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PreparatorySteps
WARNING
Toreducethepossibilityofpropertydamage
andpersonalinjuryfromelectricalshock,make
certaintheunitisisolatedfromallvoltage
sources.
WARNING
Batteriescanemitexplosivegases.Toreduce
thepossibilityofpersonalinjury,always
ventilatethecompartmentbeforeservicingthe
batteries.Toreducethepossibilityofarcing,
removethenegative()batterycablefirstand
attachthenegative()batterycablelast.
Disconnectthebatteriesorairsupplylinetotheair
startertopreventaccidentalenginestarting.
Remove
Thenondriveendbracketmustberemovedin
ordertoreplacethebearingonallframesizes.
Removethenondriveendaccesscover,the
terminalboxsides,lid,andsupportbrackets.
Removethepermanentmagnetexciterstatorand
rotor.
Donotpryonthegeneratorfantorotatethe
engine.Thefanbladescanbeeasilybentand
broken.Theentiregeneratorrotormustbe
disassembledtoreplacethegeneratorfan,if
damaged.
WARNING
Toreducethepossibilityofpropertydamage
andpersonalinjuryfromelectricalshock,make
certaintheunitisisolatedfromallvoltage
sources.
DisconnectexciterleadsXandXXaswellasP2,
P3,andP4attheauxiliaryterminalblock.
Bringtheleadsbackintothenondriveend
bracket.
Loosenthefourinnercapscrewsthatholdthe
bearinghousingcaptothebearingcartridgefirst.
Itisdifficulttokeepthebearingcartridgefrom
rotatingifthefouroutercapscrewshavebeen
removed.
Removethefouroutercapscrewsthatholdthe
bearingcartridgeorinnerbearingcaptotheend
bracket.
WARNING
Thiscomponentweighs23kg[50lb]ormore.
Toreducethepossibilityofpersonalinjury,use
ahoistorgetassistancetoliftthiscomponent.
Removeallthecapscrewsthatholdthenondrive
endbrackettotheframe.
Threadtwoofthecapscrewsintothejackingholes
intheendbrackethorizontalcenterline.Screw
thesecapscrewsintopulltheendbracketpilot
fromthelocatingrecessinthemaingenerator
frame.
Taptheendbracketlightlywhileturningthe
jackingscrewsin.Checktomakesurethebearing
cartridgeisnotstuckintheendbracket.
CAUTION
Themainexciterstatorisattachedtotheend
bracketandcomesoutwhentheendbracketis
removed.Useextremecarenottodamagethe
mainexciterstatorastheendbracketis
removed.
WARNING
Thiscomponentweighs23kg[50lb]ormore.
Toreducethepossibilityofpersonalinjury,use
ahoistorgetassistancetoliftthiscomponent.
Theendbracketmustbesupportedasitis
removedfromthebearingcartridge.
Removethecapscrewsthatholdthebearingcap
tothebearingcartridge.
Removethebearingcap.
Removethelargesnapringfromthegenerator
shaft.
CAUTION
Usetwoormoreflatwashersoraspacer
betweenthepullerandtheendoftheshaftto
avoiddamagingthethreadsintheendofthe
shaft.
Useapullertoremovethebearing.
Presstheoldbearingfromthebearingcartridge.
Theouterraceofthebearingislightlypressedinto
thebearingcartridge.Removethebearingouter
race.
CleanandInspectforReuse
WARNING
Whenusingsolvents,acids,oralkaline
materialsforcleaning,followthemanufacturers
recommendationsforuse.Weargogglesand
protectiveclothingtoreducethepossibilityof
personalinjury.
WARNING
Wearappropriateeyeandfaceprotectionwhen
usingcompressedair.Flyingdebrisanddirtcan
causepersonalinjury.
Cleanthebearingcapandbearingcartridgeusing
solvent.
Drythecomponentswithcompressedair.
Inspectthebearingcartridgeandbearingcapsfor
cracks,fretting,orothersignsofdamage.
Ifdamageispresent,replacethebearingcartridge
caps.
Install
Pack27ml[1fluidoz]oftherecommended
lubricantintothebearingandputthesame
amountoflubricantintothebearingcartridgeand
endcap.
Sealedbearingsarealsoanoption.
CAUTION
Wheninstallingthebearinginthecartridge,
pressontheouterraceofthebearingtoavoid
damagingthebearing.
WARNING
Toreducethepossibilityofpersonalinjury,use
insulatedglovestohandlethehotbearing
cartridge.
Heatthebearingcartridgeinanovento100C
[212F]for1hour.
Pressthebearingintothebearingcartridge.
NOTE:Themaximumoventemperatureshould
notexceed120C[248F]
Heatthebearingcartridge,withbearingsinstalled,
inanovento100C[212F]for2hours.
Applyathincoatingofcleanengineoiltothe
generatorshaft.
WARNING
Toreducethepossibilityofpersonalinjury,use
insulatedglovestohandlethehotbearing
cartridge.
Useinsulatedglovestoinstallthebearingontothe
shaft.Quicklypushthebearingontotheshaftuntil
itseatsagainsttheshaftshoulder.Thebearing
mustslideontheshaftandbeseatedwithout
excessiveforce.
CAUTION
Applypressuretoonlytheinsideraceofthe
bearing.Applyingpressuretotheouterbearing
racewilldamagethebearing.
Ifthebearingbindsontheshaftbeforebeingfully
seated,usealengthofpipewithaninside
diameterslightlylargerthattheshaftdiameterto
drivethebearingagainsttheshaftseat.Apply
pressuretotheinnerraceofthebearingonly.
Installthesnapringontotheshaftnexttotheinner
bearingrace.
Makesurethesnapringisseatedinthegroove.
Installthebearingcap.
NOTE:Makesurethattheendplugofthethree
wireharnesswhichisattachedtothe
permanentmagnetexciterstator,andis
throughtheendbracketandtheharnessis
retainedbytheinternalwireclamp.The
harnessisdifficulttoinstallwhentheend
bracketisonthegenerator.
Installtheendbracketontothebearingcartridge.
WARNING
Thiscomponentweighs23kg[50lb]ormore.
Toreducethepossibilityofpersonalinjury,use
ahoistorgetassistancetoliftthiscomponent.
Placeaslingaroundtheexcitermountingsurface
andlifttheendbracketandrotortopilottheend
bracketintothegeneratorframerecess.
Installtheendbracketcapscrews.
Taptheendbracketwithadeadblowhammeras
thecapscrewsaretightened
TorqueValue:60n.m[45ftlb]
Alignthebearingcartridgethreadedcapscrew
holeswiththeholesintheendbracketbyturning
thebearingcap.Thebearingcartridgewillrotatein
theendbracket.
Installandtightenthebearingcartridge
capscrews.
TorqueValue:45n.m[35ftlb]
Pullthemainexciterleads(XandXX)andthe
permanentmagneticexciterstatorleads(P2,P3,
andP4)throughtheholeintheframeterminal
box.
Connecttheleadstothecorrespondingterminals
ontheauxiliaryterminalblock.
Installthepermanentmagneticexciter.
Installthenondriveendaccesscover,theterminal
boxsides,lid,andsupportbrackets.
FinishingSteps
WARNING
Batteriescanemitexplosivegases.Toreduce
thepossibilityofpersonalinjury,always
ventilatethecompartmentbeforeservicingthe
batteries.Toreducethepossibilityofarcing,
removethenegative()batterycablefirstand
attachthenegative()batterycablelast.
Connectthebatteriesorairsupplylinetothe
airstarter.
LubricationforthePowerComponents
CAUTION
Greasingofthealternatorbearingsmustonly
takeplacewhenthegeneratorsetisin
operation.Greasingthebearingsonastatic
(nonrunning)alternatorcandamagethe
bearingcartridgeseals.
Thebearinggreasetypeandsuppliermust
alwaysbeconfirmedbycheckingthealternator
dataplate,beforethebearingsareserviced.
CAUTION
Checkthatthegreasegunnozzleandbearing
lubricationfittingsarefreefromcontaminants
beforebeginningthelubricationprocess.
Failuretodosocanallowcontaminantstobe
injectedintothebearing,whichcancause
prematurebearingfailure.
Withthegeneratorsetoperating,pumpthe
specifiedamountofgreaseintothebearings.
NOTE:Theaveragegreasegunexpels
approximately1gramperstroke.
GreaseVolumeSpecifications
Maintenance
AlternatorModel
DriveEnd NonDriveEnd
Frame7All
89grams
Frame8All
140grams 100grams
DIG130All
80grams
75grams
80grams
Clean
Internal
CAUTION
Toreducethepossibilityofpersonalinjury,the
generatorsetmustbeshutdownandthe
alternatorisolatedfromanyvoltagesource
beforeopeninganyalternatoraccessdoors.
NOTE:Greasingthebearingswiththe
generatorsetoperatingallowstheoldgrease
andexcessgreasetopurgefromthebearing
cartridgethroughinternalvents.The
terminationoftheinternalventscandifferby
alternatormanufacturerandmodel.
Thenondriveendbearinginternalventlocationis
shownintheillustration.Thedriveendinternal
ventissimilar.
Removeanyoldorexcessgreasepurgedfromthe
bearingduringthelubricationprocessbyopening
thealternatorsidepanelsandwipingthecollected
greasefromtheaffectedinternalventareas.
Additionalgreasecanpurgeaftercleaningthe
internalventareas,ifthealternatorhadnot
achievednormaloperatingtemperatureduringthe
lubricationprocess.
External
NOTE:Greasingthebearingswiththe
generatorsetoperatingallowstheoldgrease
andexcessgreasetopurgefromthebearing
cartridgethroughexternalvents.The
terminationoftheexternalventscandifferby
alternatormanufacturerandmodel.
Alternatorswithexternalbearingventsdonot
needtohavethegeneratorsetshutdownforthe
removalofpurgedgrease.
Removeanyoldorexcessgreasepurgedfromthe
bearingduringthelubricationprocessfromthe
affectedexternalventareas.
Additionalgreasecanpurgeaftercleaningthe
externalventareas,ifthealternatorhadnot
achievednormaloperatingtemperatureduringthe
lubricationprocess.
LastModified:20Nov2006
Copyright20002010CumminsInc.Allrightsreserved.