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Instruction Manual
Brushless AC Rectified DCTraction Alternator
Publication Number: 352-503001-00APublication Date: April, 1998
Includes:General Description
Installation and OperationMaintenance and Troubleshooting
Repair/Replacement
P.O. Box 8447Mankato, MN 56002-8447(507) 625-4011Fax (507) 345-2798
Kato Engineering
DANGER
ONLY QUALIFIED PERSONNEL FAMILIAR WITH THE CONSTRUCTION AND OPERA-TION OF THIS EQUIPMENT AND THE HAZARDS INVOLVED SHOULD INSTALL,
ADJUST, OPERATE AND/OR SERVICE THIS UNIT. READ AND UNDERSTAND THISMANUAL IN ITS ENTIRETY BEFORE PROCEEDING. FAILURE TO OBSERVE THISPRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE.
DANGER
THE USER IS RESPONSIBLE FOR CONFORMING TO THE NATIONAL ELECTRICCODE AND ALL OTHER APPLICABLE LOCAL CODES. WIRING, GROUNDING, DIS-
CONNECTS, AND OVERCURRENT PROTECTION ARE PARTICULARLY IMPORTANT.FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY
INJURY OR LOSS OF LIFE.
DANGER
SUBSEQUENT STEPS REQUIRE ROTATING PARTS AND/OR ELECTRICAL CIRCUITSTO BE EXPOSED. STAY CLEAR IF UNIT MUST BE RUNNING OR DISCONNECT ANDLOCKOUT AND TAG POWER SOURCE IF CONTACT MUST BE MADE. FAILURE TO
OBSERV THESE PRECAUTIONS COULD RESULT IN SEVER BODILY INJURY ORLOSS OF LIFE.
WARNINGWHEN LIFTING THIS UNIT, DO NOT PULL AT AN ANGLE ON LIFTING EYES. THELIFTING EYES ARE FOR THE UNIT ONLY AND NOT FOR THE COMPLETE SET.
ALWAYS USE SPREADER BARS WHEN LIFTING THE UNIT. FAILURE TO OBSERVETHESE PRECAUTIONS COULD RESULT IN BODILY INJURY.
SECTION
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CONTENT
INTRODUCTION & DESCRIPTIONINTRODUCTIONGENERAL DESCRIPTIONCONSTRUCTION
INSTALLATIONPRE-INSTALLATIONINSTALLATIONELECTRICAL MEASUREMENTSELECTRICAL CONNECTIONS
OPERATIONPRE-OPERATION CHECKSINITIAL START-UPPREVENTITIVE MAINTENANCE
MAINTENANCETRACTION ALTERNAOR REMOVALASSEMBLY TO PRIME MOVERPRELIMINARY CHECKSINITIAL START UPPREVENTATIVE MAINTENANCE
DISASSEMBLY
SPEED SENSOR
TROUBLESHOOTING
REPLACEMENT PARTS
TABLE OF CONTENTS
4
5
6
7
8
1
SECTION 1INTRODUCTION ANDDESCRIPTION INTRODUCTION
This manual contains instructions for installation,operation, maintenance, and assembly/disassemblyof Kato AC Rectified DC Traction Alternator. (Genera-tor).
Electrical connection drawings, dimensional drawings,and parts listings for specific model, type and serialnumber are contained as supplementary informationin a separate excerpt of the alternator manual. Thesedrawings are the official source of information formaking electrical connections or ordering replacementparts.
GENERAL DESCRIPTION
The Kato Traction Alternator is a single bearing, eightpole, synchronous alternator with a brushless exciter.
The alternator is cooled by an external electricallydriven blower supplied by others.
The multi-circuited alternator windings supply DCoutput through parallel rectifier assemblies (not byKato).The rectifier assembly is mounted in the terminal boxon top of the alternator.
CONSTRUCTION
The basic alternator includes frame and stator, rotor,AC to DC rectifier assembly (not by Kato) andbearing.
Frame and Stator
The alternator stator core is built of laminated electri-cal grade steel. Laminations are secured underpressure and clamped to steel endrings. The alterna-tor frame is fabricated from steel bars welded to theend rings. The feet are welded to the frame to simplifyinstallation and alignment with the prime mover. Liftingeyes are welded to the frame to enable lifting of theentire alternator. Windings are inserted into the statorslots and the entire assembly is vacuum pressureimpregnated with 100 percent epoxy resin (see Figure1-1). The phase leads are brought out to standardconnection lugs which are fastened to the main AC/DC rectifier assembly.
Figure 1-1 Wound Frame and stator
The alternator rotor consists of the shaft, spider, fieldpoles and windings.
The shaft is machined from a high strength steelforging.
The spider is laminated with individual dovetailspunched to anchor the field poles. The spider lamina-tions are held under pressure and riveted.
The poles are individually punched laminations whichare held together with bolts. The field windings useinsulated copper wire which are layered wound on thepoles. The wound poles are anchored to the spiderwith two tapered keys. “V” shaped blocks are placedbetween adjacent field windings and are bolted to thespider. The entire spider and pole winding assembly isvacuum pressure impregnated with 100% epoxy resin.
The rotor assembly is shrunk and keyed on the shaft.Two balancing rings are bolted to each end of the fieldpole coil support shelves.
Bearing
The bearing housing is packed with grease andrequires no periodic lubrication. The bearing should berepacked or inspected during major overhauls. Thebearing housing is insulated to prevent the flow ofstray shaft currents.
Figure 1-3 Ball Bearing
2
SECTION 2INSTALLATIONPREINSTALLATION
The Kato alternator is carefully packed and palletizedfor shipment and can withstand most shocks incurredduring transit. Before accepting shipment for thetransportation company, examine the pallet carefullyto determine if any damage has occurred duringshipment. If necessary, unpack the unit, determinethe extent of the damage, and immediately notify thetransportation company claims office and KatoEngineering. Be sure to give complete and accuratedetails when reporting damage.
Unpacking and Storage
If the alternator is received during cold weather, let theunit stabilize to room temperature before removing theprotective packing material. This precaution willminimize the condensation of moisture on coilsurfaces, eliminating the possibility of wet windingsand insulating materials.
Unpack the alternator with care to avoid scratchingpainted surfaces or otherwise damaging the unit.Move the unit to the mounting location either byattaching an overhead hoist to the lifting eyes in-stalled on the top of the alternator frame or by liftingthe alternator from underneath the skid with a forklift.Care must be taken not to damage accessoryequipment mounted in the vicinity of the lifting eyes.
WARNINGApply lifting force to structural points specificallyprovided for that purpose. DO NOT USE enclosurelifting holes to lift the whole unit. Use liftingmeans adequate for the weight. Failure to observethese instructions can result in injuries to person-nel and damage to the alternator.
Short-Term Storage (less than six months)
If the alternator is not to be installed in its operatinglocation as soon as received, it should be stored in aclean, dry area, not subject to sudden changes intemperature or humidity. Although the equipment cansafely withstand non-operating temperature rangingfrom -65 to +165 degrees fahrenheit, storage at roomtemperature is recommended.
Inspection
The alternator is carefully inspected and operationallytested before leaving the factory and is shippedassembled and serviced for operation. However, beforeinstalling the machine, it is good practice to thor-oughly inspect the unit for signs of damage or poten-tial malfunction.
Long-Term Storage
Alternators that must be stored for more than sixmonths or are stored in adverse conditions should beprepared for storage by installing desiccant bagsinside the outboard end bell and vacuum sealing theunit in a covering of plastic or other material designedfor that purpose. The unit should be tagged to ensurethat desiccant bags are removed before the unit isplaced in operation.
Grease used in ball bearings is subject to deteriora-tion. If the alternator is stored for one year or more, itis recommended that new ball bearings be installedand greased to the proper level before being put intooperation. If inspection reveals the bearings to be ingood condition (free of rust or corrosion), replacementis not necessary .
NOTEBall bearings should be inspected in place. Do notreuse a bearing that has been removed for inspec-tion.
INSTALLATION
Installation of the alternator will require careful adjust-ment. Follow the prime mover manufacturers specialinstructions for alignment and mounting.
ELECTRICAL MEASUREMENTS
NOTEInsulation Resistance test should be conductedbefore any power connections are made.
In the event the alternator was subjected to rapidchange in temperature, or freezing or wet climateduring storage, it is recommended that the insulationresistance of the windings be checked. A handcranked megger of not over 500 volts is a convenientmethod. The minimum insulation resistance value at104 degrees fahrenheit (40 degrees centigrade)should not be less than one megohm. For meggerreading conversion to 40 degrees centigrade seeFigure 2-1.
3
Exciter Field
a) Disconnect the exciter leads from the terminalstrip.
b) Connect exciter leads to one clamp of 500 voltmegger and connect the other clamp to alternatorframe.
c) Apply 500 volts form the megger and measure theresistance reading after one minute. The minimumreading should be 1.0 megohm. If not, refer to dryingmethod.
Generator Stator
lf the exciter field insulation resistance showsunacceptable megohm reading proceed with thefollowing test:
a) Disconnect all alternator leads from the rectifierassembly.
b) Connect one phase at a time (Al, A2, A3, A4) withphases isolated to one clamp of 500 volt megger andconnect the other clamp to the alternator frame.
c) Apply 500 volts from the megger and measure theresistance reading after one minute. The minimumreading should be:
Resistancein megohm= Rated voltage of machine +1000
1000
If not, refer to dry-out procedures.
Exciter Armature
a) Disconnect the exciter armature leads fromtherotating rectifiers.
CautionDo not megger the rotating rectifierassembly.
b) Connect the exciter armature leads to one clamp of500 volt megger and connect theother clamp to the exciter sleeve tubing.
c) Record the megohm reading after one minute ofapplying 500 volts. Minimum readingshould be 1.0 megohm. If not, refer to dry-outprocedures.
Generator Rotor Winding
a) Disconnect the alternator field leads from therotating rectifier assembly.
b) Connect the alternator field leads to one clamp of500 volt megger and connect the other clamp to theshaft.
c) Record the megohm reading after one minute ofapplying 500 volts. Minimum readingshould be 1.0 megohm. If not, refer to dry-outprocedures.
Drying Methods
If the insulation fails to meet the minimum valuespecified previously, the windings may be dried out byheat from a warm air oven, heat lamps, or stripheaters.
When oven drying, use a forced air circulating type,not a radiant type. The temperature of windingsshould not exceed 93 degrees centigrade (200degrees fahrenheit).
The insulation resistance drops rapidly at first as thewinding heats up, rises slowly as moisture is re-moved, and then levels off when winding is dry.Winding temperature should be raised gradually at arate of 10 degrees centigrade per hour.
ELECTRICAL CONNECTIONS
To minimize the transmission of vibration it is essen-tial that flexible conduits be used for all electricalconnections to the alternator. Be sure that electricalservice conforms to the ratings on the nameplate.Torque all connections to the following values:
Bolt Size Torque 1/4" 65 in. Ibs. 5/16" 130 in. Ibs. 3/8" 372 in. lbs. 1/2" 600 in. Ibs.
4
Figure 2-1 Chart for Converting Megger Readings
to 40 Degrees Centigrade
5
SECTION 3OPERATIONPRE-OPERATION CHECKS
After the alternator is installed and wired, and beforeoperating for the first time, perform the followingchecks:
a) Double-check all wiring against the connectiondiagrams. Inspect rectifier assembly, make sure allconnections are tight and leads in place and in goodcondition with proper labels.
b) Check all mounting bolts for proper torque.
c) Make certain no restrictive material or objects arelodged in the alternator. Remove desiccant bags ifunit has been in long-term storage. Place all coversand guards that have been removed and all safetydevices are functional.
INITIAL START-UP
WARNING
BEFORE RUNNING MACHINE, MAKE SUREGUARDS, SHIELDS, AND SCREENS PROVIDEDARE PROPERLY INSTALLED. FAILURE TO OB-SERVE THESE PRECAUTIONS COULD RESULT INSEVERE BODILY INJURY OR LOSS OF LIFE.
The alternator has been test run at the factory.However, after rebuild or any type of servicing proceedcautiously, possibility of errors and omissions alwaysexist.
Start the alternator slowly and check for properdirection of rotation.
Bring alternator to normal operating speed and duringthe first minutes check for excessive noise, vibrationor bearing temperature. High vibration, noise ortemperature calls for immediate shut down.
During the first 50 hours of operation check forvibration with and without load. A slight increase withload and temperature is normal. However, the vibrationlevels should stabilize after 2-3 hours.
Check for bearing temperatures. A properly operatingball or roller bearing should not operate above 200degrees fahrenheit (93 degrees centigrade) as mea-sured at the bearing housing. A common cause ofhigh bearing temperature is over greasing or high
ambient temperature. Make sure that hot air dis-charged from the alternator is not recirculating to theintake of the alternator.
Recheck all exposed bolts (including mounting bolts)and retorque.
PREVENTIVE MAINTENANCE
The following information is presented only as a guideand does not purport to cover every contingencywhich may occur under local operating conditions.
Preventive maintenance should include routine checksof: cleanliness, lubrication, bearing temperature,vibration. For more detail, see section 4.
Daily
a) Check for overheating (unusual radiant heat,discoloration and smoke).
b) Check for unusual noise or vibration.
Periodic
Every three months or 2000 hours of accrued operat-ing time, whichever comes first. If the equipment issubjected to excessive moisture, heat or dust, theschedule for cleaning and inspection should beshortened. Check for clogged air intakes, loosecables and bolts, and excessive dirt build up.
Cleaning
Proper maintenance of electrical equipment requiresperiodic visual examination of the machine andwindings and appropriate electrical and thermalchecks. Insulation surfaces should be examined forcracks and accumulations of dirt and dust to deter-mine required action. Lower than normal insulationresistance can be an indication that conductivecontaminant is present. The contaminant may becarbon, salts, metal dusts, or virtually any dirt satu-rated with moisture. These contaminants develop aconductive path to produce shorts or grounds withsubsequent failure. Cleaning is also advisable if heavyaccumulations of dirt and dust can be seen, or aresuspected to be restricting ventilation as manifestedby excessive heating. With no visual, electrical, orthermal evidence that dirt is present, routine cleaningshould not be initiated since more harm than goodmay result. If harmful dirt accumulations are present, avariety of cleaning techniques are available. The oneselected will depend on:
6
(1) The extent of the cleaning operation to be under-taken.
(2) The type, rating, and insulation structure of themachine involved.
(3) The type of dirt to be removed.
Field Service Cleaning-AssembledMachines.
Where cleaning is required at the installation, andcomplete disassembly of the machine is unnecessaryor not feasible, dry dirt, dust, or carbon should first bepicked up by a vacuum cleaner to prevent the redistri-bution of the contaminant. A small nonconductivenozzle or tube connected to the vacuum cleaner maybe required to reach dusty surfaces or to enter intonarrow openings. After most of the dust has beenremoved, a small brush can be affixed to the vacuumnozzle to loosen and allow removal of dirt more firmlyattached.After the initial cleaning with vacuum, compressed air(not to exceed 30 lb/in2) may be used to remove theremaining dust and dirt.An exhaust must be provided so that dirt will beremoved from the machine. Indiscriminate blowingmay produce mechanical unbalance of an armature orrotating field by redistribution of dirt.Compressed air used for cleaning should be clean andfree of moisture or oil. Air pressure or velocity shouldbe adequately controlled to prevent mechanicaldamage to the insulation. Disassembly of the machineand more effective cleaning by a qualified service shopmay be required if the previously described fieldservice cleaning procedures do not yield effectiveresults.
Service Shop-Disassembled Machines.
An initial insulation-resistance reading should be takenon the machine to check electrical integrity. (Seesection 4.4) A zero reading may indicate an insulationbreakdown requiring repair, not just cleaning.The "steam-jenny" method of cleaning, which sprays ahigh-velocity jet of hot water and water containing amild detergent, is normally effective in cleaningwindings including those subjected to flooding or saltcontamination. The detergent spray is followed bymultiple sprays with clean water to remove or dilutethe detergent. Water immersion with multiple rinsesand changes of water may also be used to removecontamination. The machine should then be dried (low-temperature oven may be used) until normal insulationresistance values are obtained at room temperature.Solvents are effective for removing oil or grease andmay be required if water or detergent is not adequate.
However, solvents may carry contamination, such asconductive dusts, metals, salts and carbon, intocracks and crevices. Removal of contamination fromsuch inaccessible areas is virtually impossible. Asolvent dampened cloth is the preferred cleaningmethod rather than the direct application of liquids.Extreme care should be taken when using solventsboth with the respect to the equipment and thepersonnel. Environmental concerns, the disposal ofwaste products, the possibility of damage to theinsulation, and the health and safety hazards for theworker should be considered when selecting a solvent.Adequate ventilation and protective gear, such as adust mask, glasses and gloves, should be used duringequipment cleaning. Of course, equipment should notbe cleaned when energized.Note: These cleaning instructions are taken from theI.E.E.E. Guide for Insulation Maintenance, Stan-dard Number 432-1992 which should be referencedfor further information.
If cleaning requires complete disassembly of the unit,or is beyond the ability of the customer, Kato Engi-neering can clean and service the unit. Contact ourparts and service department.
Lubrication
Bearings are sealed for life, but should beperiodicallyinspected.Occasional checks of bearing temperature duringoperation will give indication of the bearing condition.Bearing housing temperature should not exceed 63degrees fahrenheit (35 degrees centigrade) rise overthe ambient air temperature. Bearings can operate at200 degrees fahrenheit (95 degrees centigrade), butonce overheating occurs, this limit may be exceededrather quickly and the problem should be identifiedand remedied immediately.
The basic cause of bearing overheating is excessivefriction caused by the following conditions.
1) Contamination of grease/wrong kind of grease.
2) Insufficient/too much grease.
3) Excessive thrust due to misalignment.
4) Pounding caused by worn balls or bearing beingloose on the shaft.
5) Bearing failure caused by fatigue or wear.
A bearing replacement program is recommended toreduce the possibility of unexpected shutdown due tobearing failure. Under normal conditions and proper
7
lubrication this replacement should be during a majoroverhaul. If the alternator is removed from service,inspect the bearing for grease contamination, metalparticles in the grease, excessive wear in the bearinghousing, and fatigue damage on balls or balls path.
Vibration Check
Take vibration measurements on the bearing housingat start-up after the first 2000 hours of operation andonce a year thereafter. Normal vibration readingsshould not exceed .006 inches (peak to peak) mea-sured in any direction. Any significant change invibration from previous readings should be investi-gated.
Insulation Resistance Check
Periodic checks of winding insulation should be madeon a yearly basis. A record of insulation resistanceshould include temperature humidity and a briefdescription of the winding condition at the time of thecheck. If data shows any large changes from previousreadings, a careful winding inspection should bemade.
Winding Resistance Checks
The alternator winding resistance should not changeduring its life except for minor variations due totemperature. Use a suitable meter for the range ofresistance of interest.
8
SECTION 4MAINTENANCETRACTION ALTERNATOR REMOVAL
With power module removed from vehicle, removealternator as follows:
NOTE: Alternator removal, with the power moduleinstalled in the vehicle, may be possible. Consultvehicle manufacturer’s service manual for properprocedure.
CAUTION: Power leads must be disconnected.
WARNINGENSURE LIFTING DEVICE HAS SUFFICIENTCAPACITY TO LIFT ALTERNATOR ASSEMBLY.ALTERNATOR ASSEMBLY WEIGHT IS 8600POUNDS.
1. Remove screen cover from housing and removetwenty-four 5/8"-11 bolts securing alternator flexplates to engine flywheel.
2. Connect lifting device to lifting eyes on alternatorframe.
3. With lifting device in place, take weight off ofalternator engine mounting bracket so the eight 1"bracket bolts and sixteen 5/8" flywheel housingadapter bolts can be removed. Care must be takentaken to support the rotor to avoid damage to the driveplates.
4. Remove alternator from power module and removeshims from coupling adapter or mounting flange ifinstalled.
5. Move alternator to disassembly area.
ASSEMBLY TO PRIME MOVER
See Figure 4-1 for typical method of coupling singlebearing alternator to prime mover. The alternator andprime mover should be mounted on a rigid level base.
NOTE: Before assembling alternator to prime mover,remove blocking holding the drive discs to the adaptor.
Before mounting the alternator, check the run-out ofthe prime mover flywheel and flywheel housing (bellhousing) with a dial indicator as shown in Figures 4-2and 4-3.
TOTAL INDICATOR READING SHOULD NOTEXCEED .003 INCH PER EACH FOOT OFDIAMETER OF FLYWHEEL AND BELL HOUSING,SEE TABLE 4-1. If reading exceeds the allowablelimit, excessive vibration could result. Contact theprime mover manufacturer for recommendations.
Figure 4-1Typical Single Bearing Generator-Engine Coupling
Table 4-2Allowable Flywheel & Disc Recess Runout
9
Installation of alternator will require careful adjustment.Shims will be installed between alternator flexplatesand coupling hub. This adjustment prevents thepossibility of a pre-load on engine crankshaft andalternator bearing. Install the alternator assembly onthe power module as follows:
WARNINGENSURE LIFTING DEVICE HAS SUFFICIENTCAPACITY TO LIFT ALTERNATOR ASSEMBLY.ALTERNATOR ASSEMBLY WEIGHT IS 8600POUNDS.
1. Attach a magnetic base dial indicator to alternatorframe face and set pointer on coupling adapter ma-chined surface, adjust dial indicator to zero. Moverotor in each direction as far as it will go and measuretotal travel.
CAUTION: If end play is other than .010 to .045,disassemble and correct.
2. Check distance between alternator frame face andalternator coupling face. In order to obtain an accuratedimension, use the following steps:
A. Push rotor towards engine end.Place aparallel steel bar across alternator frame faceand with a depth gauge, measuredistance between coupling face and alterna-tor frame face. Obtain four readings 90° apartand note average reading. This total is the“alternator dimension”.
3. Check distance between engine flywheel andflywheel housing adapter. In order to obtain an accu-rate dimension, use the following steps:
A. Center the crankshaft end play, place aparallel steel bar across the flywheel housingadapter face and with a depth gauge, measure distance between engine flywheel flexplate and flywheel housing adapter face.Obtain four readings 90° apart and noteaverage reading. This average reading is“engine dimension”.
4. Shim Selection
A. If alternator dimension exceeds “enginedimension” shims must be removed betweenalternator drive plates and coupling hub. Shim thickness to be removed will be thedifference between “alternator dimension” and“engine dimension” with an allowable tolerance of .005 inch.
B. If “engine dimension” exceeds “alternatordimension”, flex plate coupling shims mustbe added between alternator flex plate and
Figure 4-2Checking Flywheel Run-out
Figure 4-3Checking Engine Flywheel Housing Runout
10
Figure 4-4Single Bearing Generator Drive Plate and Adaptor
Figure 4-5SAE Flywheel
11
alternator coupling hub. Shim thickness willbe the difference between “engine dimension”and “alternator dimension” with an allowabletolerance of .005 inch.
C. If “engine dimension” equals “alternatordimension”, no change is required.
5. Connect lifting device to lifting eyes on alternatorframe, lift and move alternator into alignment withengine.
6. Install sixteen 1/2-13 bolts, coated with anti-seizecompound,securing alternator to engine flywheelhousing adapter. Torque in a star pattern to 170 Lb.-ft.
7. Install twenty-four 5/8-11 bolts, coated with anti-seize compound, through access hole in flywheelhousing, securing flywheel flex plate to alternatorcoupling adapter. Torque in a star pattern to 170 lb ft.Install access hole plug to engine fIywheel housing.
8. Install eight 1"-8 bolts coated with anti-seizecompound, securing alternator to power module.Torque to 480 lb ft.
9. Use lock-washers on all bolts used to secure the
Table 4-2Recommended Torque SAE 5 Steel and SAE Steel cap Screws
Figure 4-6Checking Generator Shaft Run-out
12
alternator to engine and base. Use recommended torquevalues for each type of cap screws given in Table 4-2.
10. Before installing any covers, check runout of thealternator shaft. Check run-out by placing the base ofthe dial indicator on the alternator frame rib endpositioning the indicator finger on the shaft as shown inFigure 4-6. Total shaft run-out should not exceed .003inch. If this figure is exceeded, rotate shaft so that highreadig is on top. Loosen bolts attaching drive plates toflywheel, allowing the high spot to "settle". Recheckrunout. If the .003 figure is still exceeded, remove drivedisc bolts and rotate alternator relative to the engineflywheel. Reinstall bolts and check runout again.
PRELIMINARY CHECKS
Before initial start-up, perform the following preliminarychecks:
1. Check all mounting bolts for proper torque.
2. Check brush installation.
3. Check for proper installation of guards and safetydevices at any hazardous location. Make sure allcovers are in place.
4. Check cable labeling. Make sure all leads are ingood condition.
CAUTION: After assembly of alternator or whenplacing in service, proceed cautiously, even though thebest installation instructions and practices are fol-lowed. Possibilities of errors or omissions alwaysexist.
WARNINGBEFORE RUNNING MACHINE, MAKE SUREGUARDS, SHIELDS, SCREENS PROVIDED AREPROPERLY INSTALLED.
INITIAL START-UP
The traction alternator has been test run at the factory.However, after rebuild or initial start-up, perform thefollowing recommended procedures:
1. Start traction alternator slowly and under as light aload as possible; bring traction alternator to normaloperating speed During this time, constantly check forunusual sound or excessive vibration.
2. After 50 hours of operation, all exposed bolts(including mounting bolts) should be re-torqued.
DIODE REPLACEMENT
The diodes can be accessed through the coverplate on the bottom of the alternator. The rotorwill have to be rotated to reach all of the dides.
PREVENTIVE MAINTENANCE
Please refer to the maitenance manual provided underseperate cover.
13
Figure 4-7 Cut Away View Of Traction Alternator
14
SECTION 5,DISASSEMBLYTRACTION ALTERNATOR
Utilization of a clean work area around alternator willenable workers to keep parts clean and in proper orderfor reassembly. Keep in mind that many parts go backtogether in reverse order of disassembly. Use woodenblocks, pallets or skids for storing.
1. Rotating Field Assembly Removal
All interference objects boxes, pumps, leads, etc.must be removed prior to rotating field removal.
A. Rotating field assembly is removed with alternatorin horizontal position from opposite drive plate end.
B. Remove covers (A ), (B) (4) & (C) as shown in figure5-4.
C. Disconnect auxillary leads in box (A). They leadstie wraps must be removed. Tie wraps on exciter framecan be accessed through access cover panels (B) and(C). Pull the bearing RTD wire (H) through the acesshole. See figures 5-1 & 5-4.
D. The speed sensor can be accessed through thebottom access cover as shown in figure 5-2. Removethe speed sensor and the tie wraps securing thespeed sensor wire to the excitor frame. Place out ofthe way inside the stator.
E. Remove the eight bolts (D) holding the exciterframe to the endbell. Push the exciter back, it will reston the exciter armature. See figure 5-3.
ACCESS COVER
FIGURE 5-1
FIGURE 5-2
FIGURE 5-3
15
A
BD
EF
G
H
C
FIGURE 5-4
16
F. Remove the bolts holding the bearing cap (G) to theendbell. Remove the bearing cap, carefully remove therubber seal, inspect and set it aside, Remove the wavywashers and set aside. See figure 5-6.
F. Support the endbell from the top with a strap andremove the 12 bolts holding the endbell to the alterna-tor frame. Push the endbell off using 2 pusher bolts, 1top and 1 bottom. Move endbell aside. See figure 5-7.
NOTE: At this point the bearing can be removed orthe entire rotor floated out depending on your need.
G. To remove the bearing, remove the bearing snapring in front of the bearing. Slide rear bearing capbackwards to allow clearance to the bearing. Use abearing puller to pull bearing.
H. Anytime a bearing is pulled, it must be replaced. Toinstall a new bearing, heat it to 250o F. Push it ontoshaft flush against the rear bearing snap ring.
I. Fill the bearing with a good quality grease.KatoEngineering recomends Mobilith SHC 220. Peakgrease in bearing caps as shown in figure 5-9.
J. To remove the rotor, 2 hoists will be needed. Place anylon starp over the bearing end of the shaft. Anaadptor will be needed to support the driveplate end ofthe shaft. It should be similar to the examples shown iffigures 5-10. The dimensions for this adaptor can be
FIGURE 5-6
FIGURE 5-7
FIGURE 5-8
17
FIGURE 5-10
taken from the hub layout drawing in the drawingssection of this manual. Attach a pipe to the adaptortool and support it with a hoist. Carefully remove rotoras shown in figure 5-11.
FIGURE 5-9
FIGURE 5-11
18
1. Install sensor, shims, and 5/16-UNC bolts and lockwashers (X2). NOTE:BOLTS MUST BE NO LONGER THAN 1.50 INCH.
2. Install shims to achieve a 0.031 +/- 0.005 inch clearance between sensortip and gear teeth. (see below figure)
SECTION 6Speed Sensor Installation
19
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Section 7TroubleshootingTroubleshooting is the process of recognizing malfunctions of the system, intelligently analyzing themalfunction, and necessary corrections to place the unit back into operation. Be alert for any signs of alternatortrouble. Common symptoms are listed in the following chart. Correct minor problems immediately. Minor defectsleft uncorrected can cause serious damage.
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Section 8Replacement PartsReplacement parts must be of the same physicalconstruction and have the same operating characteris-tics as parts installed in the alternator at the factory.Do not attempt to substitute “similar” parts. Orderparts by part name and part number. As additionalinformation, always include the order number, thealternator serial number and the alternator and excitertype and model numbers. For fastest service directparts order to:
KATO ENGINEERING,Parts and Service Department,P. O. Box 8447, Mankato, Minnesota 56001or call (507) 625-4011FAX. (507)-345-2798
