SEAL-O-RING 1W0115 - Caterpillar

PMG Removal Procedure
Table 1
Required Tools
Qty Part Number Part Description
1 195-4609 Seal Pick
2 Guide Stud
Thread Size (Inch): (3/8-16-THD by 10 inches Long) Start By:
Remove the exciter cover and rotating rectifier assembly. Refer to Systems Operation, Test and Adjust, Disassembly and Assembly, KENR8990, "Diode Assembly - Remove and Install" for rectifier-related information.
The permanent magnet (PMG) rotor contains strong magnets. During the removal process for the rotor, these magnets can cause a crush hazard between the rotor and the stator for the PMG. Use the proper tooling in order to remove the rotor.
Illustration 1 g01651078
(1) Resistance temperature detector (RTD) and PMG connectors
(2) Cable strap
(3) PMG stator Note: Ensure that the connectors (1) have been labeled before disassembly.
Remove the cable strap (2).
Disconnect the "Resistance Temperature Detector" (RTD) and PMG connectors (1). Position the connectors so the connectors do not interfere with further disassembly procedures.
Illustration 2 g03450036
(4) Access cover removed
(5) RTD location
Disconnect space heater wiring from the 40 pin generator interface connector (AC-C4) plug in the AC terminal box. Refer to Systems Operation, Testing and Adjusting, Disassembly and Assembly, KENR8990, "Generator Operation" for space heater information and electrical diagrams.
Illustration 3 g01661034
(10) End bracket
(11) PMG stator
(12) Alignment marks
Put alignment marks (12) on both the PMG stator (11) and the end bracket (10) for installation alignment purposes.
Illustration 4 g01651076
(11) PMG stator
(13) PMG stator mounting bolts
(14) PMG rotor
Remove two of the PMG stator mounting bolts (13). Install two of the guide studs in the position of the PMG stator mounting bolts (13) that were removed.
Remove the two remaining PMG stator mounting bolts (13). Remove the PMG stator (11).
Illustration 5 g03443316
The permanent magnet (PMG) rotor contains strong magnets. During the removal process for the rotor, these magnets can cause a crush hazard between the rotor and the stator for the PMG. Use the proper tooling in order to remove the rotor.
Use a pry bar (15) to remove the PMG rotor (14). Refer to Illustration 5. PMG Installation Procedure
Table 2
Required Tools
Qty Part Number Part Description
2 Guide Stud
Thread Size (Inch): (3/8-16-THD by 10 inches Long)
Illustration 6 g01651077
Position the permanent magnet rotor (14) onto the main rotor shaft.
Illustration 7 g01661514
Position the PMG stator (11) onto the guide studs. Install two of the PMG stator mounting bolts (13). Do not torque the mounting bolts yet.
Remove the guide studs. Install the remaining two PMG stator mounting bolts (13). Torque the mounting bolts.
Connect the RTD and PMG connectors (1) to the mating connectors.
Illustration 8 g01662975
Install a cable strap (20) in order to secure the RTD and PMG cables.. End By:
Install the revolving rectifier. Refer to Disassembly and Assembly, "Revolving Rectifier - Remove and Install". 3000 Frame End Bracket Removal
Table 3
Required Tools
Qty Part Number Description
2 FT3220(1) Polyethylene Strips - Thickness of 5 mm or Wedge
4 FT3219(1) Guide Stud
2 154-6184 Forcing Bolt
(1) Drawings for fabricated tools can be found at https://dealer.cat.com/dealer-service-tools
Start By:
Rotate the generator to the position which puts two of the main rotor poles at a 4 o'clock and 8 o'clock position. Refer to Illustration 9.
Remove the PMG components. Refer to the Disassembly and Assembly, "PMG