GEAR-SUN 3P3059 - Caterpillar

Generator Set: 3456 GEN SET (S/N: C1G1-1079; C3G1-701; C4G1-537; C2T1-292) 3406C GEN SET (S/N: C2G1-1523; C5G1-669; C8G1-251) C18 GEN SET (S/N: G4C1-1267) C9 GEN SET (S/N: C9E1-128)Engine: C15 (S/N: C5L1-125)Electric Power Generation: SR4B (S/N: G6B1-959)Introduction
This Special Instruction will provide instructions for the replacement of the exciter rotor for the LC6 frame generators.
Personal injury or death can result from high voltage.When power generation equipment must be in operation to make tests and/or adjustments, high voltage and current are present.Improper test equipment can fail and present a high voltage shock hazard to its user.Make sure the testing equipment is designed for and correctly operated for high voltage and current tests being made.When servicing or repairing electric power generation equipment:
Make sure the unit is off-line (disconnected from utility and/or other generators power service), and either locked out or tagged DO NOT OPERATE.
Remove all fuses.
Make sure the generator engine is stopped.
Make sure all batteries are disconnected.
Make sure all capacitors are discharged.Failure to do so could result in personal injury or death. Make sure residual voltage in the rotor, stator and the generator is discharged.
If the generator that is to be repaired is equipped with the permanent magnet generator (PMG) option, then refer to the "Remove PMG" section of this document first for information to remove the PMG.LC6 Exciter Rotor Removal
Isolate the generator set before any work on the unit is begun. Activate all required emergency stops. Open the generator set breaker. Disconnect the battery cables. Ensure that all health and safety requirements are adhered to at all times.
Remove the generator exciter end bracket (36). Refer to Illustration 1.
Illustration 1 g01426073
Alternator Break Down (1) Main Stator Assembly (4) Main Rotor Assembly (21) Lifting Ring (36) Exciter End Shield (37) Exciter End Shield Mounting Bolts (48) Top Cover (51) Air Intake Grill (70) Exciter End Bearing (71) Cover (72) Bearing Retainer Ring Mounting Bolts (78) Bearing Retainer Ring (79) Preload Washer (90) Exciter Stator (100) Exciter Rotor (343) Diode Bridge Assembly (347) Varistor (349) O Ring (365) Rear Cover (366) Side Cover (367) Side Cover
Remove the air intake grill (51) .
Illustration 2 g01433670
(51) Air Intake Grill
Remove the lid of the protective cover (48). Remove the side panels (366) and (367) .
Illustration 3 g01433827
(21) Lifting Hook (48) Top Cover (71) Cover on Exciter End Shield (365) Rear Cover (366) Side Cover
Remove the hook (21). Remove the rear cover panel (365) .
Install the hook (21) onto the exciter end bracket (36). The hook will allow a means to manipulate the bracket (36) during removal.
Remove the main rotor shaft cover (71) that is on the exciter end shield.
Disconnect the exciter wires (5+) and (6-) .
Illustration 4 g01434494
Cable Straps Near AVR Terminal (36) Exciter End Shield (60) Cable Straps (67) Exciter Stator Leads
A paper or cardboard type shim should be installed between the main rotor (4) and the main stator (1) windings in order to protect the stator and rotor windings.
Attach a suitable lifting device to the hook (21) .
Remove the two mounting bolts (72) for the bearing retainer ring (78) that