Uninterruptible Power Supply (UPS) 250 Caterpillar

Removal Procedure

Illustration 1	g00730784
(1) Screw (2) Commutation Sensor Assembly (3) O-ring (4) Bolt (5) Commutation Sensor Wheel (6) Spacer (7) Screw (8) Plate for the Commutation Sensor Port (9) Plug and O-ring (10) O-ring (11) Rotor Retainer (12) Polished Rotor Retainer Bolt (13) O-ring (14) Rotor Static discharge Drain (15) Screw

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Illustration 2	g00700951
Serial terminal "J1"

1. Connect a PC to the RS-232/RS-485 port. The port is located on the bottom back corner of the system's I/O board.

2. Click on "Enter Password" menu option in order to view the "Enter User Name / Password" dialog box.

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Illustration 3	g00697157
The "Enter User Name / Password" dialog box

3. Enter a valid "User Name" and then enter a valid "Password".

   After the password has been entered, the menu options will change. The menu bar will contain a "Calibrate" option.

4. Depress the "" keys and hold the "" keys.

   The system will enter the "MANUAL" mode.

5. Depress the "" keys and hold the "" keys. This is done in order to bring the system to zero RPM.

6. The system will prompt you to confirm the option. Depress the "" key.

   Note: This procedure is only available once during a 24 hour period.

   A minimum of 15 minutes is required to secure the rotor.

7. Ensure that the flywheel is at zero rpm.

8. Isolate the system from the load by closing the bypass circuit breakers.

9. Open the circuit breaker for the output of the system.

10. Open the AC circuit breaker for the input of the system.

11. Allow the capacitor banks to bleed down for approximately 5 minutes.

    Note: When the flywheel is spinning, the following components are energized: the bus, the armature leads and the fuses. Accomplish the procedure as quickly as possible. During the procedure, the rotor is spinning on the bottom bearing.

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Illustration 4	g00689031
(17) Vacuum Hose

12. Remove vacuum hose (17) from the system. This relieves the vacuum from the system.

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Illustration 5	g00702253
(11) Rotor Retainer (12) Polished Rotor Retainer Bolt (13) O-ring (14) Rotor Static Discharge Drain (15) Screw (16) Plug and O-ring (17) Lower End Plate (18) Screw

13. Disconnect the yellow connector for the thermistor and the nineteen pin instrument connector.

14. . Remove four screws (15). Remove rotor static discharge drain (14) .

15. Remove polished rotor retainer bolt (12) .

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Illustration 6	g00702346
Points for the Measurements (19) Hole

16. Use three feeler gauges. Measure the gap that is between the bearing cartridge and the end plate. Take measurements at three locations.

    The measurements will be used during the installation of the new bearing. Record the results in the following table.

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    Table 2

    Location	Measurement
    1
    2
    3

17. Remove four plugs (16) from the lower end plate. Remove four O-rings from the four plugs.

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Illustration 7	g00712417
190-8386 Shim

18. Install four 190-8386 Shims. Install one tool in each hole (19). The holes are located in lower end plate (17) .

    Note: Refer to illustration 7 for the correct placement of the 190-8386 Shims .

    The shims prevent the rotor from setting down on the hall effect sensors.

19. Loosen eight screws (18). Use quarter turns. Use a star pattern. Loosen the screws until the rotor rests on the 190-8386 Shim .

    When the rotor is setting on 190-8386 Shim, remove eight screws (18) .

20. Install a 191-5217 Guide Pin in one of the eight bolt holes that are located in the bearing cartridge. This will prevent the bearing cartridge from turning.

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Illustration 8	g00702558
190-8385 Bearing Puller Gp (20) Center Bolt

21. Install the 190-8385 Bearing Puller Gp on the bearing cartridge.

22. Turn center bolt (20) clockwise until the bolt contacts the bearing shaft.

Note: When the bearing is clear of the bearing shaft, the bearing cartridge may fall. Maintain one hand on the bearing cartridge.

23. Turn center bolt (20) in order to remove the bearing cartridge.

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Illustration 9	g00689055
(22) Bearing Cartridge (23) O-ring (24) Brass Shim

24. Remove O-ring (23) from the bearing cartridge.

25. Remove brass shim (24) from bearing cartridge (22).

26. Measure the old brass shim and record the measurement.

    Each bearing cartridge has a unique shoulder height. The height is stamped on the cartridge. The shims are added or removed in order to adjust the height of the shoulder. Record the height of the shoulder.

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    Table 3

    Bearing Measurements
    Old Brass Shim Thickness
    Old Shoulder Height

    Save the brass shim. The shim may be used during the installation procedure.

Installation Procedure

Illustration 10	g00730784
(1) Screw (2) Commutation Sensor Assembly (3) O-ring (4) Bolt (5) Commutation Sensor Wheel (6) Spacer (7) Screw (8) Plate for the Commutation Sensor Port (9) Plug and O-ring (10) O-ring (11) Rotor Retainer (12) Polished Bolt (13) O-ring (14) Rotor Static Discharge Drain (15) Screw

Each bearing cartridge has a unique shoulder height. The height is stamped on the cartridge. Shims are added or removed in order to adjust the height of the shoulder.

1. Compare the shoulder height of the old bearing cartridge and the shoulder height of the new bearing cartridge. When brass shims are needed, add brass shims or subtract brass shims. The tolerance of the measurement is ± 0.0508 mm (± 0.002 inch).
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   Table 5

   Bearing Measurements
   Old Brass Shim Thickness
   Old Shoulder Height (1)
   New Shoulder Height (1)
   New Brass Shim Thickness

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   ( 1 )

   The Shoulder Height is stamped on the shoulder.

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Illustration 11	g00689055
(22) Bearing Cartridge (23) O-ring (24) Brass Shim

2. Apply 6V-2055 High Vacuum Grease to O-ring (23).

3. Install O-ring (23) on bearing cartridge (22) .

4. Install a 191-5217 Guide Pin in one of the eight bolt holes that are located in the end plate. This pin should be installed 180° away from the first pin. This will locate the bearing cartridge during installation.

5. Align the four pin connector for the thermistor so that the yellow cable will reach the connector.

6. Install the new bearing cartridge. Use your hand and seat the bearing cartridge.

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Illustration 12	g00730657
190-8379 Bearing Installer Gp (21) Nut (26) Center Bolt

7. Install 190-8379 Bearing Installer Gp on the bearing housing.

8. Turn center bolt (26) clockwise until bearing cartridge (22) is approximately 12.7 mm (0.5 inch) from end plate (17) .

9. Refer to "Removal Procedure" and then refer to illustration 7 for the position of the feeler gauges.

10. Position the feeler gauges.

11. Turn nut (21). Seat the bearing cartridge.

12. Remove the two 191-5217 Guide Pins .

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Illustration 13	g00702253
(11) Rotor Retainer (12) Polished Rotor Retainer Bolt (13) O-ring (14) Rotor Static Discharge Drain (15) Screw (16) Plug and O-ring (17) Lower End Plate (18) Screw

13. Install eight screws (18). Use quarter turns. Tighten the screws in a star pattern. Tighten the screws until the rotor does not rest on the Shim. Torque the screws to 27.1 N·m (20 lb ft).

14. Remove the three feeler gauges.

15. Remove the four 190-8386 Shims .

16. Apply 6V-2055 High Vacuum Grease to the O-rings that are located on four plugs (16) .

17. Install four plugs (16) .

18. Clean the threads on the polished rotor retainer bolt (12) with a wire brush or replace the bolt.

19. Place one drop of 7M-7456 Bearing Mount Compound on the threads of polished rotor retainer bolt (12) .

20. Install rotor retainer (11) so that the lip faces the flywheel.

21. Install polished rotor retainer bolt (12). Torque the bolt to 38 N·m (28 lb ft).

22. Apply 6V-2055 High Vacuum Grease to O-ring (13). Install the O-ring (13) in the rotor static discharge drain (14) .

23. Install rotor static discharge drain (14) and tighten the bolts.

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Illustration 14	g00689031
(17) Vacuum Hose

24. Apply 6V-2055 High Vacuum Grease to the O-ring for vacuum hose (17). Connect vacuum hose (17) .

25. Connect the yellow connector for the thermistor and the nineteen pin instrument connector.