UPS Bearing Type I to G3.5 Conversion{4480} Caterpillar


UPS Bearing Type I to G3.5 Conversion{4480}

Usage:

UPS 250 APZ
Uninterruptible Power Supply:
UPS 150 (S/N: CPC1-UP)
ES12F (S/N: CZE1-UP)
UPS 1000S (S/N: CZS1-UP)
UPS 120 (S/N: CNK1-UP)
UPS 1200S (S/N: CZT1-UP)
UPS 250 (S/N: CNM1-UP; APZ1-UP)
UPS 300 (S/N: CNJ1-UP; CPZ1-UP)
UPS 301 (S/N: CSY1-UP)
UPS 500 (S/N: CSE1-UP)
UPS 600 (S/N: CTX1-UP)
UPS 750 (S/N: CPM1-UP)
UPS 900 (S/N: CRY1-UP)

Introduction

The bearings should be replaced periodically. The recommended interval is estimated at 2 and 1/2 years. The bearings are contained in removable cartridges. The cartridges are replaced at the same time as the bearings. The cartridges must be accurately positioned for proper operation. Only trained personnel may perform the replacement.

Note: The lower bearing and upper bearing are always changed as a set. The lower bearing is changed first. Then, the upper bearing is changed. The flywheel must be de-energized and the flywheel must be at zero rpm.

Note: Shut down the System before attempting to remove the lower bearing. Refer to the Operation and Maintenance Manual, SEBU8145, "System Shutdown" for the proper shutdown procedure.

Note: All firmware must be revision 3.56/3.59 or higher.

Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method or operating technique that is not specifically recommended by Caterpillar is used, you must ensure that it is safe for you and for other people to use.

You should ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance or the repair procedures that are used.

Load Cell

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

Removal Procedure




Illustration 1g01932015

Flywheel with Lower Components

(1) Flywheel

(2) Plug

(3) O-ring

(4) Brass Shim Pack

(5) Lower Bearing Cartridge

(6) Spacer

(7) Polished Retainer Bolt

(8) Mounting Hardware (Screw)

(9) Mounting Hardware (Washer)

(10) Mounting Hardware (Discharge Drain)

(11) Load Plate

(12) Washer

(13) Load Cell

(14) Hex Bolt




Illustration 2g01932133

Flywheel with Upper Components

(2) Plug

(19) Magnetic Rotor Position Sensor (RPS) Assembly Screw

(20) Magnetic Rotor Position Sensor (RPS) PWA

(21) Magnetic Rotor Position Sensor (RPS) O-ring

(22) Polished Retaining Bolt

(23) Rotor Wheel with Teeth

(24) Bearing Cartridge Mounting Screw

(25) Spacer

(26) Upper Bearing Cartridge

(27) Brass Shim Pack

(28) O-ring

Table 1
Required Tools    
Qty     Part Number     Part Description    
4     190-8386     Shims    
2     191-5217     Guide Pins    
1     190-8385     Bearing Puller Gp    



    Illustration 3g01932585

  1. Remove the three plugs (2) from the bottom of the flywheel housing. Refer to Illustration 3.



    Illustration 4g00712417

    190-8386 Shims in place (cutaway view)

  1. Install the three 190-8386 Shims . Install one shim in each hole. Refer to Illustration 4 for the correct placement of the shims.

    Note: The shims prevent the rotor from setting down on the sensors.

  1. Disconnect the following items from the bottom of the flywheel: the 19-pin connector, the cable for the thermistor and the vacuum hose.

    Note: Do not disconnect the armature post or the connections for the field coil.

  1. Disconnect the 19-pin connector.

  1. Disconnect the yellow connector for the thermistor.



    Illustration 5g01932634

    View of Right Side Without Panel

    (32) Vacuum Hose

  1. Remove the vacuum hose (32) from the system. This relieves the vacuum from the system.

  1. Remove the six bolts that connect the load cell to the bearing cartridge. Use a crisscross pattern in order to remove the bolts.

  1. Remove the load cell from the bearing cartridge.

  1. Remove the polished retainer bolt (7) and the spacer (6). Refer to Illustration 1.



    Illustration 6g01934173

  1. Use four feeler gauges (33) in order to measure the gap that is between the bearing cartridge and the end plate. Take measurements at four locations. Record the measurements for later use. Refer to Illustration 6.

    The measurements will be used during the installation of the new bearing. Record the results in Table 2.

    Table 2
    Location     Measurement    
    1        
    2        
    3        
    4        

  1. Loosen the eight bolts by using quarter turns in a star pattern until the bolts are loose. Loosen the screws until the rotor rests on the 190-8386 Shim .

    When the rotor is setting on the 190-8386 Shims , remove the eight bolts.

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




    Illustration 7g01934216

    (34) 190-8385 Bearing Puller Gp

    (35) 191-5217 Guide Pins

  1. Install the 190-8385 Bearing Puller Gp (34) on the lower bearing cartridge (5). Refer to Illustration 7.

  1. Install the two 191-5217 Guide Pins (35) in two opposite holes of the eight bolt holes that are located in the lower bearing cartridge. This will prevent the lower bearing cartridge from turning.

  1. Carefully turn the center bolt by hand until the bolt contacts the shaft.

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

  1. Turn the center bolt in order to remove the bearing cartridge.



    Illustration 8g01932638

    (37) Brass shims

    (38) O-ring

    (39) Lower Bearing Cartridge

  1. Remove the brass shims (37) from lower bearing cartridge (39). Verify that no brass shims (37) are remaining in the flywheel housing.

  1. Remove the O-ring (38) from the lower bearing cartridge (39) .



    Illustration 9g01810454

  1. Measure the old brass shims and record the measurement. Refer to Illustration 9.

    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 that is stamped on the face of the bearing cartridge.

    Table 3
    Bearing Measurements    
    Old brass shim thickness        
    Old shoulder height        

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

Installation Procedure

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). The total shoulder height of the new bearing cartridge must match the total height of the old bearing cartridge.

    Table 4
    Bearing Measurements    
    Old brass shim thickness        
    Old shoulder height (1)        
    New shoulder height (1)        
    New brass shim thickness        
    ( 1 ) The Shoulder Height is stamped on the shoulder.



    Illustration 10g01932638

    (37) Brass shims

    (38) O-ring

    (39) Lower Bearing Cartridge

  1. Apply 6V-2055 Grease to the O-ring (38).

  1. Install the new O-ring (38) on the lower bearing cartridge (39) .

  1. Align the bearing assembly for the cable for the thermistor so that the yellow cable will reach the connector.

  1. Install the new bearing cartridge with the required number of shims from Step 1. Use your hand in order to seat the bearing cartridge.



    Illustration 11g01946335

    190-8379 Bearing Installer Gp

    (40) Nut

    (41) Center Bolt

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

  1. Hand tighten the nut (40). Use a wrench in order to tighten the nut (40) until the bearing is completely seated on the flywheel.

  1. Insert the eight bolts in the sockets for the lower bearing cartridge. Thread the bolts loosely.

  1. Insert the four feeler gauges that were defined in Step 10.

  1. Remove the two 191-5217 Guide Pins .

  1. Remove the 190-8379 Bearing Installer Gp .

  1. Torque the eight bolts to 27.1 N·m (20 lb ft).

  1. Clean the threads on the polished retainer bolt (7) with a wire brush or replace the bolt.

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

  1. Install the spacer (6) so that the lip faces the flywheel.

  1. Install the polished retainer bolt (7). Torque the bolt to 38 N·m (28 lb ft).

  1. Install the yellow cable for the thermistor.



    Illustration 12g01813233

  1. Verify the angle for the static discharge drain by using the angle block. If the angle block does not match the block, adjust the angle of the static drain.

  1. Apply 6V-2055 Grease to the new O-ring.

  1. Install the new O-ring on the load cell.

  1. Insert the load cell. Use the six bolts in order to attach the assembly to the bearing cartridge.

  1. Torque the six bolts to 27.1 N·m (20 lb ft).

  1. Remove the four feeler gauges.

  1. Apply 6V-2055 Grease to the O-rings that are located on the three plugs (2). Refer to Illustration 1.

  1. Install the three plugs (2) .



    Illustration 13g01932634

    View of Right Side Without Panel

    (36) Vacuum Hose

  1. Apply 6V-2055 Grease to the new O-ring for the vacuum hose (36). Connect the vacuum hose (36) .

  1. Connect the following items to the bottom of the flywheel: the 19-pin connector, the cable for the thermistor and the vacuum hose.

  1. Refer to ""Magnetic RPS" " or ""Optical RPS" " in order to replace the appropriate type of upper bearing for your system.

Magnetic Rotor Position Sensor (RPS)

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




Illustration 14g01933714

(45) Screw

(46) Magnetic assembly

(47) O-ring

(48) Hex bolt

(49) Wheel

(50) Spacer

Removal Procedure

Table 5
Required Tools    
Qty     Part Number     Part Description    
2     191-5217     Guide Pins    
1     190-8385     Bearing Puller Gp    



Illustration 15g01932133

Flywheel with Upper Components

(2) Plug

(19) Comm/Accel Assembly Screw

(20) Comm/Accel PWA

(21) Comm/Accel O-ring

(22) Polished Retaining Bolt

(23) Rotor Wheel with Teeth

(24) Bearing Cartridge Mounting Bolt

(25) Spacer

(26) Upper Bearing Cartridge

(27) Brass Shim Pack

(28) O-ring

  1. Disconnect the upper bearing (thermistor), the ribbon cable for the RPS, and the upper connector for the upper field coil.

  1. Remove the three bolts that hold the RPS in place by using a static discharge wrist strap.

  1. Remove the RPS.

    Note: Use caution when you remove the RPS. Ensure that bolts are not dropped into the flywheel.

  1. Place the assembly in a static free environment.

  1. Remove the polished retainer bolt (22) .

  1. Remove the wheel (23) .

  1. Remove the spacer (25) .



    Illustration 16g01934853

  1. Use four feeler gauges (33) in order to measure the gap that is between the bearing cartridge and the end plate. Take measurements at four locations. Refer to Illustration 16.

    The measurements will be used during the installation of the new bearing. Record the measurements in Table 6 for later use.

    Table 6
    Location     Measurement    
    1        
    2        
    3        
    4        

  1. Loosen the eight bolts by using quarter turns in a star pattern until the bolts are loose.

  1. Remove the eight bolts.

  1. Install the two 191-5217 Guide Pins (55) in two opposite holes 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 for the thermistor must be maintained when the bearing is reinstalled.




    Illustration 17g01934876

  1. Install the 190-8385 Bearing Puller Gp (56) on the upper bearing cartridge. Refer to Illustration 17.

  1. Turn the center bolt by hand until the bolt contacts the bearing shaft.

  1. Turn the center bolt by using a wrench in order to remove the upper bearing cartridge.



    Illustration 18g01812204

    (11 26) Upper bearing cartridge

    (12 28) O-ring

    (13 27) Brass shims

  1. Remove the brass shims (13) from upper bearing cartridge (11) .



    Illustration 19g01810454

  1. Measure the old brass shims and record the measurement. Refer to Illustration 27.

    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 that is stamped on the face of the bearing cartridge.

    Table 7
    Bearing Measurements    
    Old brass shim thickness        
    Old shoulder height        

    Save the brass shims (13). The shims may be used during the installation procedure.

Installation Procedure

Table 8
Required Tools    
Qty     Part Number     Part Description    
2     191-5217     Guide Pins    
1     190-8379     Bearing Installer Gp    
1     7M-7456     Bearing Mount Compound    
1     190-8380     Spare Shim Kit (1)    
1     6V-2055     High Vacuum Grease    
( 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)

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.

  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 (± 0.00200 inch). The total height of the new bearing cartridge must match the total height of the old bearing cartridge.

    Table 9
    Bearing Measurements    
    Old brass shim thickness        
    Old shoulder height (1)        
    New shoulder height (1)        
    New brass shim thickness        
    ( 1 ) The Shoulder Height is stamped on the shoulder.



    Illustration 20g01812204

    (11) Upper bearing cartridge

    (12) O-ring

    (13) Brass shims

  1. Apply 6V-2055 Grease to the new O-ring (12).

  1. Install the new O-ring (12) on the upper bearing cartridge (11) .

  1. Install the new bearing cartridge with the required number of shims from Step 1. Use your hand in order to seat the bearing cartridge.

  1. Install the four feeler gauges.



    Illustration 21g01946342

    190-8379 Bearing Installer Gp

    (40) Nut

    (41) Center Bolt

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

  1. Hand tighten the nut (40). Use a wrench in order to tighten the nut until the bearing is completely seated.

  1. Remove the two 191-5217 Guide Pins .

  1. Insert the eight bolts in the sockets for the bearing cartridge. Thread the bolts loosely.

  1. Remove the 190-8379 Bearing Installer Gp .

  1. Torque the eight bolts to 27.1 N·m (20 lb ft).

  1. Remove the four feeler gauges (33) .

  1. Clean the threads on the polished retainer bolt (22) with a wire brush or replace the bolt.

  1. Place one drop of 7M-7456 Bearing Mount Compound on the threads of the polished retainer bolt (22) .

  1. Install the spacer (25) so that the lip faces the flywheel. Refer to Illustration 2.

  1. Install the polished retainer bolt (22). Torque the bolt to 38 N·m (28 lb ft).

  1. Use a digital multimeter in order to check the continuity from the retainer bolt to the casting for the flywheel. The measurement should be less than 5 ohms.

  1. Verify the proper gap between the magnetic pickup and the wheel. Refer to Systems Operation, Testing and Adjusting, RENR2476, "Rotor Position Sensor - Adjust (The Procedure for the Setting of The Rotor Position Sensor Gap)" for more information on setting the gap.

  1. Reinstall the RPS with the three screws (19) .

  1. Connect the connector for the field coil, the upper thermistor, and the ribbon cable for the sensor.

    Note: Return the system to operation after you are finished with the procedure. Refer to the Operation and Maintenance Manual, SEBU8145, "System Startup" for the proper start-up procedure.

Optical RPS

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




Illustration 22g01813733

(1) Screw

(2) RPS

(3) O-ring

(4) Hex bolt

(5) Wheel

Removal Procedure

Table 10
Required Tools    
Tool     Part Number     Part Description     Qty    
A     191-5217     Guide Pins     2    
B     190-8385     Bearing Puller Gp     1    



Illustration 23g01813734

(1) Screw

(2) RPS

(3) O-ring

(4) Hex Bolt

(5) Wheel

(7) Screw

(8) Shipping Plug

(9) Plug with an O-ring

(10) O-ring

(11) Top Bearing cartridge

  1. Disconnect the upper bearing (thermistor), the ribbon cable for the RPS, and the connector for the upper field coil.

  1. Remove the three bolts that hold the RPS in place by using a static discharge wrist strap.

  1. Remove the RPS.

    Note: Use caution when you remove the RPS. Ensure that bolts are not dropped into the flywheel.

  1. Place the assembly in a static free environment.

  1. Remove the polished retainer bolt (4) .

  1. Remove the wheel (5) .



    Illustration 24g00852370

  1. Use four feeler gauges in order to measure the gap that is between the bearing cartridge and the end plate. Take measurements at four locations. Record the measurements for later use. Refer to Illustration 24.

    The measurements will be used during the installation of the new bearing. Record the results in Table 11.

    Table 11
    Location     Measurement    
    1        
    2        
    3        
    4        

  1. Loosen the eight bolts by using quarter turns in a star pattern until the bolts are loose.

  1. Remove the eight bolts.

  1. Install the two 191-5217 Guide Pins in two opposite holes of the eight bolt holes that are located in the upper bearing cartridge. This will prevent the bearing cartridge from turning.

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




    Illustration 25g00852427

    190-8385 Bearing Puller Gp

  1. Install the 190-8385 Bearing Puller Gp on the upper bearing cartridge. Refer to Illustration 25.

  1. Turn the center bolt by hand until the bolt contacts the bearing shaft.

  1. Turn the center bolt by using a wrench in order to remove the bearing cartridge.



    Illustration 26g01812204

    (11) Upper bearing cartridge

    (12) O-ring

    (13) Brass shims

  1. Remove the brass shims (13) from the upper bearing cartridge (11) .



    Illustration 27g01810454

  1. Measure the old brass shims and record the measurement. Refer to Illustration 27.

    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 that is stamped on the face of the bearing cartridge.

    Table 12
    Bearing Measurements    
    Old brass shim thickness        
    Old shoulder height        

    Save the brass shims (13). The shims may be used during the installation procedure.

Installation Procedure

Table 13
Required Tools    
Part Number     Part Description     Qty    
191-5217     Guide Pins     2    
190-8379     Bearing Installer Gp     1    
7M-7456     Bearing Mount Compound     1    
190-8380     Spare Shim Kit (1)     1    
6V-2055     Grease     1    
( 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)

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.

  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 (± 0.00200 inch). The total height of the new bearing cartridge must match the total height of the old bearing cartridge.

    Table 14
    Bearing Measurements    
    Old brass shim thickness        
    Old shoulder height (1)        
    New shoulder height (1)        
    New brass shim thickness        
    ( 1 ) The Shoulder Height is stamped on the shoulder.



    Illustration 28g01812204

    (11) Upper bearing cartridge

    (12) O-ring

    (13) Brass shims

  1. Apply 6V-2055 Grease to the new O-ring (12) .

  1. Install the new O-ring (12) on the upper bearing cartridge (11) .

  1. Install the new bearing cartridge with the required number of shims from Step 1. Use your hand in order to seat the bearing cartridge.

  1. Install the four feeler gauges.



    Illustration 29g01946343

    190-8379 Bearing Installer Gp

    (40) Nut

    (41) Center Bolt

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

  1. Hand tighten the nut (40). Use a wrench in order to tighten the nut (40) until the upper bearing cartridge is completely seated.

  1. Insert the eight bolts in the sockets for the upper bearing cartridge. Thread the bolts loosely.

  1. Remove the two 191-5217 Guide Pins .

  1. Remove the 190-8379 Bearing Installer Gp .

  1. Torque the eight bolts to 27.1 N·m (20 lb ft).

  1. Remove the four feeler gauges.

  1. Clean the threads on the polished retainer bolt (4) with a wire brush or replace the bolt.

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

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

  1. Use a digital multimeter in order to check the continuity from the retainer bolt to the casting for the flywheel. The measurement should be less than 5 ohms.

  1. Reinstall the RPS with the three screws (1) .

  1. Connect the connector for the field coil, the upper thermistor, and the ribbon cable for the sensor.

    Note: Return the system to operation after you are finished with the procedure. Refer to the Operation and Maintenance Manual, SEBU8145, "System Startup" for the proper start-up procedure.

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