UPS 250, UPS 300, UPS 500, UPS 600, UPS 750 and UPS 900 Uninterruptible Power Supply Caterpillar

Upper Bearing - Remove and Install

Usage:

Note: Whenever the upper bearing is replaced, the lower bearing must be replaced as well.

Removal Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	191-5217	Guide Pin	1
B	190-8385	Bearing Puller Gp	1

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Illustration 1	g00985643
(1) (1) Screw (2) Assembly (Rotor Position Sensor) (3) O-ring (4) Hex Bolt (5) Wheel (Rotor) (6) Spacer (7) Screw (8) Shipping Plug (9) Plug with an O-ring (10) O-ring (11) Assembly (Top Bearing) (12) Sensor (Vacuum) (13) Assembly (Bottom Bearing) (14) Spacer (15) Retaining Bolt (16) Mounting Hardware for the Drain (Charge) (17) Mounting Hardware for the Drain (Charge) (18) Drain (Charge) (19) Load Plate (20) Shims (Load Cell) (21) Load Cell and Base Plate Assembly (22) Hex Bolt (23) Spacer (24) Hex Bolt with Polished Head (25) Screw (26) O-ring (27) Assembly (Static Drain)

Shut down the System before attempting to remove the upper bearing. Refer to Testing and Adjusting, "System Shutdown" for the proper shutdown procedure.

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Illustration 2	g00843202

Remove vacuum hose (30) from the system. This relieves the vacuum from the system.

Disconnect the yellow connector for the thermistor and the 19 pin instrument connector.

Remove three screws (1) .

Remove assembly (Rotor Position Sensor) (2) .

Remove O-ring (3) .

Remove bolt (4) .

Remove commutation sensor wheel (5) .

Remove spacer (6) .

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Illustration 3	g00852370

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

4

Table 2
Location	Measurement
1
2
3
4

Loosen eight screws. Use quarter turns. Use a star pattern.

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.
Note: The location for the connector for the cable (thermistor) must be maintained when the bearing is reinstalled.

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Illustration 4	g00852427
190-8385 Bearing Puller Gp

Install the 190-8385 Bearing Puller Gp on the bearing cartridge.
Reference: Refer to Illustration 4.

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

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

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Illustration 5	g00863802
(35) Bearing Cartridge (36) O-ring (37) Brass Shim

Remove brass shim (37) from bearing cartridge (35).

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 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.

Table 3
Bearing Measurements
Old Brass Shim Thickness
Old Shoulder Height

Installation Procedure

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Table 4
Required Tools
Tool	Part Number	Part Description	Qty
A	191-5217	Guide Pin	2
B	190-8379	Bearing Installer Gp	1
C	7M-7456	Bearing Mount Compound	1
D	190-8380	Spare Shim Kit ⁽¹⁾	1
E	6V-2055	High Vacuum Grease	1

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^( 1 )

The kit contains the following brass shims: Eight 190-8381 Brass Shim (0.05 mm), Four 190-8382 Brass Shim (0.13 mm), Two 190-8383 Brass Shim (0.25 mm) and One 190-8384 Brass Shim (0.50 mm)

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Illustration 6	g00985643
(1) (1) Screw (2) Assembly (Rotor Position Sensor) (3) O-ring (4) Hex Bolt (5) Wheel (Rotor) (6) Spacer (7) Screw (8) Shipping Plug (9) Plug with an O-ring (10) O-ring (11) Assembly (Top Bearing) (12) Sensor (Vacuum) (13) Assembly (Bottom Bearing) (14) Spacer (15) Retaining Bolt (16) Mounting Hardware for the Drain (Charge) (17) Mounting Hardware for the Drain (Charge) (18) Drain (Charge) (19) Load Plate (20) Shims (Load Cell) (21) Load Cell and Base Plate Assembly (22) Hex Bolt (23) Spacer (24) Hex Bolt with Polished Head (25) Screw (26) O-ring (27) Assembly (Static Drain)

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

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.

Table 5
Bearing Measurements
Old Brass Shim Thickness
Old Shoulder Height ⁽¹⁾
New Shoulder Height ⁽¹⁾
New Brass Shim Thickness

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Illustration 7	g00863802
(35) Bearing Cartridge (36) O-ring (37) Brass Shim

Apply 6V-2055 High Vacuum Grease to O-ring (36).

Install O-ring (36) on bearing cartridge (35) .

Install another 191-5217 Guide Pin in one of the eight bolt holes that are located in bearing cartridge (13). This pin should be installed 180° away from the first pin. This will locate the bearing cartridge during installation.

Align the 4-pin connector for the thermistor so that the cable will reach the connector.

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

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Illustration 8	g00863883
190-8379 Bearing Installer Gp (40) Nut (41) Center Bolt

Install 190-8379 Bearing Installer Gp on the bearing housing.
Reference: Refer to Illustration 8.

Turn center bolt (41) clockwise until bearing cartridge (35) is approximately 12.7 mm (0.5 inch) from end plate (17) .

Refer to "Removal Procedure" and then refer to illustration 3 for the position of the feeler gauges.

Position the 4 feeler gauges.

Turn nut (40). Seat the bearing cartridge.

Remove the two 191-5217 Guide Pins .

Install eight screws. Use quarter turns. Tighten the screws in a star pattern. Torque the screws to 27.1 N·m (20 lb ft).

Remove the four feeler gauges.

Install spacer (6) .

Install commutation sensor wheel (5) .

Clean the threads of bolt (4) with a wire brush or replace the bolt.

Place one drop of 7M-7456 Bearing Mount Compound on the threads of bolt (4) .

Install bolt (4). Torque the bolt to 38 N·m (28 lb ft).

Apply 6V-2055 High Vacuum Grease to O-ring (3). Install the O-ring (3) in the commutation sensor assembly (2) .

Install the assembly (Rotor Position Sensor) (2) so that the assembly points to the 1 o'clock and the 7 o'clock positions. The 12 o'clock position is the center of the back of the cabinet.