PIN A. 7J5020 - Caterpillar

Slide 38 mm (1.5 inch) of heat shrink tubing (H) over the crimped lug. Position tubing (H) so that is covers a portion of the lug barrel and lead wire. Apply heat using Tooling (D).
Slide 51 mm (2.0 inch) of heat shrink tubing (G) over the ring resistor and main field lead wires. Do not apply heat until after the leads are secured in the next steps.Replacing the Ring Resistor Ring Terminal
Illustration 13 g06083798
(AH) Former ring resistor (insulated ring terminal)
(E) New ring resistor terminal
(F) Heat shrink tubing
Slide heat shrink tubing (F) over ring resistor lead wire.
Illustration 14 g06083800
(X) Ring resistor leads
(Y) Main field leads
(AD) Locknut
(AG) Inner hex nut
Crimp the ring resistor ring terminal (E) to the lead wire using Tooling (A).Note: Before crimping, ring resistor ring terminal must be positioned as shown in Illustration 14, which is the closest terminal to the inner hex nut (AG). The flat face of the ring resistor ring terminal should point toward the flat face of the main field lug.
Slide heat shrink tubing over the ring terminal barrel and apply heat with Tooling (D).Securing the Terminations
Illustration 15 g06083787
(K) Locknut
(L) Belleville washer
(M) Flat washer
After the repairs have been completed, use hardware shown in Illustration 15 to assemble ring resistor and main field leads to the 3/8" studs.
Tighten the 3/8” locknut (K) to 27 3 N m (20 2 lb ft).
Position the heat shrink tubing (G) over the ends of the leads. Apply heat using Tooling (D).Exciter Windings and Leads (DC, AC)
Inspection
Illustration 16 g06117896
Disassemble the generator to make the necessary repairs.
Disconnect all 3 of the exciter armature and diode flying leads from the studs on the rectifier group.Note: Discard all hardware and replace with current production hardware.
Determine the extent of the damage to the exciter armature windings and leads.Winding and Leads Repair
If there is visible winding damage and windings pass electrical testing complete the following repair procedure.
Clean the damaged area.
Apply winding repair epoxy.
Cure procedure
Harden: Room temperature: 4-6 hours by applying thin films
Complete cure (at room temp): 7 days
Harden: Low temp bake ( 60° C (140° F)): 25 to 35 minutes
Complete cure ( 60° C (140° F)): 4 to 6 hours
If lacing (AI) must be cut to expose more lead wire, use Tooling (D) to heat the area near the failed lead wire (AJ) and cut the lacing.
Illustration 17 g06117898
Cut the damaged end of the failed lead keeping as much of the wire as possible. Strip the insulation from the wire to crimp on the splice (U).
Crimp the splice onto the lead wire using Tooling (B).
Add new lead wire (N) at the other end of the splice. Use Tooling (B) to complete the crimp. Solder both ends of the splice.
Cut the heat shrink tubing (T) into 51 mm (2.0 inch) strips. Install 2 layers over the splice joint. Apply heat to each layer using Tooling (D).
Repeat the previous steps for the other 2 AC leads of the exciter armature if any damage is found to the lead wire or lug.
Complete the following steps to route the exciter armature