2001/04/30 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 brushes on the 160-4233 Hydraulic Generator. Replace the brushes on the 166-4141 Hydraulic Generator. Use the following parts.

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.

Show/hide table



Illustration 1	g00792141

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.

Show/hide table



Illustration 2	g00792190

Show/hide table



Illustration 3	g00792193

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. Identify each lead when you disconnect the leads from the brush support. Refer to the wiring diagram.

Show/hide table



Illustration 4	g00792213

9. To replace the 177-4445 Support, loosen and remove the four 1/4 inch hex head screws. Remove the 177-4445 Support. Check the condition of the support. You should replace the support if the support needs to be replaced.

10. Remove the 177-4446 Brushes. Check the condition of the 177-4447 Retainer. Replace the 177-4446 Brushes if the brushes need to be replaced. Replace the 177-4447 Retainer if the retainer needs to be replaced.

11. After the new parts are assembled hook up the brush leads to the proper terminals.

12. Use two 1/4 inch hex screws to fasten the brush retainers to the end plate.

13. Repeat steps 9 through 12 in order to replace the remaining brushes., Repeat steps 9 through 12 in order to replace the retainer and the brush support.

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

Show/hide table



Illustration 5	g00792225

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

16. 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.

Show/hide table



Illustration 6	g00792271

17. 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.

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

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

Show/hide table



Illustration 7	g00792273

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

21. 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.

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