12/29/22, 10:50 AM SIS 2.

2022/05/30 Collector Rings - Remove and Install - Low Voltage (M0069644-49)

SMCS - 7000 i09238767

Removal Procedure

PIP
Required Tools
Tool Part Number Part Description QTY
A

Table 1
- Loctite 243 -
-
202 025 1
2
13: /12/2 417 4
5
M0 :15- 9
Do not operate or work on this equipment unless you have read

0
and understand the instructions and warnings in the Operation
and Maintenance Manuals. Failure to follow the instructions or
heed the warnings could result in injury or death. Contact your

0 0
Caterpillar dealer for replacement manuals. Proper care is your

6
© 2 964 3:00
responsibility.

0
Cat 2 C2 4
e r
Con pilla terpia
Hot hydraulic oil under high pressure can remain in the
components of the hydraulic system or the power train system
after the engine has been stopped. The uncontrolled release of

llar
the hydraulic oil can cause sudden machine movement and can

fide r:
also result in the following conditions:

Inc
Burns

ntia .
The penetration of body tissue

lG
Other personal injury

Death
ree
n
If hydraulic oil penetrates body tissue, the injury must be treated
immediately by a doctor who is familiar with this type of injury.
Use a board or a piece of cardboard to check for a hydraulic oil
leak. Make sure that all of the attachments have been lowered to
the ground and that all trapped pressure has been released from
the hydraulic system and the power train system. Also, make
sure that the hydraulic oil is cool before the removal of any
components or lines. Remove the hydraulic oil filler cap only
when the engine is stopped and the filler cap is cool enough to
touch with your bare hand.

ELECTROCUTION HAZARD - Ensure proper grounding.

Avoid a buildup of hazardous live voltages on exposed surfaces

by ensuring that all grounding wires/straps are always properly
connected.

Disconnected grounding wires, including grounding wires/straps

for hazardous-voltage components and electrical enclosures,
must be properly reconnected before connecting equipment to
the power supply.

Failure to follow these instructions will result in personal injury

or death.

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12/29/22, 10:50 AM SIS 2.0

ELECTROCUTION HAZARD - The electrical system contains

hazardous voltage levels.

DO NOT remove any covers that will expose energized

hazardous-voltage electrical components without shutting down
and discharging the electrical system.

DO NOT perform any maintenance on the electrical system until

after the electrical system has been shut down and the voltage
has been discharged by qualified personnel.

Read and understand the instructions and warnings found in the

Operation and Maintenance Manual to properly shut down the
electrical system and discharge hazardous-voltage electrical
components.

Failure to follow these instructions will result in personal injury

or death.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and
repair of the product. Be prepared to collect the fluid with
suitable containers before opening any compartment or
disassembling any component containing fluids.

Refer to Special Publication, PERJ1017, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain
fluids on Cat® products.

Dispose of all fluids according to local regulations and

mandates.

1. Prepare the machine for maintenance, perform voltage shutdown.

a. For (S/N: ER6, ER7, and ER8) machines refer to Testing and Adjusting Machine Preparation  for the correct procedure.

b. For (S/N: R3R and R3F) machines refer to Operation and Maintenance Manual Prepare the Machine for Maintenance  for the correct
procedure.
Note: The electrician is responsible for ensuring the shovel is properly locked out.

Illustration 1 g06149742

2. Low voltage collector rings group (2) is located below hoist drum (1).

Illustration 2 g06147633
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12/29/22, 10:50 AM SIS 2.0

3. Remove bolts (3) and cover (4).

Illustration 3 g06147656

Illustration 4 g06148216

4. Disconnect hose assemblies (5) and harness assemblies (6). Reposition hose assemblies (5) and harness assemblies (6) out of the way.

Illustration 5 g06147675

5. Remove bolts (7), plates (8), plate (9), and cover (10).

Illustration 6 g06147701

6. Remove bolts (11) and (12). Remove plate (13) and cover (14) from the right junction box.

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12/29/22, 10:50 AM SIS 2.0

Illustration 7 g06147745
7. Disconnect harness assemblies (15) that connects to the low voltage collector rings.

8. Repeat Step 6 and Step 7 to disconnect the harness assemblies from the left junction box.

Illustration 8 g06148282

9. Remove bolts (17) and nuts (16).

Illustration 9 g06149156

10. Use two people to remove cover (19). The weight of cover (19) is approximately 40 kg (88 lb). Remove bolts (18) and cover (19). Repeat the
step for the opposite side.

Illustration 10 g06149187

11. Remove bolts (22) from junction boxes (20) and (21). Use two people to reposition junction boxes (20) and (21). The weight of each junction
box is approximately 32 kg (71 lb). Reposition junction boxes (20) and (21).

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12/29/22, 10:50 AM SIS 2.0

Illustration 11 g06149170
12. Remove bolts (24) and lock-bars (25). Use two people or a suitable lifting device to remove low voltage collector rings (23). The weight of low
voltage collector rings (23) is approximately 72 kg (159 lb). Remove low voltage collector rings (23).

Collector Rings Inspection

1. Check the insulators for cracks or chipping and replace promptly if damaged.
Note: Verify that the screws securing the rings to the insulators do not protrude beyond the countersunk holes of the rings.

2. Inspect the collector rings and shoes frequently for grease and contaminant accumulations on the rings, shoes, insulators, and incoming
wires.
Note: The lubricated collector ring shoe should be replaced when the thickness of the center portion wears down to 6.35 mm (0.25 inch). The
collector rings and shoes generally need to be replaced every 1 – 2 years.

Note: Clean the collector rings and related parts with an approved solvent regularly to prevent high potential grounds.

Note: Make sure that each shoe bears firmly against the collector ring.

Note: The shoes are spring-loaded to maintain constant contact.

3. Check the insulators for cracks or chipping and replace promptly if damaged.

4. Verify that the screws securing the rings to the insulators do not protrude beyond the countersunk holes of the rings.

Collector Rings Repair

Note: Repair of the collector rings involves replacement of damaged insulators or defective shoes. The collector ring life expectancy exceeds the
life expectancy of the machine.

1. To replace the insulators or shoes:

a. Disconnect electrical power to the machine.

b. Remove the attaching hardware securing the insulator or shoe to the mounting.

c. Access to the shoes mounted to the truck frame is obtained by entering the truck frame through the bottom access opening.

d. Install new insulators or shoes.

e. Make sure that all electrical leads are securely attached to the shoes and collector rings.

Installation Procedure
1. Verify that the machine is prepared for maintenance.

a. For (S/N: ER6, ER7, and ER8) machines refer to Testing and Adjusting Machine Preparation  for the correct procedure.

b. For (S/N: R3R and R3F) machines refer to Operation and Maintenance Manual Prepare the Machine for Maintenance  for the correct
procedure.

2. Install the low voltage collector rings in the reverse order of removal.

a. Apply Tooling (A) to the threads of bolts (17) and nuts (16).

PIP-10254417
2022/12/29
13:50:08-03:00
i06875447
© 2022 Caterpillar Inc.

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12/29/22, 10:50 AM SIS 2.0

Caterpillar:
Confidential Green

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