N3 Series Brushless Alternators Caterpillar

Disassembly Procedure

Start By:

1. 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.

The following disassembly procedure shows the disassembly of the N3 series alternator (35 amperes).

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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.

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Illustration 1	g00870070

3. Remove the two screws (1). Then remove the regulator cover.

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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.

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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) .

8. Disconnect the two leads for the "D+" terminal (7). Disconnect the one lead for the "DF" terminal (6) .

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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

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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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Illustration 6	g00870533

11. Position the following items in the press: drive end housing face, rotor assembly and the tooling (12) .

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NOTICE
In the next step, the bearing may be damaged.

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Illustration 7	g00870539

12. Use the press to remove the rotor assembly from the drive end housing face.

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Illustration 8	g00870541

13. Remove the spacer ring (13) .

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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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Illustration 10	g00870562

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

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Illustration 11	g00870563

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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.

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Illustration 12	g00870583

17. Remove the six screws (18) on the front side of the drive end housing face.

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Illustration 13	g00870563

18. Remove the lead for the field winding (15) and the field winding (17) .

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Illustration 14	g00870589

19. Remove the intermediate ring (19) .

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

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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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Illustration 16	g00870596

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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

23. Unsolder the soldering sleeve from the "R" terminal.

24. Remove the two screws (25) .

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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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Illustration 19	g00870601

27. Remove the three screws (26) .

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Illustration 20	g00870602

28. Remove the ring (27) from the rear frame.

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Illustration 21	g00870603

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Illustration 22	g00870604

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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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Illustration 23	g00870605

30. Remove bearing outer race (30) with tooling (B) .