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Modifications implemented after shipment from Kato Engineering are not represented in this documentation and are not supported by Kato Engineering. Kato Engineering, Inc. P.O. Box 8447 Mankato, MN USA 56002-8447 Tel: 507-625-4011 KatoEngineering@mail.nidec.com www.KatoEngineering.com Fax: 507-345-2798...
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Proximity Probe Transmitter Trendsetter Model TXR (Radial) and TXA (Axial) Specifi cations Unless otherwise noted, all specifi cations are specifi ed at 21°C (70°F), +24 Vdc power supply, gap set to 1.27 mm (50 mils) and using Metrix AISI 4140 steel target. Operating Temperature Range: -40°C to 85°C (-40°F to 185°F) Operating Humidity Range:...
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Proximity Probe Transmitter Trendsetter Model TXR (Radial) and TXA (Axial) Specifi cations (continued) Hazardous Area Ratings: Weight & Dimensions CSA Certifi ed: Intrinsically Safe Class • I, Div 1, Grps A, B, C & D, Temp Code T4. • CSA Certifi ed: Non-Incendive Class I, Div 2, Grps A, B, C &...
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Proximity Probe Transmitter Trendsetter Model TXR (Radial) and TXA (Axial) How to Select For Series 10000 and 7200 System System 4-20 mA Range* 4-20 mA Range* Probe Series Probe Series Length Diameter Length Diameter 3 mils, pk-pk 5 5 meters 0 5&8 mm 0 20 to 80 mils 5 5 meters...
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Proximity Probe Transmitter Trendsetter Model TXR (Radial) and TXA (Axial) Cross-Reference from 5465/5488 to Trendsetter TXR/TXA *For negative polarity, please add an “N” after the designated number for the Range. Example: TXA-729-31N www.metrix1.com • info@metrix1.com Vibration - Condition Monitoring Sales & Service Tel: 281-940-1802 • Fax: 281-940-1799 • REV A and Protection 1.23...
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3300 5mm Transducer Product Datasheet Bently Nevada* Asset Condition Monitoring Description Transducer System The 3300 5mm Proximity Transducer System consists of: 1, 2 a 3300 5mm probe a 3300 XL extension cable (ref 141194-01) 3, 4, 5 a 3300 XL Proximitor Sensor (ref 141194- When combined with a 3300 XL Proximitor...
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tip spacing requirements as compared to an XL individual component matching or bench 8mm probe. Use the 5mm probe when physical (not electrical) constraints preclude the use of an 8mm calibration. probe, such as mounting between thrust bearing pads or other constrained spaces. When your Proximity Probe application requires narrow sideview probes, use the 3300 XL NSv* probe and extension cable with...
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Specifications Resistance from the Center Conductor to the Probe Length (m) Outer Conductor (Ω) 8.73 ± 0.70 Unless otherwise noted, the following 9.87 ± 0.90 specifications are for a proximity transducer system between +18°C and +27°C (+64 °F to +80 °F) with a -24 Vdc power supply, a 10 kΩ...
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Performance Specification 155687 for signal rolloff Minimum Target Size at high frequencies when using longer field wiring 15.2mm (0.6 in) diameter (flat target). lengths or external safety barriers located some Shaft Diameter distance from the monitoring system. Linear Range Minimum 2mm (80 mils).
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Electrical Certification Complies with the European CE mark. Europe 3300 XL Hazardous Area Approvals II 1 G EEx ia IIC T4/T5. EC certificate number Proximitor BAS99ATEX1101, when installed per drawing Sensor, ia: 141092. Note: Multiple approvals for hazardous areas certified by II 3 G Ex nA II T4/T5. ...
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IEC Ex Hazardous Area Conditions of Safe IECEx BAS04.0055X Use: 3300 XL Proximitor Sensor, ia Ex ia IIC T4 (-51°C ≤ Ta ≤ +100°C) ATEX / T5 (-35ºC ≤ Ta ≤ +85ºC) Ui= -28VCi = 0 Follow the conditions of safe use included on the Terminal Block Connections Ii= 140mALi =10µH Declaration of Conformance sent with each...
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Mechanical Table 6: Recommended Torque Tightening Probe Tip Connector Type Polyphenylene sulfide (PPS) Instructions Material 2 3300 XL gold "click" type connectors Finger tight Probe Case AISI 303 or 304 stainless steel (SST) 1 non-XL stainless steel connector Finger tight plus 1/8 Material and 1 3300 XL connector turn using pliers...
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shipment. Contact our custom design department if a test of the pressure seal for your application is required. Note: It is the responsibility of the customer or user to ensure that all liquids and gases are contained and safely controlled should a proximity probe leak. In addition, solutions with high or low pH values may erode the tip assembly of the probe causing media to leak into surrounding areas. ...
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C: Total Length Option Ordering Information 05 0.5 metre (1.6 feet) 10 1.0 metre (3.3 feet) 20 2.0 metres (6.6 feet) For a detailed listing of country and product 50 5.0 metres (16.4 feet) specific approvals, refer to the Approvals Quick 90 9.0 metres (29.5 feet) Reference Guide (document 108M1756) located at D: Connector Option...
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D: Connector Option 3300 5mm Proximity Probes, Metric 01 Miniature coaxial ClickLoc connector with connector protector, standard cable 330173 3300 5mm Probe, M8 x 1 thread, 02 Miniature coaxial ClickLoc connector, standard cable without armor 11 Miniature coaxial ClickLoc connector with connector protector, FluidLoc cable 330174 3300 5mm Probe, M8 x 1 thread, 12 Miniature coaxial ClickLoc connector,...
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Connector Protectors 27474 -AXX 40180-03 Package containing 10 pairs of 75Ω Coaxial A: Thread size Connector Protectors. 02 1/4-28 75Ω Triaxial/95 ohm Coaxial Male Connector 03 M8 x 1 Protector 75Ω ClickLoc Connector Kit 03839410 Placed onto the extension cable; attaches to the female connector protector on the 5 mm probe to 330153-AA provide environmental protection of connectors.
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Graphs Figure 1: Typical 3300 5mm probe and 1 metre of cable at high and low temperatures (XL Proximitor Sensor and XL extension cable are at 25°C) Part Number: 172036 Rev. K (05/16) Page 12 of 16...
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Figure 2: 3300 5 metre XL Proximitor Sensor at high temperatures (3300 5mm probe and XL extension cable at 25° C) Part Number: 172036 Rev. K (05/16) Page 13 of 16...
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Dimensional Diagrams 1. Probe tip, 5.2mm [0,21 in] diameter 2. 11.1 mm [7/16in] for 1/4-28 threads, 13.0mm [0.51in] for M8 thread. See Note 3. 3. Case thread 4. 5.6 [7/32] wrench flats for 1/4-28 threads, 7.0 [0.28] for M8 threads 5.
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1. 12mm [0.40in] maximumd diameter 2. 36.3mm [1.43in] maximum 3. 51.1mm [2.01in] maximum 4. Connector protector (fluorosilicone material) Figure 4: Installed Connector Protectors 1. 7.2mm [0.25 in] maximum diameter 2. Miniature male coaxial connector 3. FEP or PFA coated armor. Armor length is 300mm [11.8in] less than cable length. See Note 5. 4.
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Notes: 1. All dimensions are in millimetres (inches) unless otherwise noted. 2. Standard mount 5mm probes supplied with 13 mm or 7/16-in lock nut. 3. Letters inside quotation marks refer to probe ordering options. 4. Stainless steel armor is supplied with FEP outer jacket for standard probes, PFA outer jacket for ETR probes. 5.
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Publication 350-11111-00 April 2012 Instruction Manual Water - to - Air Cooler Maintenance Kato Generators...
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Table of Contents Description Cleaning the Cooler Cooler Removal Cooler Installation Torque Chart...
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Figure 1 Typical Kato generator equipped with a water - to - air cooler...
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Description Air Cooler Assembly The air cooler assembly (water-to-air heat exchanger) is mounted on top of the gen- erator and may be positioned either vertically or horizontally. The air cooler extracts heat from the generator cooling air and transfers it to the water fl owing through heat exchanger tubes.
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Air Cooler Housing The air cooler housing is located on top of the generator and supports the water cooler and directs the air fl ow. Lifting eyes to remove the cooler are located on each corner. Water Boxes Water boxes are located on each end of the cooler and direct water between the tubes and the fl...
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Cleaning the Cooler Cleaning Deposits in the Water boxes and Tubes Light coatings of sludge or scale will cause a considerable reduction in heat transfer capability of the cooler and a greater drop in the tube side pressure. An indication of either of the above would normally indicate that cleaning is necessary.
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Cooler Removal This manual show a vertically posi- tioned cooler. Removal of a horizontally mounted cooler is basically the same. refer to the drawing section in your Shut off water to the cooler, and disconnect the water input and output lines from the Instruction Manual.
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In the examples shown, the drip tray is built into the cooler housing, and the cooler does not bolt to it. Refer to the specifi c drawings for you generator. Use safe lifting practices to avoid dam- age to the cooler or injury to personnel. See the cooler weight on your draw- ings or the cooler plate Figure 4...
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Use safe lifting practices to avoid dam- age to the cooler or injury to personnel. See the cooler weight on your draw- ings or the cooler plate Figure 5 Remove the fasteners that attach the cooler housing to the generator. Lifting points Figure 6 Remove the cooler housing.
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Cooler Installation Installation with the cooler in the cooler housing: In the examples shown, the drip tray Bolt in lifting eyes at all four corners of the cooler housing. Attach a chain to is built into the cooler cover, and the the lifting eyes, and set the cooler hood on top of the drip tray assembly.
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Instruction Manual Installation Operation Maintenance Standard AC Generator Single or Two-Bearing Drive-End Air Discharge Publication 350-01001-00 B (01-2019) Kato Engineering, Inc. P.O. Box 8447 Mankato, MN USA 56002-8447 Tel: 507-625-4011 KatoEngineering@mail.nidec.com www.KatoEngineering.com Fax: 507-345-2798...
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Please read this manual and all Publication Date Description included manuals in entirety before Revision unpacking, installing, and operating 350-01001-00 A November 2015 Original document. your generator. If your manual came 350-01001-00 B January 2019 Updated document format. on a CD, read all the files included on the CD.
Contents Introduction Foreword Safety Instructions Ratings/Description Construction and Operating Principles Stator Rotor Bearings Connection Boxes Excitation System Optional PMG System Other Options Installation Receiving Inspection Unpacking and Moving Location Base Design Assemble to Prime Mover Alignment Foot Deflection Doweling Electrical Connections Space Heaters Inspection Before Startup Operation...
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Figures Overview of Excitation System Flywheel Housing Check Flywheel Check Generator Adapter Check Generator Coupling Check Engine Coupling Check Alignment Check Rough Alignment Angular Alignment Parallel Alignment Generator Coupling Check Single Bearing Generator Drive Plate and Adaptor SAE Flywheel and Adapter Disc-to-Flywheel Installation Moving Sheet Metal Fans Runout Check...
Introduction Foreword This manual contains instructions for installing, operating and WARNING: Shock hazard—Do not maintaining Kato Engineering AC brushless revolving field generators. service the generator or other electrical These generators are manufactured in many sizes and ratings and with machinery without de-energizing and various options.
Construction and Operating Principles Stator The stator consists of the supporting frame, core, and armature windings. The stator core is made from laminations, thin sheets of electrical steel, which are stacked and held in place by steel endrings and support bars.
Power input Voltage regulator Output leads Main stator (armature) Exciter stato PMG stato (field) (armature) Main rotor (DC) Prime mover Shaft PMG rotor (field) Rectifier Exciter armature (AC) Figure 1 Overview of Excitation System Connection Boxes The main lead connection box houses the load lead terminals. In addition, the generator may have auxiliary connection boxes for connecting temperature detector outputs, space heater connectors, and sensing outputs.
Excitation system functional overview: Exciter field control is established by the strength of the exciter field current developed by the voltage regulator system. The DC voltage and current levels of the exciter field signal from the voltage regulator varies depending upon the generator output voltage and the loading of the output lines (see Figure 1).
Installation WARNING: Electric shocks can Receiving Inspection occur from faulty ground connections on Before accepting a shipment, examine the packaging for any sign of portable electrical equipment and failure damage that might have occurred during transit. Report any damage to to ground stationary equipment which the transportation company and Kato Engineering.
Assemble to Prime Mover Alignment This manual covers three alignment options. Follow the procedures that correspond to your generator model. If your generator model as two bearings but no adapter to bolt to an engine flywheel housing see Two-Bearing Alignment. If your generator model has two bearings and an adapter for bolting to a flywheel housing, see Two-Bearing Close-Coupled Alignment.
NOTE: TIR = Total indicator runout Table 1 Maximum Allowable Flywheel Housing Runout SAE Housing Housing Inside Allowable Runout Number Diameter (TIR) NOTE: Compensation for engine thermal Inch Inch growth must be taken into account on this measurement. 10.500 0.002 0.051 12.375 0.003...
NOTE: Mounting of the indicators must Check the generator adapter’s radial and face runout by mounting a allow complete rotation of the prime dial indicator on the generator shaft or coupling as shown in Figure 4. mover. The maximum radial and face runout on the generator adaptor must not exceed 0.010"...
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Install the portion of the coupling that fits into the engine flywheel following the manufacturer’s recommended procedures and in accordance with engine manufacturer’s specifications. Check the coupling’s radial and face runout by mounting a dial indicator to the engine flywheel housing as shown in Figure 6. The maximum radial and face runout on the coupling must not exceed 0.004"...
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Mount a dial indicator on the flywheel coupling to the face of the generator half coupling for angular alignment as shown in Figure 7. Align the engine by rotating the prime mover in 90° incre ments and measuring TIR (total indicator runout). Tighten the generator to the base before taking each set of readings.
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Two-Bearing Alignment Follow the tolerances specified by the coupling manufacturer when they are less than described in this manual. Use shims, if necessary, between the mounting pad and the base to properly level and align the generator to the prime mover. Install the coupling(s) on the generator and engine drive shafts in accordance with coupling manufacturer installation procedures.
Dial indicator Figure 9 Angular Alignment Parallel Alignment: Fasten a dial indicator to one of the coupling halves, and scribe the position of the dial button on the top of the opposite coupling half as shown in Figure 10. Rotate both shafts simultaneously, keeping the finger or button on the indicator at the reference mark on the coupling hub.
Single-Bearing Alignment Before assembling the generator to the prime mover, remove the exciter cover and adapter cover. Remove the blocking holding the drive discs to the adapter. Also make sure the generator bearing end clearance is not less than the total engine crankshaft axial movement plus 1/16"...
Measure the axial distance from the surface on the generator adapter to the outside surface on the drive disc coupling plates (dimension Y in Figure 12). This dimension is recorded on the Factory Recorded Dimensions sheet, which was packaged with the generator. If the dimensions do not match, move the rotor axially relative to the stator until the dimensions are equal.
Tapped bolt holes NOTE: Mounting of the indicators must allow complete rotation of the prime mover. Use dial indicators that are rigid so indicator sag won’t be a factor. Using the shortest offset distance of the indicator bracket will reduce the effects of indicator droop or sag.
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• With the three-frame units that have an aluminum fan, loosen the fan hub bolts to move the fan. After installing the drive disc-to-flywheel bolts, move the fan back so the rotor-side edge is flush with the air opening and the minimum distance between the windings and the fan is 3/8"...
After installing the drive disc-to-flywheel bolts, check the runout of the generator shaft by placing the base of a dial indicator on the generator frame and positioning of the probe on the shaft as shown in Figure 16. If the total indicated runout exceeds 0.003" (0.0762 mm), remove the drive discs bolts, and rotate the generator relative to the engine flywheel.
Foot Deflection After alignment, check for foot deflection or “soft foot” condition on each shim location to eliminate distortion of the generator frame. Do this by loosing one mounting bolt at a time and checking deflection after retightening. Deflection at the shim location from shims under compression to a loosened condition must not exceed 0.003"...
Inspection Before Startup After electrical connections have been made, perform the following checks: WARNING: Do not pry on the • Check all the connections to the electrical diagrams provided. generator fan blades. Blades can weaken • Secure all covers and guards. which could result in serious injury or death from flying debris.
Operation Initial startup Units with Automatic and Manual Voltage Control NOTE: Do not actuate the auto-manual 1. Disconnect the generator output from the load by opening the switch with the full load applied to the main circuit breaker. generator. Generator over-voltage will result which may cause damage to 2.
Restoring Residual Magnetism/Field Flashing The direct current necessary to magnetize the revolving field is obtained from the exciter. Upon starting the generator, current and voltage is induced into the exciter by the magnetic lines of force set up by residual magnetism of the exciter field poles. Residual magnetism of the exciter field poles may be lost or weakened by a momentary reversal of the field connection, a strong neutralizing magnetic field from any source, or non-operation for a long time.
Continuous Operation Operate the generator within the nameplate values. If the generator is NOTE: Operating the unit beyond operated below the rated power factor and voltage, decrease the kVA nameplate values may cause equipment to prevent overheating of the field and stator windings. Consult the damage or failure.
Idling Unless the voltage regulator has V/Hz protection built in, having the generator set in operating mode while idling the engine can cause permanent equipment damage. If engine adjustments require that the engine be run at idle speed and the regulator does not have V/Hz protection, make the generator regulating system inoperative during idling by one of the following methods: When the generator is provided with a voltage shutdown switch, be...
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System bus Load Synchronizing switch lamps Load lines from the incoming generator Figure 19 Synchronizing Paralleled Generators with Test Lamps If cross-current compensation is used, paralleling current transformers must give the same secondary current. Current transformer secondary windings provide reactive kVA droop signal to the voltage regulator.
Maintenance Schedules A regular preventive maintenance schedule will ensure peak performance, minimize breakdowns and maximize generator life. The schedule listed below is a guide for operating under standard conditions. Specific operating conditions may require reduced or increased maintenance intervals. Also, if there is a different or more specific schedule for your generator than the schedule provided below, it will be included as a supplement to the manual package.
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Every 20,000 Hours or 3 Years of Operation With generators that have sleeve oil bearings, perform a sleeve bearing inspection to include the removal of the upper bearing housing and bearing liner to inspect the liner, shaft journal, and seal surfaces for wear and scoring.
Maintenance Procedures Visual Inspection Methods of Windings Electric machines and their insulation systems are subjected to WARNING: Shock hazard—Do not mechanical, electrical, thermal and environmental stresses that give service the generator or other electrical machinery without de-energizing and rise to many deteriorating influences. The most significant of these are tagging the circuits as out of service.
Abrasion: Abrasion or contamination from other sources, such as chemicals and abrasive or conducting substances, may damage coil and connection surfaces. Cracking: Cracking or abrasion of insulation may result from prolonged or abnormal mechanical stress. In stator windings, looseness of the bracing structure is a certain sign of such phenomena and can itself cause further mechanical or electrical damage if allowed to go unchecked.
Insulation Resistance Tests at Low Voltage IMPORTANT: New generators should measure about 100 megohms of Insulation tests are conducted for two reasons: to discern existing insulation resistance when meggered. weakness or faults, or to give some indication of expected service Generators that read 50 megohms or reliability.
Main Rotor 1. Disconnect the generator field leads from the posi tive and Table 3 DC Voltage to be Applied negative terminals of the rotating rectifier assembly. During Insulation Resistance Tests 2. Connect the positive and negative leads to one clamp of the 500-volt Megger, and connect the other clamp to the shaft.
resistance values level off. Monitor winding temperatures. Raise winding temperature gradually at a rate of 10° to 20° F (5° to 10° C) per hour up to 200° F (93° C). Measure insulation resistance at 1-hour intervals. Typically, the insulation resistance will slowly drop while the temperature is coming up and then gradually increase and level out.
Ohmmeter: Connect the ohmmeter leads across the rectifier in one direction (see Figure 21). Note the meter reading. Reverse the leads, and note the meter reading. The meter should indicate a low resistance when the leads are across the rectifier in one direction and a high resistance when the leads are across the rectifier in the opposite direction.
Disassembly IMPORTANT: The following procedures are meant to be a general guide. Overall Disassembly Procedures for your unit may vary. 1. Remove the terminal box cover, and disconnect the load leads and all other leads. Tag the leads to ensure they are correctly WARNING: Ensure the generator connected when the generator is reassembled.
Exciter Armature and PMG Removal See Figure 24. 1. Remove the exciter cover. 2. Remove the retaining bolt and washer. 3. Disconnect the field wires on the rotating rectifier assembly. 4. To remove the PMG rotor, pull it off separately using hand force. Wrap the PMG rotor in plastic to avoid contamination with metal filings.
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Plate Hydraulic jack Threaded rod Exciter sleeve Figure 25 Pulling the Armature Assembly Locknut Lock washer and tab Figure 26 PMG Rotor with Locking Nut Page 39...
Bearing Removal 1. Remove the endbracket(s) to expose the bearing(s). 2. Use a puller to remove the bearing from the shaft end with a cap. If the bearing is going to be used again, make sure the puller supplies pressure only against the bearing inner ring. See Figure 27.
Assembly Bearing Installation Bearing is installed prior to installing the rotor. 1. Heat the bearing to 220° F (104° C) to 250° F (121° C) in a clean CAUTION: Make sure all oven or with an induction heater. components are clean before assembly. 2.
7. If the generator has a PMG, place it onto the end of the exciter sleeve. Make sure it is aligned with the pin slot in the end of the IMPORTANT: To measure air gap, exciter sleeve. measure completely around the gap between the exciter armature and exciter 8.
Storage NOTE: Grease used in ball and roller bearing generators is subject to If the generator is not installed in its operating location as soon as deterioration over time. Before placing received, store it in a clean, dry area, not subject to vibrations or the unit into service after long-term sudden temperature or humidity changes.
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NOTE: Torque values specified on drawings Table 5 Recommended ASTM and SAE Torque Values ASTM and SAE Torque Values supersede this generic table. Recommended lubricated torque values. (If no lubricant is used, increase values by 25%.) Specific Drawings, OMS, BOMS supercede this generic table. Grade 5 Grade 2 Grade 5...
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Metric Torque Values NOTE: Torque values specified on drawings Table 6 Recommended Metric Torque Values Recommended lubricated torque values. (If no lubricant is used, increase values by 25%.) supersede this generic table. Specific Drawings, OMS, BOMS supercede this generic table. Class 8.8 Class 4.8 to 6.8 Class 6.9 to 8.8...
Troubleshooting Guide Corrective Maintenance Between regular preventive maintenance inspections, be alert for any WARNING: Problems left signs of trouble. Correct any trouble immediately. See Table 7 for uncorrected can result in injury or serious symptoms, causes and remedies. damage, which can result in costly repairs and downtime.
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Symptom Cause Remedy Low voltage Shorted leads between Test and repair the exciter armature and generator field Incorrect stator Check the connections and reconnect connections. Improper adjustment of Adjust rheostat voltage adjust rheostat Excessive load Reduce load. With three-wire, single-phase and four-wire, three-phase generators, the load on each leg must be as evenly balanced as possible and must not exceed the rated current on any leg.
Symptom Cause Remedy Vibrations Defective or dry bearings Replace defective bearings Misalignment of generator Align the generator set and prime mover Generator not properly Check mounting. Correct defective mounting. mounted Transfer of vibration from Isolate the generator set from the source of vibration another source by installing vibration dampeners between generator set base and foundation.
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Exciter cover Exciter stator Lead connection Drip proof Rectifier cover Adapter Exciter armature Endbracket Rotor Coupling Stator windings Feet Bearing Figure 28 Main Part Location (Typical) Page 49...
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Kato Engineering Support The brand you trust, the power you depend on. Include the serial number and model number for your machine in the email subject line. Field Service KatoService@mail.nidec.com Manuals KatoManuals@mail.nidec.com Parts KatoParts@mail.nidec.com Remanufacturing KatoRemanufacturing@mail.nidec.com Warranty/Quality Assurance KatoWarranty@mail.nidec.com Kato Engineering, Inc.
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