Publication Number: 352-503001-00A

Publication Date: April, 1998

Instruction Manual

Brushless AC Rectified DC
Traction Alternator

Includes:
General Description
Installation and Operation
Maintenance and Troubleshooting
Repair/Replacement

Kato Engineering
P.O. Box 8447
Mankato, MN 56002-8447
(507) 625-4011
Fax (507) 345-2798
 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 THIS
MANUAL IN ITS ENTIRETY BEFORE PROCEEDING. FAILURE TO OBSERVE THIS
PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE.

DANGER

THE USER IS RESPONSIBLE FOR CONFORMING TO THE NATIONAL ELECTRIC

CODE 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 CIRCUITS

TO BE EXPOSED. STAY CLEAR IF UNIT MUST BE RUNNING OR DISCONNECT AND
LOCKOUT AND TAG POWER SOURCE IF CONTACT MUST BE MADE. FAILURE TO
OBSERV THESE PRECAUTIONS COULD RESULT IN SEVER BODILY INJURY OR
LOSS OF LIFE.

WARNING
WHEN LIFTING THIS UNIT, DO NOT PULL AT AN ANGLE ON LIFTING EYES. THE
LIFTING EYES ARE FOR THE UNIT ONLY AND NOT FOR THE COMPLETE SET.
ALWAYS USE SPREADER BARS WHEN LIFTING THE UNIT. FAILURE TO OBSERVE
THESE PRECAUTIONS COULD RESULT IN BODILY INJURY.
 TABLE OF CONTENTS

SECTION CONTENT PAGE

1 INTRODUCTION & DESCRIPTION 1

INTRODUCTION 1
GENERAL DESCRIPTION 1
CONSTRUCTION 1

2 INSTALLATION 2
PRE-INSTALLATION 2
INSTALLATION 2
ELECTRICAL MEASUREMENTS 2
ELECTRICAL CONNECTIONS 3

3 OPERATION 5
PRE-OPERATION CHECKS 5
INITIAL START-UP 5
PREVENTITIVE MAINTENANCE 5

4 MAINTENANCE 8
TRACTION ALTERNAOR REMOVAL 8
ASSEMBLY TO PRIME MOVER 8
PRELIMINARY CHECKS 12
INITIAL START UP 12
PREVENTATIVE MAINTENANCE 12

5 DISASSEMBLY 14

6 SPEED SENSOR 18

7 TROUBLESHOOTING 19

8 REPLACEMENT PARTS 21
SECTION 1
INTRODUCTION AND
DESCRIPTION
INTRODUCTION

This manual contains instructions for installation,

operation, maintenance, and assembly/disassembly
of Kato AC Rectified DC Traction Alternator. (Genera-
tor).

Electrical connection drawings, dimensional drawings,

and parts listings for specific model, type and serial
number are contained as supplementary information
in a separate excerpt of the alternator manual. These Figure 1-1
drawings are the official source of information for Wound Frame and stator
making electrical connections or ordering replacement
parts. The alternator rotor consists of the shaft, spider, field
poles and windings.
GENERAL DESCRIPTION
The shaft is machined from a high strength steel
The Kato Traction Alternator is a single bearing, eight forging.
pole, synchronous alternator with a brushless exciter.
The spider is laminated with individual dovetails
The alternator is cooled by an external electrically punched to anchor the field poles. The spider lamina-
driven blower supplied by others. tions are held under pressure and riveted.

The multi-circuited alternator windings supply DC The poles are individually punched laminations which
output through parallel rectifier assemblies (not by are held together with bolts. The field windings use
Kato). insulated copper wire which are layered wound on the
The rectifier assembly is mounted in the terminal box poles. The wound poles are anchored to the spider
on top of the alternator. with two tapered keys. “V” shaped blocks are placed
between adjacent field windings and are bolted to the
spider. The entire spider and pole winding assembly is
CONSTRUCTION vacuum pressure impregnated with 100% epoxy resin.

The basic alternator includes frame and stator, rotor, The rotor assembly is shrunk and keyed on the shaft.
AC to DC rectifier assembly (not by Kato) and Two balancing rings are bolted to each end of the field
bearing. pole coil support shelves.

Frame and Stator Bearing

The alternator stator core is built of laminated electri- The bearing housing is packed with grease and
cal grade steel. Laminations are secured under requires no periodic lubrication. The bearing should be
pressure and clamped to steel endrings. The alterna- repacked or inspected during major overhauls. The
tor frame is fabricated from steel bars welded to the bearing housing is insulated to prevent the flow of
end rings. The feet are welded to the frame to simplify stray shaft currents.
installation and alignment with the prime mover. Lifting
eyes are welded to the frame to enable lifting of the
entire alternator. Windings are inserted into the stator
slots and the entire assembly is vacuum pressure
impregnated with 100 percent epoxy resin (see Figure
1-1). The phase leads are brought out to standard
connection lugs which are fastened to the main AC/ Figure 1-3
DC rectifier assembly. Ball Bearing
1
SECTION 2 Inspection

INSTALLATION The alternator is carefully inspected and operationally

tested before leaving the factory and is shipped
assembled and serviced for operation. However, before
PREINSTALLATION installing the machine, it is good practice to thor-
oughly inspect the unit for signs of damage or poten-
The Kato alternator is carefully packed and palletized tial malfunction.
for shipment and can withstand most shocks incurred
during transit. Before accepting shipment for the Long-Term Storage
transportation company, examine the pallet carefully
to determine if any damage has occurred during Alternators that must be stored for more than six
shipment. If necessary, unpack the unit, determine months or are stored in adverse conditions should be
the extent of the damage, and immediately notify the prepared for storage by installing desiccant bags
transportation company claims office and Kato inside the outboard end bell and vacuum sealing the
Engineering. Be sure to give complete and accurate unit in a covering of plastic or other material designed
details when reporting damage. for that purpose. The unit should be tagged to ensure
that desiccant bags are removed before the unit is
Unpacking and Storage placed in operation.
If the alternator is received during cold weather, let the Grease used in ball bearings is subject to deteriora-
unit stabilize to room temperature before removing the tion. If the alternator is stored for one year or more, it
protective packing material. This precaution will is recommended that new ball bearings be installed
minimize the condensation of moisture on coil and greased to the proper level before being put into
surfaces, eliminating the possibility of wet windings operation. If inspection reveals the bearings to be in
and insulating materials. good condition (free of rust or corrosion), replacement
is not necessary .
Unpack the alternator with care to avoid scratching
painted surfaces or otherwise damaging the unit. NOTE
Move the unit to the mounting location either by Ball bearings should be inspected in place. Do not
attaching an overhead hoist to the lifting eyes in- reuse a bearing that has been removed for inspec-
stalled on the top of the alternator frame or by lifting tion.
the alternator from underneath the skid with a forklift.
Care must be taken not to damage accessory INSTALLATION
equipment mounted in the vicinity of the lifting eyes.
Installation of the alternator will require careful adjust-
WARNING ment. Follow the prime mover manufacturers special
Apply lifting force to structural points specifically instructions for alignment and mounting.
provided for that purpose. DO NOT USE enclosure
lifting holes to lift the whole unit. Use lifting ELECTRICAL MEASUREMENTS
means adequate for the weight. Failure to observe
these instructions can result in injuries to person- NOTE
nel and damage to the alternator. Insulation Resistance test should be conducted
before any power connections are made.
Short-Term Storage (less than six months)
In the event the alternator was subjected to rapid
If the alternator is not to be installed in its operating change in temperature, or freezing or wet climate
location as soon as received, it should be stored in a during storage, it is recommended that the insulation
clean, dry area, not subject to sudden changes in resistance of the windings be checked. A hand
temperature or humidity. Although the equipment can cranked megger of not over 500 volts is a convenient
safely withstand non-operating temperature ranging method. The minimum insulation resistance value at
from -65 to +165 degrees fahrenheit, storage at room 104 degrees fahrenheit (40 degrees centigrade)
temperature is recommended. should not be less than one megohm. For megger
reading conversion to 40 degrees centigrade see
Figure 2-1.

2
Exciter Field Generator Rotor Winding

a) Disconnect the exciter leads from the terminal a) Disconnect the alternator field leads from the
strip. rotating rectifier assembly.

b) Connect exciter leads to one clamp of 500 volt b) Connect the alternator field leads to one clamp of
megger and connect the other clamp to alternator 500 volt megger and connect the other clamp to the
frame. shaft.

c) Apply 500 volts form the megger and measure the c) Record the megohm reading after one minute of
resistance reading after one minute. The minimum applying 500 volts. Minimum reading
reading should be 1.0 megohm. If not, refer to drying should be 1.0 megohm. If not, refer to dry-out
method. procedures.

Generator Stator Drying Methods

lf the exciter field insulation resistance shows If the insulation fails to meet the minimum value
unacceptable megohm reading proceed with the specified previously, the windings may be dried out by
following test: heat from a warm air oven, heat lamps, or strip
heaters.
a) Disconnect all alternator leads from the rectifier
assembly. When oven drying, use a forced air circulating type,
not a radiant type. The temperature of windings
b) Connect one phase at a time (Al, A2, A3, A4) with should not exceed 93 degrees centigrade (200
phases isolated to one clamp of 500 volt megger and degrees fahrenheit).
connect the other clamp to the alternator frame.
The insulation resistance drops rapidly at first as the
c) Apply 500 volts from the megger and measure the winding heats up, rises slowly as moisture is re-
resistance reading after one minute. The minimum moved, and then levels off when winding is dry.
reading should be: Winding temperature should be raised gradually at a
rate of 10 degrees centigrade per hour.
Resistance
in megohm= Rated voltage of machine +1000 ELECTRICAL CONNECTIONS
1000
To minimize the transmission of vibration it is essen-
If not, refer to dry-out procedures. tial that flexible conduits be used for all electrical
connections to the alternator. Be sure that electrical
service conforms to the ratings on the nameplate.
Exciter Armature Torque all connections to the following values:

a) Disconnect the exciter armature leads from Bolt Size Torque

therotating rectifiers. 1/4" 65 in. Ibs.
5/16" 130 in. Ibs.
Caution 3/8" 372 in. lbs.
Do not megger the rotating rectifier 1/2" 600 in. Ibs.
assembly.

b) Connect the exciter armature leads to one clamp of

500 volt megger and connect the
other clamp to the exciter sleeve tubing.

c) Record the megohm reading after one minute of

applying 500 volts. Minimum reading
should be 1.0 megohm. If not, refer to dry-out
procedures.

3
 Figure 2-1
Chart for Converting Megger Readings
to 40 Degrees Centigrade

4
SECTION 3 ambient temperature. Make sure that hot air dis-
charged from the alternator is not recirculating to the
OPERATION intake of the alternator.

Recheck all exposed bolts (including mounting bolts)

PRE-OPERATION CHECKS and retorque.
After the alternator is installed and wired, and before PREVENTIVE MAINTENANCE
operating for the first time, perform the following
checks: The following information is presented only as a guide
and does not purport to cover every contingency
a) Double-check all wiring against the connection which may occur under local operating conditions.
diagrams. Inspect rectifier assembly, make sure all
connections are tight and leads in place and in good Preventive maintenance should include routine checks
condition with proper labels. of: cleanliness, lubrication, bearing temperature,
vibration. For more detail, see section 4.
b) Check all mounting bolts for proper torque.
Daily
c) Make certain no restrictive material or objects are
lodged in the alternator. Remove desiccant bags if a) Check for overheating (unusual radiant heat,
unit has been in long-term storage. Place all covers discoloration and smoke).
and guards that have been removed and all safety
devices are functional. b) Check for unusual noise or vibration.
INITIAL START-UP Periodic
WARNING Every three months or 2000 hours of accrued operat-
ing time, whichever comes first. If the equipment is
BEFORE RUNNING MACHINE, MAKE SURE subjected to excessive moisture, heat or dust, the
GUARDS, SHIELDS, AND SCREENS PROVIDED schedule for cleaning and inspection should be
ARE PROPERLY INSTALLED. FAILURE TO OB- shortened. Check for clogged air intakes, loose
SERVE THESE PRECAUTIONS COULD RESULT IN cables and bolts, and excessive dirt build up.
SEVERE BODILY INJURY OR LOSS OF LIFE.
Cleaning
The alternator has been test run at the factory.
However, after rebuild or any type of servicing proceed Proper maintenance of electrical equipment requires
cautiously, possibility of errors and omissions always periodic visual examination of the machine and
exist. windings and appropriate electrical and thermal
checks. Insulation surfaces should be examined for
Start the alternator slowly and check for proper cracks and accumulations of dirt and dust to deter-
direction of rotation. mine required action. Lower than normal insulation
resistance can be an indication that conductive
Bring alternator to normal operating speed and during contaminant is present. The contaminant may be
the first minutes check for excessive noise, vibration carbon, salts, metal dusts, or virtually any dirt satu-
or bearing temperature. High vibration, noise or rated with moisture. These contaminants develop a
temperature calls for immediate shut down. conductive path to produce shorts or grounds with
subsequent failure. Cleaning is also advisable if heavy
During the first 50 hours of operation check for accumulations of dirt and dust can be seen, or are
vibration with and without load. A slight increase with suspected to be restricting ventilation as manifested
load and temperature is normal. However, the vibration by excessive heating. With no visual, electrical, or
levels should stabilize after 2-3 hours. thermal evidence that dirt is present, routine cleaning
should not be initiated since more harm than good
Check for bearing temperatures. A properly operating may result. If harmful dirt accumulations are present, a
ball or roller bearing should not operate above 200 variety of cleaning techniques are available. The one
degrees fahrenheit (93 degrees centigrade) as mea- selected will depend on:
sured at the bearing housing. A common cause of
high bearing temperature is over greasing or high

5
(1) The extent of the cleaning operation to be under- However, solvents may carry contamination, such as
taken. conductive dusts, metals, salts and carbon, into
cracks and crevices. Removal of contamination from
(2) The type, rating, and insulation structure of the such inaccessible areas is virtually impossible. A
machine involved. solvent dampened cloth is the preferred cleaning
method rather than the direct application of liquids.
(3) The type of dirt to be removed. Extreme care should be taken when using solvents
both with the respect to the equipment and the
Field Service Cleaning-Assembled personnel. Environmental concerns, the disposal of
Machines. waste products, the possibility of damage to the
insulation, and the health and safety hazards for the
Where cleaning is required at the installation, and worker should be considered when selecting a solvent.
complete disassembly of the machine is unnecessary Adequate ventilation and protective gear, such as a
or not feasible, dry dirt, dust, or carbon should first be dust mask, glasses and gloves, should be used during
picked up by a vacuum cleaner to prevent the redistri- equipment cleaning. Of course, equipment should not
bution of the contaminant. A small nonconductive be cleaned when energized.
nozzle or tube connected to the vacuum cleaner may Note: These cleaning instructions are taken from the
be required to reach dusty surfaces or to enter into I.E.E.E. Guide for Insulation Maintenance, Stan-
narrow openings. After most of the dust has been dard Number 432-1992 which should be referenced
removed, a small brush can be affixed to the vacuum for further information.
nozzle to loosen and allow removal of dirt more firmly
attached. If cleaning requires complete disassembly of the unit,
After the initial cleaning with vacuum, compressed air or is beyond the ability of the customer, Kato Engi-
(not to exceed 30 lb/in2) may be used to remove the neering can clean and service the unit. Contact our
remaining dust and dirt. parts and service department.
An exhaust must be provided so that dirt will be
removed from the machine. Indiscriminate blowing Lubrication
may produce mechanical unbalance of an armature or
rotating field by redistribution of dirt. Bearings are sealed for life, but should beperiodically
Compressed air used for cleaning should be clean and inspected.
free of moisture or oil. Air pressure or velocity should Occasional checks of bearing temperature during
be adequately controlled to prevent mechanical operation will give indication of the bearing condition.
damage to the insulation. Disassembly of the machine Bearing housing temperature should not exceed 63
and more effective cleaning by a qualified service shop degrees fahrenheit (35 degrees centigrade) rise over
may be required if the previously described field the ambient air temperature. Bearings can operate at
service cleaning procedures do not yield effective 200 degrees fahrenheit (95 degrees centigrade), but
results. once overheating occurs, this limit may be exceeded
rather quickly and the problem should be identified
Service Shop-Disassembled Machines. and remedied immediately.

An initial insulation-resistance reading should be taken The basic cause of bearing overheating is excessive
on the machine to check electrical integrity. (See friction caused by the following conditions.
section 4.4) A zero reading may indicate an insulation
breakdown requiring repair, not just cleaning. 1) Contamination of grease/wrong kind of grease.
The "steam-jenny" method of cleaning, which sprays a
high-velocity jet of hot water and water containing a 2) Insufficient/too much grease.
mild detergent, is normally effective in cleaning
windings including those subjected to flooding or salt 3) Excessive thrust due to misalignment.
contamination. The detergent spray is followed by
multiple sprays with clean water to remove or dilute 4) Pounding caused by worn balls or bearing being
the detergent. Water immersion with multiple rinses loose on the shaft.
and changes of water may also be used to remove
contamination. The machine should then be dried (low- 5) Bearing failure caused by fatigue or wear.
temperature oven may be used) until normal insulation
resistance values are obtained at room temperature. A bearing replacement program is recommended to
Solvents are effective for removing oil or grease and reduce the possibility of unexpected shutdown due to
may be required if water or detergent is not adequate. bearing failure. Under normal conditions and proper

6
lubrication this replacement should be during a major
overhaul. If the alternator is removed from service,
inspect the bearing for grease contamination, metal
particles in the grease, excessive wear in the bearing
housing, and fatigue damage on balls or balls path.

Vibration Check

Take vibration measurements on the bearing housing

at start-up after the first 2000 hours of operation and
once a year thereafter. Normal vibration readings
should not exceed .006 inches (peak to peak) mea-
sured in any direction. Any significant change in
vibration from previous readings should be investi-
gated.

Insulation Resistance Check

Periodic checks of winding insulation should be made

on a yearly basis. A record of insulation resistance
should include temperature humidity and a brief
description of the winding condition at the time of the
check. If data shows any large changes from previous
readings, a careful winding inspection should be
made.

Winding Resistance Checks

The alternator winding resistance should not change

during its life except for minor variations due to
temperature. Use a suitable meter for the range of
resistance of interest.

7
SECTION 4 TOTAL INDICATOR READING SHOULD NOT
EXCEED .003 INCH PER EACH FOOT OF
MAINTENANCE DIAMETER OF FLYWHEEL AND BELL HOUSING,
SEE TABLE 4-1. If reading exceeds the allowable
limit, excessive vibration could result. Contact the
TRACTION ALTERNATOR REMOVAL prime mover manufacturer for recommendations.

With power module removed from vehicle, remove

alternator as follows:

NOTE: Alternator removal, with the power module

installed in the vehicle, may be possible. Consult
vehicle manufacturer’s service manual for proper
procedure.

CAUTION: Power leads must be disconnected.

WARNING
ENSURE LIFTING DEVICE HAS SUFFICIENT
CAPACITY TO LIFT ALTERNATOR ASSEMBLY.
ALTERNATOR ASSEMBLY WEIGHT IS 8600
POUNDS.

1. Remove screen cover from housing and remove Figure 4-1

twenty-four 5/8"-11 bolts securing alternator flex Typical Single Bearing Generator-Engine Coupling
plates to engine flywheel.

2. Connect lifting device to lifting eyes on alternator

frame.

3. With lifting device in place, take weight off of

alternator engine mounting bracket so the eight 1"
bracket bolts and sixteen 5/8" flywheel housing
adapter bolts can be removed. Care must be taken
taken to support the rotor to avoid damage to the drive
plates.

4. Remove alternator from power module and remove

shims from coupling adapter or mounting flange if
installed.

5. Move alternator to disassembly area.

ASSEMBLY TO PRIME MOVER

See Figure 4-1 for typical method of coupling single

bearing alternator to prime mover. The alternator and
prime 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 of

the prime mover flywheel and flywheel housing (bell
housing) with a dial indicator as shown in Figures 4-2
and 4-3. Table 4-2
Allowable Flywheel & Disc Recess Runout

8
 A. Push rotor towards engine end.Place a
parallel steel bar across alternator frame face
and with a depth gauge, measure
distance between coupling face and alterna-
tor frame face. Obtain four readings 90° apart
and note average reading. This total is the
“alternator dimension”.

Figure 4-3
Checking Engine Flywheel Housing Runout

Figure 4-2
Checking Flywheel Run-out

Installation of alternator will require careful adjustment. 3. Check distance between engine flywheel and
Shims will be installed between alternator flexplates flywheel housing adapter. In order to obtain an accu-
and coupling hub. This adjustment prevents the rate dimension, use the following steps:
possibility of a pre-load on engine crankshaft and
alternator bearing. Install the alternator assembly on A. Center the crankshaft end play, place a
the power module as follows: parallel steel bar across the flywheel housing
adapter face and with a depth gauge, mea
WARNING sure distance between engine flywheel flex
ENSURE LIFTING DEVICE HAS SUFFICIENT plate and flywheel housing adapter face.
CAPACITY TO LIFT ALTERNATOR ASSEMBLY. Obtain four readings 90° apart and note
ALTERNATOR ASSEMBLY WEIGHT IS 8600 average reading. This average reading is
POUNDS. “engine dimension”.

1. Attach a magnetic base dial indicator to alternator 4. Shim Selection

frame face and set pointer on coupling adapter ma-
chined surface, adjust dial indicator to zero. Move A. If alternator dimension exceeds “engine
rotor in each direction as far as it will go and measure dimension” shims must be removed between
total travel. alternator drive plates and coupling hub.
Shim thickness to be removed will be the
CAUTION: If end play is other than .010 to .045, difference between “alternator dimension” and
disassemble and correct. “engine dimension” with an allowable toler
ance of .005 inch.
2. Check distance between alternator frame face and
alternator coupling face. In order to obtain an accurate B. If “engine dimension” exceeds “alternator
dimension, use the following steps: dimension”, flex plate coupling shims must
be added between alternator flex plate and

9
 Figure 4-4
Single Bearing Generator Drive Plate and Adaptor

Figure 4-5
SAE Flywheel
10
 Table 4-2
Recommended Torque SAE 5 Steel and SAE Steel cap Screws

alternator coupling hub. Shim thickness will

be the difference between “engine dimension”
and “alternator dimension” with an allowable
tolerance of .005 inch.

C. If “engine dimension” equals “alternator

dimension”, no change is required.

5. Connect lifting device to lifting eyes on alternator

frame, lift and move alternator into alignment with
engine.

6. Install sixteen 1/2-13 bolts, coated with anti-seize

compound,securing alternator to engine flywheel
housing 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 flywheel
housing, securing flywheel flex plate to alternator
coupling adapter. Torque in a star pattern to 170 lb ft.
Install access hole plug to engine fIywheel housing. Figure 4-6
Checking Generator Shaft Run-out
8. Install eight 1"-8 bolts coated with anti-seize
compound, securing alternator to power module.
Torque to 480 lb ft.

9. Use lock-washers on all bolts used to secure the

11
alternator to engine and base. Use recommended torque 2. After 50 hours of operation, all exposed bolts
values for each type of cap screws given in Table 4-2. (including mounting bolts) should be re-torqued.

10. Before installing any covers, check runout of the

alternator shaft. Check run-out by placing the base of DIODE REPLACEMENT
the dial indicator on the alternator frame rib end
positioning the indicator finger on the shaft as shown in The diodes can be accessed through the cover
Figure 4-6. Total shaft run-out should not exceed .003 plate on the bottom of the alternator. The rotor
inch. If this figure is exceeded, rotate shaft so that high will have to be rotated to reach all of the dides.
readig is on top. Loosen bolts attaching drive plates to
flywheel, allowing the high spot to "settle". Recheck PREVENTIVE MAINTENANCE
runout. If the .003 figure is still exceeded, remove drive
disc bolts and rotate alternator relative to the engine Please refer to the maitenance manual provided under
flywheel. Reinstall bolts and check runout again. seperate cover.

PRELIMINARY CHECKS

Before initial start-up, perform the following preliminary

checks:

1. Check all mounting bolts for proper torque.

2. Check brush installation.

3. Check for proper installation of guards and safety

devices at any hazardous location. Make sure all
covers are in place.

4. Check cable labeling. Make sure all leads are in

good condition.

CAUTION: After assembly of alternator or when

placing in service, proceed cautiously, even though the
best installation instructions and practices are fol-
lowed. Possibilities of errors or omissions always
exist.

WARNING
BEFORE RUNNING MACHINE, MAKE SURE
GUARDS, SHIELDS, SCREENS PROVIDED ARE
PROPERLY INSTALLED.

INITIAL START-UP

The traction alternator has been test run at the factory.

However, after rebuild or initial start-up, perform the
following recommended procedures:

1. Start traction alternator slowly and under as light a

load as possible; bring traction alternator to normal
operating speed During this time, constantly check for
unusual sound or excessive vibration.

12
Figure 4-7 Cut Away View Of Traction Alternator

13
SECTION 5,
DISASSEMBLY
TRACTION ALTERNATOR

Utilization of a clean work area around alternator will

enable workers to keep parts clean and in proper order
for reassembly. Keep in mind that many parts go back
together in reverse order of disassembly. Use wooden
blocks, pallets or skids for storing.

1. Rotating Field Assembly Removal FIGURE 5-1

All interference objects boxes, pumps, leads, etc.

must be removed prior to rotating field removal.

A. Rotating field assembly is removed with alternator

in horizontal position from opposite drive plate end.

B. Remove covers (A ), (B) (4) & (C) as shown in figure

5-4.

C. Disconnect auxillary leads in box (A). They leads ACCESS COVER

tie wraps must be removed. Tie wraps on exciter frame
can be accessed through access cover panels (B) and
(C). Pull the bearing RTD wire (H) through the acess
hole. See figures 5-1 & 5-4.

D. The speed sensor can be accessed through the

bottom access cover as shown in figure 5-2. Remove FIGURE 5-2
the speed sensor and the tie wraps securing the
speed sensor wire to the excitor frame. Place out of
the way inside the stator.

E. Remove the eight bolts (D) holding the exciter

frame to the endbell. Push the exciter back, it will rest
on the exciter armature. See figure 5-3.

FIGURE 5-3

14
 C

F E
H

B
D

FIGURE 5-4

15
F. Remove the bolts holding the bearing cap (G) to the
endbell. Remove the bearing cap, carefully remove the
rubber seal, inspect and set it aside, Remove the wavy
washers and set aside. See figure 5-6.

FIGURE 5-6

F. Support the endbell from the top with a strap and

remove the 12 bolts holding the endbell to the alterna-
tor frame. Push the endbell off using 2 pusher bolts, 1
top and 1 bottom. Move endbell aside. See figure 5-7.

NOTE: At this point the bearing can be removed or

the entire rotor floated out depending on your need.

G. To remove the bearing, remove the bearing snap

ring in front of the bearing. Slide rear bearing cap FIGURE 5-7
backwards to allow clearance to the bearing. Use a
bearing puller to pull bearing.

H. Anytime a bearing is pulled, it must be replaced. To

install a new bearing, heat it to 250o F. Push it onto
shaft flush against the rear bearing snap ring.

I. Fill the bearing with a good quality grease.Kato

Engineering recomends Mobilith SHC 220. Peak
grease in bearing caps as shown in figure 5-9.

J. To remove the rotor, 2 hoists will be needed. Place a

nylon starp over the bearing end of the shaft. An
aadptor will be needed to support the driveplate end of
the shaft. It should be similar to the examples shown if
figures 5-10. The dimensions for this adaptor can be
FIGURE 5-8

16
taken from the hub layout drawing in the drawings
section of this manual. Attach a pipe to the adaptor
tool and support it with a hoist. Carefully remove rotor
as shown in figure 5-11.

FIGURE 5-9

FIGURE 5-10

FIGURE 5-11

17
SECTION 6
Speed Sensor Installation
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 sensor
tip and gear teeth. (see below figure)

18
Section 7
Troubleshooting
Troubleshooting is the process of recognizing malfunctions of the system, intelligently analyzing the
malfunction, and necessary corrections to place the unit back into operation. Be alert for any signs of alternator
trouble. Common symptoms are listed in the following chart. Correct minor problems immediately. Minor defects
left uncorrected can cause serious damage.

SYMPTOM PROBABLE CAUSE REMEDY

No voltage from generator. Excitation lead open, Check for continuity. Check
shorted or grounded to F1 and F2 for ground.
frame. Replace damaged lead if
necessary.
Short circuit on output. Disconnect load leads from
plus and minus terminals of
the output rectifier assembly.
If voltage is normal check for
short or ground in the load. If
no voltage, disconnect the
generator leads of the
rectifier assembly and check
for short or ground in
generator leads. If the
generator windings are
normal, check the generator
winding field.
Field coils shorted or open. Check for short or open
circuit in the generator field.
See instructions to access
the rotating rectifier
assembly. Disconnect the
generator field leads from
the rotating rectifier
assembly to check the
generator field winding.
No excitation to the Check the output of the
generator. regulator at F1 and F2.
Refer to system manual for
regulator operation.

19
 SYMPTOM PROBABLE CAUSE REMEDY
Low voltage from generator. Excessive load. Reduce load.
High resistance connections Check connections at the
(connections will be warm or rectifiers. Tighten
hot). connections to the
recommended torques.
Weak field due to high Improve ventilation.
temperature.
Excitation circuit not Refer to system manual for
Fluctuating voltage from functioning properly. regulator operation.
generator with constant
sp e e d . Defective bearing causing Replace bearing
uneven air gap.
High voltage from generator. Excitation circuit not Refer to system manual for
functioning properly. regulator operation.
Overspeed. Correct speed of prime
mover.
Overheating Generator over loaded. Reduce load.
Blocked ventilation Clear air passages.
p a ssa g e s.
Dirty Windings. Clean Windings.
High Ambient temperature. Improve circulation to lower
heat build up.
Vibration Improper mounting or Correct Alignment. Refer to
misalignment of coupling. Prime movers instructions.
Defective bearing. Replace bearing.
Rotor out of balance after Re-balance with cooling fan
repair. in place.
Vibration caused by other Check other equipment.
equipment.
Rotor out of balance due to Check for overspeed
winding failure. condition. Repair or replace
rotor, including re-balance if
necessary.

20
Section 8
Replacement Parts
Replacement parts must be of the same physical
construction and have the same operating characteris-
tics as parts installed in the alternator at the factory.
Do not attempt to substitute “similar” parts. Order
parts by part name and part number. As additional
information, always include the order number, the
alternator serial number and the alternator and exciter
type and model numbers. For fastest service direct
parts order to:

KATO ENGINEERING,
Parts and Service Department,
P. O. Box 8447, Mankato, Minnesota 56001
or call (507) 625-4011
FAX. (507)-345-2798

21
LME Standard
LME Standard
LME High
LME High
EH
EH