SWITCH GP-ROCKER 3361845 - Caterpillar

Cleanliness
The inside and the outside if the generator should be kept free of dirt, oil, grease. water and other substances. If the generator vent passages become clogged, overheating and premature failure can occur.Connections
Check all connections to confirm that they are tight.Vibration
Excessive vibration or loose mounting hardware can damage the generator bearings, brushes and commutatorNoise
Listen for unusual or excessive noise, especially in the bearing area. Check for loose parts on the generator such as through bolts and mounting hardware.Lubrication and Bearings
The grease used in the generator bearings loses it's lubricating ability with time and use. The effective life of the lubricant depends on the following:1. Type of lubricant used2. Size of the bearing3. Operating speed of the bearing4. Operating conditionsRecommended generator bearing grease is:1. Shell Dolium R2. Chevron SRIRecommended intervals for generator bearing lubrication are:1. Generators 20KW and below, every 2 years2. Generators above 20KW, every yearLubrication Procedure
Keep hands, tools and all other equipment clear of the rotating machinery.1. Wipe the grease fitting clean before applying grease.2. Remove the grease outlet plug.3. Apply grease through the fitting until grease appears at the shaft hole or purge outlet.4. Run the generator for 10 minutes.5. Clean any excess grease from the outlet plug area and reinstall the plug.Brush Replacement
Do not change grades or the number of brushes per pole. Changing grades or the number of brushes per pole may void the warranty and/or cause unsafe conditions.Brush life will vary due to generator load conditions and the environment. The brush pigtail leads should be checked for a secure connection to the brush support stud. Brushes should be replaced when their pigtails touch the top of the brush holder.Brush Replacement
Brush Seating Procedure
1. Wrap a strip of coarse grit (#60) sandpaper, rough side out, around the commutator and under the brush holder. Do not use metal oxide based sandpaper or emery cloth that contains electrically conductive materials.2. Slide the new brush into the holder and snap the spring clip in place.3. Rotate the armature slowly in the direction of normal generator rotation.4. Remove the brush and inspect the face of the brush. The brush should be seated over 90% of the face area and completely seated from the leading to trailing edge.Brushes should move freely in their holders. If brushes stick, the cause is usually due to build up of dirt and oil. Brushes should be inspected regularly. Check for sufficient brush length. The brush should press firmly against the commutator Brush springs should have equal tension. Only brushes of the same size, grade and shape as those originally supplied should be used.All generators have their set on neutral before leaving the factory. After replacing the brush holder, realign it to the factory neutral mark.When replacing a turned-down commutator with a new commutator, the brush holder assembly must be adjusted. Maintain .062 (1/16") clearance between the bottom of the brush holder and the commutator. The brush holder assembly is designed with a nut/bolt guide assembly for ease in positioning the brush box.During regular inspections,