2001/12/10 Caterpillar

Asphalt Paver:

AP-1000B (S/N: 7HN1-UP)

AP-1050B (S/N: 6ZN1-UP)

AP-1055B (S/N: 8BM1-UP; ABB1-UP)

BG-2455C (S/N: 6TN1-UP; ACM1-UP)

BG-245C (S/N: 4XN1-UP)

BG-260C (S/N: 8GN1-UP)

Replace the 5P-7807 Ball Bearing for the 8 kW 160-4233 Hydraulic Generator. Replace the 5P-7807 Ball Bearing for the 6 kW 166-4141 Hydraulic Generator.

1. Loosen and remove the four 5/16-18 hex head screws that hold the end plate for the motor drive.

2. Use a soft hammer. Tap on the ears of the end plate for the drive until the plate is loose. Remove the plate from the generator. Do not lose the O-rings from the hubs of the rotor. Check the condition of the motor shaft and the key. Inspect the key way on the hub of the rotor.

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Illustration 1	g00790104

3. Loosen and remove the four 5/16-18 hex head screws that hold the end plate for the bearing. The end plate is located on the other end of the generator.

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Illustration 2	g00790123

4. Fasten a puller with two 5/16 hex head screws to the threaded holes beside the bearing cup on the end plate of the bearing. See illustration (2). If the holes are not threaded, use a 5/16-18 tap to thread the holes.

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Illustration 3	g00790128

5. Remove the two 1/4 inch hex head screws that hold the retainers for the brushes to the end plate of the bearing.

6. Push the shaft for the rotor as far as possible in the housing. Reach inside the end of the bearing cap. Move the retainers for the brushes and move the brushes away from the rotor shaft.

7. Use the puller to carefully push the rotor bearing out of the bearing cup. Do not use a hammer.

8. Take the rotor out of the shell.

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Illustration 4	g00790158

9. Use a bearing puller to remove the old bearing. Remove the old retaining ring. Replace the old retaining ring with a 6K-8162 Retaining Ring. Replace the old bearing with a 5P-7807 Ball Bearing.

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Illustration 5	g00790159

10. Press the new 5P-7807 Ball Bearing on the shaft until the bearing is against the 6K-8162 Retaining Ring .

11. Slide the rotor in the shell.

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Illustration 6	g00790160

12. Place the generator on the end of the fan on a short block of wood. The wood should only support the rotor shaft.

13. Use two 1/4 inch screws to fasten each retainer for the brush to the end plate for the bearing.

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Illustration 7	g00790161

14. Apply Never Seize to the bearing cup on the end plate of the bearing. Place a wood block across the top of the bearing cup. Use a soft hammer to tap on the bearing cup until the bearing is fully seated in the bearing cup. Watch all six brushes when you replace the bearing cup. Do not damage the brushes.

15. Look through the vents in the end plate on the brush when the generator is in a vertical position. Make sure that the wires are clear of obstructions. Make sure that the brushes are positioned correctly on the slip rings.

16. Rotate the generator to the opposite end. Apply Never Seize to the key way.

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Illustration 8	g00790162

17. Place the O-rings in the hub of the rotor.

18. Line up the key with the key way in the rotor hub. Slide the end plate of the motor on the rotor shaft.

19. Use 5/16-18 hex head screws and 5/16 lockwashers to assemble the end plate to the generator. Alternate the pattern of torque until the hex head screws are to the proper torque.

20. Make sure that the groove in the end plate is seated squarely in the generator housing.