1
Tooling that is needed A B C
Soldering iron (180 watt)
Vise or clamping support with vee blocks
Press
6V-2166 Puller Group 1
5F-7465 Puller 1
9S-9152 Bearing Pulling Attachment 1
1P-0456 Spacer 1
5B-9603 Bolt (3/8 - 16 NC) 2
5M-2894 Washer (3/8 inch flat) 2
1P-0074 Slide Hammer Puller Group 1
2P-2312 Legs 2
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3. 5/8 - 18 Hardened Flat Washer 1
5/8 - 18 Jam Nut 1
The following disassembly procedure shows the disassembly of the N3 series alternator (35
amperes).
NOTICE
Care must be taken in the following step not to damage the alternator.
Do not overtighten the vise.
1. Position the alternator in a vise or a similar clamping device.
2. Remove the following components: the pulley nut, the pulley and the fan.
Illustration 1 g00870070
3. Remove the two screws (1). Then remove the regulator cover.
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4. Illustration 2 g00870086
4. Remove the nut from the "D+" terminal (2) .
5. Disconnect the lead for the suppression capacitor (3) .
6. Remove the two screws (4) that mount the regulator.
Note: The step may be unnecessary, if the component will not be tested or replaced.
Illustration 3 g00870144
7. Pull the regulator (5) partially away from the frame. This will expose the terminals for the
regulator. The terminals for the regulator are the "D+" (7) and the "DF" terminals (6) .
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5. 8. Disconnect the two leads for the "D+" terminal (7). Disconnect the one lead for the "DF"
terminal (6) .
Illustration 4 g00870150
9. Mark the following components with a marker for proper alignment during assembly:front
frame, stator, end frame and drive end housing face
Illustration 5 g00870170
10. Remove the four hex socket head bolts (8). Separate the drive end housing face (9) and the
rotor as an assembly from the rear housing (10) and the stator frame (11) .
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6. Illustration 6 g00870533
11. Position the following items in the press: drive end housing face, rotor assembly and the
tooling (12) .
NOTICE
In the next step, the bearing may be damaged.
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7. Illustration 7 g00870539
12. Use the press to remove the rotor assembly from the drive end housing face.
Illustration 8 g00870541
13. Remove the spacer ring (13) .
Illustration 9 g00870558
14. Inspect the bearing inner race (14). Replace the bearing inner race (14), if the bearing inner
race is worn, damaged, or the bearing has been replaced.
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8. Illustration 10 g00870562
15. Use tooling (C) to remove the bearing race.
Illustration 11 g00870563
NOTICE
Epoxy putty (16) covers the lead for the field winding (15). Care must
be taken in the next step when removing the epoxy, so that the lead is
not damaged.
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9. 16. Remove the epoxy (16) from the deep groove in the drive end housing face.
Illustration 12 g00870583
17. Remove the six screws (18) on the front side of the drive end housing face.
Illustration 13 g00870563
18. Remove the lead for the field winding (15) and the field winding (17) .
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10. Illustration 14 g00870589
19. Remove the intermediate ring (19) .
20. Remove the bearing (20) from the seat in the drive end housing face.
Illustration 15 g00870592
21. Disconnect the three leads for the stator windings (24) from the three rectifier bridge
terminals (21).
22. Remove the stator frame (23) from the rear frame assembly.
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11. Illustration 16 g00870596
NOTICE
When unsoldering the "R" terminal in the next step, do not grip both
of the outside edges of the sleeve. The sleeve will collapse with too much
pressure. While heating with the soldering iron, grip the edge with long
nose pliers.
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12. Illustration 17 g00870559
23. Unsolder the soldering sleeve from the "R" terminal.
24. Remove the two screws (25) .
Illustration 18 g00870600
25. Remove the following retaining nuts for the rectifier terminal on the outside of the rear
frame assembly: (B+), (D+) and (B-) .
26. Remove the following components: rectifier, washers for the rectifier terminal and
insulators.
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13. Illustration 19 g00870601
27. Remove the three screws (26) .
Illustration 20 g00870602
28. Remove the ring (27) from the rear frame.
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14. Illustration 21 g00870603
Illustration 22 g00870604
NOTICE
Do not remove the bearing in the next step. The bearing will be
destroyed if removed in the next step.
29. Use tooling "A" in order to remove the roller bearings (29) and the retaining cage (28) .
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15. Illustration 23 g00870605
30. Remove bearing outer race (30) with tooling (B) .
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All Rights Reserved.
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16. Shutdown SIS
Previous Screen
Product: TRACK-TYPE TRACTOR
Model: D8K TRACK-TYPE TRACTOR 76V
Configuration: D8K TRACTOR / DIRECT DRIVE / 76V00505-UP (MACHINE) POWERED BY 342 ENGINE
Disassembly and Assembly
N3 Series Brushless Alternators
Media Number -SENR2082-01 Publication Date -01/03/2002 Date Updated -12/03/2002
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
8H-8581 Feeler Gauges 3
1P-0510 Driver Set 1
1P-0466 Plate 1
1P-0529 Handle 1
6L-5897 Bolt 1
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17. Illustration 1 g00871248
1. Install the roller bearing (1) with tooling (B) .
Note: If necessary, apply grease to the bearing.
Illustration 2 g00871460
2. Install the ring (2) in the rear frame.
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19. Illustration 3 g00871252
3. Install the insulators for terminal "B+" and terminal "D+".
Illustration 4 g00871347
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.
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20. 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) .
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21. Illustration 7 g00871385
10. Install the bearing (9) in the rear frame.
Note: The bearing is a loose fit.
Illustration 8 g00871389
11. Install the intermediate ring (10) .
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22. Illustration 9 g00871402
12. Install the field winding (11). The leads for the winding must fit in the deep groove. Install the six
screws on the reverse side of the frame.
13. Apply the epoxy putty 5P-3321 Adhesive over the lead and the groove.
Illustration 10 g00871407
14. Install the spacer ring (12) .
NOTICE
In the next step you must support the spacer ring. The spacer ring is
supported in order to support the bearing inner race.
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