BALLJOINT AS-R 3780112 - Caterpillar

* Optional parts depending on Gen Setconfiguration and degree of failure as outlined in the rework procedure.
Insulation exposing copper braid
Where there is no heat-shrink tubing fitted ateach end of the power looms, similar to that shown in Figure 6, followthe steps below to add heat shrinkable tubing (one at each end) to coverboth the copper braid and the sleeving. Where there is existing heat-shrinktubing in place, there is no need to perform these steps.
Cut back the sleeve to expose approx 100mm (3.9inches) of copper braid at each end. Use scissors or fine wire cutters.Do not use blade cutters. Care should be taken to prevent damaging thecopper braids.
Fit 2 100mm (3.9 inches) lengths of heat shrinkabletubing (one at each end) to cover both the copper braid and the sleeving.The part number for the heat-shrinkable tubing is 7X2639 which has an internaldiameter of 50.8mm (2 inches) before shrinkage and a minimum of 25.4mm(1 inch) after shrinkage.
Apply hot air to the heat-shrink tubing to shrinkit securely on to both the braid and the sleeve. Be careful not to damagethe sleeving in the process.
Figure 6
Generator looms making contact with adjacentbusbar
To prevent the looms coming into contact withadjacent generator busbars, firstly add heat-shrink tubing as shown inFigure 6, if not already fitted. This should make the loom sufficientlystiff that it should not easily fall and come into contact with the adjacentbusbar.
Using cables straps (part number 7K-1181), ensurethat the looms are secured at a minimum of 10mm (0.39 inches) from theadjacent busbars.
If necessary, use cables straps (part number 7K-1181)to ensure that the phase and neutral looms will not be damaged throughphysical contact with other metal parts, such as generator studs.
Loom termination fixing onto generator busbar
Ensure that the screws are tightened tothe following torque:
M6 8.9 lb (+/-2.2 lb) [12Nm (+/-3 Nm)]M10 34.7 lb (+/-6.6 lb) [47Nm (+/-9 Nm)]
Insulation chaffing
Add 4 (part number 7H-8213) rubber mats to loomsas they enter the control panel as shown in Figure 7 to better insulatethe looms from the chassis.
Secure the mats to the looms with 8 (part number7K-1181) cable straps.
Figure 7
Add 4 (part number 7H-8213) rubber mats to loomsas they enter the turret as shown in Figure 8 to better protect the loomsfrom chaffing.
Secure the mats to the looms with 8 (part number7K-1181) cable straps.
Figure 8
Add 1 (part number 7H-8213) rubber mat to thecenter loom to insulate it from the other two phase looms, where the othertwo phase looms are cable-strapped to it, as shown in Figure 9. DO NOTsecure the mat with a cable strap.
Figure 9
Add 1 or 2 (part number 7H-8213) rubber mats asrequired around the three phase looms, as shown in Figure 10.
Secure all the mats with 2 (part number 7K-1181)cable straps.
Figure 10
Add 1 (part number 7H-8213) rubber mat aroundthe neutral loom where it meets the opening in the top of the alternatorhousing, as shown in Figure 11.
Secure the mat with 2 (part number 7K-1181) cablestraps.
Figure 11Note: The turret mats should then look similarto that shown in Figure 12: Figure 12