Caterpillar cat d8 k track type tractor dozer bulldozer (prefix 76v) service repair manual (76v00505 and up)

Service Repair Manual
Models
D8K TRACK-TYPE TRACTOR

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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
1/14D8K TRACTOR / DIRECT DRIVE / 76V00505-UP (MACHINE) POWERED BY 34...
2019/12/30https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

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.

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.
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) .

8. Disconnect the two leads for the "D+" terminal (7). Disconnect the one lead for the "DF"
terminal (6) .
9. Mark the following components with a marker for proper alignment during assembly:front
frame, stator, end frame and drive end housing face
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) .

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.

12. Use the press to remove the rotor assembly from the drive end housing face.
13. Remove the spacer ring (13) .
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.

15. Use tooling (C) to remove the bearing race.
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.

16. Remove the epoxy (16) from the deep groove in the drive end housing face.
17. Remove the six screws (18) on the front side of the drive end housing face.
18. Remove the lead for the field winding (15) and the field winding (17) .

19. Remove the intermediate ring (19) .
20. Remove the bearing (20) from the seat in the drive end housing face.
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.

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.
10/14D8K TRACTOR / DIRECT DRIVE / 76V00505-UP (MACHINE) POWERED BY ...

23. Unsolder the soldering sleeve from the "R" terminal.
24. Remove the two screws (25) .
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.

27. Remove the three screws (26) .
28. Remove the ring (27) from the rear frame.

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) .

30. Remove bearing outer race (30) with tooling (B) .
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Mon Dec 30 17:23:33 UTC+0800 2019

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

1. Install the roller bearing (1) with tooling (B) .
Note: If necessary, apply grease to the bearing.
2. Install the ring (2) in the rear frame.

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3. Install the insulators for terminal "B+" and terminal "D+".
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.

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.
9. Solder the leads for the stator winding (8) to the terminals for the rectifier (6) .

10. Install the bearing (9) in the rear frame.
Note: The bearing is a loose fit.
11. Install the intermediate ring (10) .

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.
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.

Caterpillar cat d8 k track type tractor dozer bulldozer (prefix 76v) service repair manual (76v00505 and up)

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Caterpillar cat d8 k track type tractor dozer bulldozer (prefix 76v) service repair manual (76v00505 and up)