2001/04/30 Caterpillar

Asphalt Paver:

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

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

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

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

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

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

Replace the 177-4448 Bridge Rectifier for the 8 kW 160-4233 Hydraulic Generator. Replace the 177-4448 Bridge Rectifier 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	g00791980

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.

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 2	g00791984

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Illustration 3	g00791985

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	g00792006

9. Locate the bridge rectifier. The bridge rectifier is located on the end of the housing. Remove the silicone compound that covers the terminals.

10. Mark the four leads from the bridge rectifier and remove the four leads from the bridge rectifier., As an alternative, you can follow the wiring diagram for the hookup.

11. Loosen and remove the 10-24x1/2 inch screw from the bridge rectifier.

12. Apply the heat sink compound from the kit to the bottom side of the new bridge rectifier.

13. Use the 10-24x1/2 inch screw that is provided to install the new bridge rectifier.

14. Refer to the wiring diagram in order to assemble the leads.

15. Repeat steps 9 through 14 in order to replace the other bridge rectifier.

16. Apply a silicone compound to the rectifiers and the wire terminals.

17. Slide the rotor in the shell.

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

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Illustration 5	g00792018

19. Use two 1/4 inch screws to fasten the retainer for the brushes to the end plate for the bearing.

20. 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.

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Illustration 6	g00792025

21. 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.

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

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

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Illustration 7	g00792029

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

25. 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.

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