Caterpillar Cat D8K TRACK-TYPE TRACTOR Dozer Bulldozer (Prefix 76V) Service Repair Manual Instant Download (76V00505) 2

1
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 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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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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• Illustration 2 g00870086
• Remove the nut from the "D" terminal (2) .
• Disconnect the lead for the suppression capacitor
  (3) .
• 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) .
6
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 assemblyfront 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) .
7
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.
8
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.
9
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.
10
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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Illustration 14
g00870589

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

• Illustration 15 g00870592
• Disconnect the three leads for the stator
  windings (24) from the three rectifier bridge
  terminals (21).
• Remove the stator frame (23) from the rear frame
  assembly.

12
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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• Illustration 17 g00870559
• Unsolder the soldering sleeve from the "R"
  terminal.
• Remove the two screws (25) .

• Illustration 18 g00870600
• Remove the following retaining nuts for the
  rectifier terminal on the outside of the rear
  frame assembly (B), (D) and (B-) .
• Remove the following components rectifier,
  washers for the rectifier terminal and insulators.

14
Illustration 19
g00870601
27. Remove the three screws (26) .
Illustration 20 g00870602 28. Remove the ring
(27) from the rear frame.
15
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) .
16
Illustration 23 g00870605 30. Remove bearing
outer race (30) with tooling (B) .
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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
i01688996
Alternator - Assemble SMCS - 1405-016 Assembly
Procedure Table 1
Tooling that is needed 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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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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Illustration 3 g00871252 3. Install the
insulators for terminal "B" and terminal "D".
Illustration 4
g00871347

1. Install the "R" terminal, if the "R" terminal was
   replaced.
2. Install the rectifier (3) in the rear frame.
3. Install the two screws. Solder the sleeve (4)
   over terminal "R".
4. Install the following components on terminals
   "D", "B" and B- terminal insulators, washers
   and nuts.

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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) .
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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• Illustration 9 g00871402
• 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.
• 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.
24
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the link into your browser. The full manual is
available for immediate download. https//www.ebo
oklibonline.com