Alternator Service Guide

Introduction
Scheduled service and repair are vital to the operated in adverse or unusual environmental
reliable operation of your alternator and the conditions, the service intervals may need
safety of those who come in contact with it. to be more frequent. The alternator should
The service activities included in this guide be continually monitored between service to
are intended to maximise the life of the identify any potential failure modes, signs of
alternator, but will not vary, extend or change misuse, or excessive wear and tear.
the terms of the manufacturer’s standard
warranty or your obligations in that warranty.
Each service interval should be used as a
guide only, and developed on the basis that
the alternator was installed and is operated
in accordance with the manufacturer’s
guidelines. If the alternator is located and/or
Disclaimer
This guide contains guidance and
instructions for servicing and maintenance of
the alternator only.
Before operating the alternator, refer to the
Installation, Service and Maintenance manual
to make sure that all personnel who work on
the equipment have access to the manual
and all additional documentation supplied
with it. Misuse and failure to follow the
instructions, and the use of non-approved
parts, may invalidate the product warranty
and lead to potential accidents.
The manual is an essential part of the
alternator and should be available to all users
throughout its life.
Notice
This guide states service intervals and key Information in this guide was correct at time
components to inspect throughout the life of going to print. It may be superseded due
of the alternator. Refer to the full instructions to our policy of continuous improvement.
in the Installation, Service & Maintenance
manual when servicing the alternator.
Please visit:
This guide is written for skilled electrical
www.stamford-avk.com
and mechanical technicians and engineers,
for latest documentation.
who have prior knowledge and experience
of generating equipment of this type. If in
doubt, please seek expert advice or contact
your local Cummins Generator Technologies
subsidiary.
Safety Precautions
Safety Information and Notices General Guidance
Danger, Warning and Caution panels are used in this manual to describe the sources of hazards, their
consequences and how to avoid injury. Notice panels emphasize important or critical instructions.
NOTICE
These safety precautions are for general guidance and supplement your own safety procedures and all
applicable laws and standards.
DANGER
Danger indicates a hazardous situation which, if not avoided, WILL result in death or serious injury. Skill Requirements of Personnel
Service and maintenance procedures must only be carried out by experienced and qualified
WARNING engineers, who are familiar with the procedures and the equipment.

Warning indicates a hazardous situation which, if not avoided, COULD result in death or serious injury.
Risk Assessment
A risk assessment has been performed on this product by Cummins, however a separate risk
CAUTION
assessment must be performed by the user/operating company to establish all personnel-related
Caution indicates a hazardous situation which, if not avoided, COULD result in minor or risks. All affected users must be trained on the identified risks. Access to the Power PlanUGenerator
moderate injury.
Set during operation must be restricted to persons who have been trained on these risks.

NOTICE
Caution indicates a hazardous situation which, if not avoided, COULD result in minor or
moderate injury.
Personal Protective Equipment (PPE) Electrical Equipment
All persons operating, servicing, maintaining or working in or with a power plant or a generator set
must wear appropriate Personal Protective Equipment (PPE) Recommended PPE includes: DANGER
Live electrical conductors can cause serious injury or death by electric shock and burns.
• Ear and Eye Protection To prevent injury and before removing covers over electrical conductors, isolate the generator set
from all energy sources, remove stored energy and use lock out/tag out safety procedures.
• Head and face protection
• Safety footwear All electrical equipment can be dangerous if not operated correctly. Always install, service and
maintain the alternator in accordance with this manual. Work that requires access to electrical
• Overalls that protect the lower arms and legs conductors must comply with all applicable local and national electrical safety procedures for the
voltages involved and any site specific rules. Always use genuine branded replacement parts.
Ensure that all persons are fully aware of the emergency procedures in case of accidents.

Noise Lock Out/Tag Out

WARNING WARNING
Noise from a running alternator can cause serious injury by permanent hearing damage. Reconnected Energy Source
To prevent injury, wear appropriate personal protection equipment (PPE). Accidental reconnection of energy sources during service and maintenance work can cause serious
injury or death by electric shock, burns, crushing, severing or trapping.
To prevent injury and before starting service and maintenance work, use appropriate lock out/tag out
Maximum A-weighted noise emissions depend on alternator type. Contact the supplier for
safety procedures to keep the generator set isolated from energy sources. Do not defeat or bypass the
application-specific details. lock out/tag out safety procedures.
Lifting Alternator Operating Areas
DANGER WARNING
Falling mechanical parts can cause serious injury or death by impact, crushing, severing or trapping. Debris ejected during catastrophic failure can cause serious injury or death by impact, severing or
To prevent injury and before lifting: stabbing.
• Check the capacity, condition and attachment of lifting equipment (crane, hoists and jacks, To prevent injury:
including attachments to anchor, fix or support the equipment). • Keep away from the air inlet and air outlet when the alternator is running.
• Check the capacity, condition and attachment of accessories for lifting (hooks, slings, shackles • Do not put operator controls near the air inlet and air outlet.
and eye bolts for attaching loads to lifting equipment). • Do not cause overheating by running the alternator outside rating plate parameters.
• Check the capacity, condition and attachment of lifting fixtures on the load. • Do not overload the alternator.
• Check the mass, integrity and stability (e.g. unbalanced or shifting center of gravity) of the load. • Do not run an alternator with excessive vibration.
• Do not synchronize parallel alternators outside the specified parameters.
WARNING
Always wear suitable PPE when working in the hatched areas
Falling mechanical parts can cause serious injury or death by impact, crushing, severing or
trapping. shown in the diagram or directly in-line with any air inlet/outlet.
To prevent injury and before lifting the alternator: Make sure this consideration is captured in your risk assessment.
• Do not lift the complete generator set by the alternator lifting fixtures.
• Keep the alternator horizontal when lifting.
• Fit drive end and non-drive end transit fittings to single bearing alternators to keep the main rotor
in the frame.

Do not remove the lifting label attached to one of the lifting points.
Hazard Warning Labels Hazard Warning Labels - continued
WARNING
Safety Cover Removed
A hazard exposed when a safety cover is removed can cause serious injury or death.
To prevent injury:
• Fit the safety labels at the locations shown on the back of the label sheet supplied.
• Observe the safety labels.
• Refer to the service manual before removing covers.

The generator set manufacturer is responsible for fitting the self-adhesive hazard warning labels
supplied with the alternator.
Replace labels that are missing, damaged or painted over.
 P0/P1
Alternator

P0/P1
Alternator Commission Post Commission
6 Month Service
1,000 Hour
1 Year Service
10,000 Hours
2 Year Service
30,000 Hours
5 Year Service
 Commission
P0/P1 Alternator
Alternator
Inspect
■■ Alternator rating
■■ Bedplate arrangement
■■ Coupling arrangement
■■ Environmental conditions
and cleanliness
■■ Complete machine damage,
loose parts and earth bonds
■■ Guards, screens, warning
and safety labels
■■ Maintenance access
Test
■■ Ambient temperature (inside
and outside)
■■ Electrical nominal operating
conditions and excitations
while alternator is running
■■ Vibration while alternator is
running
Controls and Auxiliaries
Inspect
■■ Synchronisation settings
Test
■■ Initial AVR set up
■■ AVR settings while
alternator is running
■■ Customer connections of
auxiliaries
■■ Function of auxiliaries
■■ Synchronisation while
alternator is running
Cooling
Inspect
■■ Air flow (rate and direction
while alternator is running)
■■ Condition of fan
Test
■■ Condition of air filter
Windings
Inspect
■■ Condition of windings
■■ Customer settings for
temperature sensors
Test
■■ Insulation resistance of all
windings (P0/P1 test for LV)
■■ Insulation resistance of
rotor, exciter and EBS
■■ Temperature sensors while
alternator is running
Rectifier
Inspect
■■ Diodes and varistors
Post Commission 250 Hours/6 Months
P0/P1 Alternator
Bearings Alternator
Inspect Inspect
■■ Condition of bearings ■■ Environmental conditions
■■ Customer settings for and cleanliness
temperature sensors ■■ Complete machine damage,
loose parts, and earth
bonds
Test
■■ Guards, screens, warning
■■ Temperature sensors while and safety labels
alternator is running
Test
■■ Ambient temperature (inside
and outside)
■■ Electrical nominal operating
conditions and excitations
Terminal Box while alternator is running
■■ Vibration while alternator is
Inspect running
■■ All alternator/customer
■■ Connections and cabling
Controls and Auxiliaries Windings Bearings
Test Inspect Inspect
■■ AVR settings while ■■ Condition of windings ■■ Condition of bearings
alternator is running
■■ Function of auxiliaries Test
■■ Synchronisation while
■■ Insulation resistance of all
alternator is running windings (P0/P1 test for LV)
■■ Insulation resistance of
rotor, exciter and EBS
■■ Temperature sensors while
alternator is running
Cooling Rectifier Terminal Box
Inspect Inspect Inspect
■■ Condition of fan ■■ Diodes and varistors ■■ All alternator/customer
connections and cabling
Test
■■ Condition of air filter
Clean
■■ Air filter
 1,000 Hours/1 Year Service 10,000 Hours/2 Year Service
P0/P1 Alternator

Alternator
Inspect
■■ Environmental conditions
and cleanliness
■■ Complete machine damage,
loose parts, and earth
bonds
■■ Guards, screens, warning
and safety labels
Test
■■ Ambient temperature (inside
and outside)
■■ Electrical nominal operating
conditions and excitations
while alternator is running
■■ Vibration while alternator is
running
Controls and Auxiliaries Windings
Test Inspect
■■ AVR settings while ■■ Condition of windings
alternator is running
■■ Customer connections of Test
auxiliaries
■■ Insulation resistance of all
■■ Function of auxiliaries windings (P0/P1 test for LV)
■■ Synchronisation while
■■ Insulation resistance of
alternator is running rotor, exciter, and EBS
■■ Temperature sensors while
alternator is running
Cooling Rectifier
Inspect Inspect
■■ Condition of fan ■■ Diodes and varistors
P0/P1 Alternator
Bearings Alternator
Inspect Inspect
■■ Condition of bearings ■■ Coupling arrangement
■■ Environmental conditions
Test and cleanliness
■■ Complete machine damage,
■■ Temperature sensors while
alternator is running loose parts, and earth
bonds
■■ Guards, screens, warning
and safety labels
Test
■■ Ambient temperature (inside
and outside)
■■ Electrical nominal operating
Terminal Box conditions and excitations
while alternator is running
Inspect ■■ Vibration while alternator is
■■ All alternator/customer running
connections and cabling
Controls and Auxiliaries
Inspect
■■ Anti condensation heater
Test
■■ AVR settings while
alternator is running
■■ Customer connections of
auxiliaries
■■ Function of auxiliaries
■■ Synchronisation while
alternator is running
Cooling
Inspect
■■ Condition of fan
Windings Bearings
Inspect Inspect
■■ Condition of windings ■■ Condition of bearings
Test
■■ Insulation resistance of all
windings (P0/P1 test for LV)
■■ Temperature sensors while
alternator is running
Rectifier Terminal Box
Inspect Inspect
■■ Diodes and varistors ■■ All alternator/customer
connections and cabling

Test Test
■■ Condition of air filter ■■ Condition of air filter

Clean Clean
■■ Air filter ■■ Air filter
P0/P1 Alternator 30,000 Hours/5 Year Service Kits 30,000 Hours/5 Year Service

P0/P1 Alternator
Alternator Controls and Auxiliaries Windings Bearings
For the 30,000 hour service interval Kit Number Contents
Inspect Replace Inspect Replace
we recommend replacing several
■■ Coupling arrangement ■■ Anti condensation heater ■■ Condition of windings ■■ Bearings
components in order to optimise the
A051C107 ■■ Rectifier Service Kit ■■ Environmental conditions
alternator’s performance. and cleanliness
(P0/P1 1 Bearing 30,000 Hour Service Kit) ■■ NDE Bearing Kit Test Test
■■ Complete machine damage, ■■ AVR settings while ■■ Insulation resistance of all
loose parts, and earth alternator is running windings (P0/P1 test for LV)
For the P0/P1 alternator, the kits bonds
detailed in this table contain all parts ■■ Customer connections of ■■ Temperature sensors while
A051C115 ■■ Rectifier Service Kit ■■ Guards, screens, warning auxiliaries alternator is running
necessary to execute the maintenance P0/P1 2 Bearing 30,000 Hour Service Kit) ■■ DE and NDE Bearing Kit and safety labels
■■ Function of auxiliaries ■■ Insulation resistance of
and repairs. rotor, exciter and EBS
■■ Synchronisation while
Test alternator is running
■■ Ambient temperature (inside
Frame Part Number Description and outside)
■■ Electrical nominal operating
P0/P1 45-1161 Heater Kit UL 230V conditions and excitations Cooling Rectifier Terminal Box
while alternator is running
■■ Vibration while alternator is Inspect Replace Inspect
P0/P1 45-1162 Heater Kit UL 115V
running ■■ Condition of fan ■■ Diodes and varistors ■■ All alternator/customer
connections and cabling
P0/P1 45-1163 Heater Kit UL 24V
Test
■■ Condition of Air filter
P0/P1 45-1164 Heater Kit UL 12V
 S0/S1
Alternator

S0/S1
Alternator Commission Post Commission
6 Month Service
1,000 Hour
1 Year Service
10,000 Hours
2 Year Service
30,000 Hours
5 Year Service
 Commission
S0/S1 Alternator
Alternator
Inspect
■■ Alternator rating
■■ Bedplate arrangement
■■ Coupling arrangement
■■ Environmental conditions
and cleanliness
■■ Complete machine damage,
loose parts and earth bonds
■■ Guards, screens, warning
and safety labels
■■ Maintenance access
Test
■■ Ambient temperature (inside
and outside)
■■ Electrical nominal operating
conditions and excitations
while alternator is running
■■ Vibration while alternator is
running
Controls and Auxiliaries
Test
■■ Initial AVR set up
■■ AVR settings while
alternator is running
■■ Customer connections of
auxiliaries
■■ Function of auxiliaries
■■ Synchronisation while
alternator is running
Cooling
Inspect
■■ Air flow (rate and direction
while alternator is running)
■■ Condition of fan
Windings
Inspect
■■ Condition of windings
Test
■■ Insulation resistance of all
windings (S0/S1 test for LV)
■■ Insulation resistance of
rotor, exciter and auxiliary
Rectifier
Inspect
■■ Diodes and varistors
Post Commission 250 Hours/6 Months
S0/S1 Alternator
Bearings Alternator Controls and Auxiliaries Windings Bearings
Inspect Inspect Test Inspect Inspect
■■ Condition of bearings ■■ Environmental conditions ■■ AVR settings while ■■ Condition of windings ■■ Condition of bearings
and cleanliness alternator is running
■■ Complete machine damage, ■■ Function of auxiliaries Test
loose parts, and earth
bonds ■■ Insulation resistance of all
windings (S0/S1 test for LV)
■■ Guards, screens, warning
and safety labels ■■ Insulation resistance of
rotor, exciter and auxiliary
Test
■■ Ambient temperature (inside
and outside)
■■ Electrical nominal operating
conditions and excitations
Terminal Box while alternator is running Cooling Rectifier Terminal Box
■■ Vibration while alternator is
Inspect running Inspect Inspect Inspect
■■ All alternator/customer ■■ Condition of fan ■■ Diodes and varistors ■■ All alternator/customer
connections and cabling connections and cabling
 1,000 Hours/1 Year Service
S0/S1 Alternator
Alternator
Inspect
■■ Environmental conditions
and cleanliness
■■ Complete machine damage,
loose parts, and earth
bonds
■■ Guards, screens, warning
and safety labels
Test
■■ Ambient temperature (inside
and outside)
■■ Electrical nominal operating
conditions and excitations
while alternator is running
■■ Vibration while alternator is
running
Controls and Auxiliaries Windings
Test Inspect
■■ AVR settings while ■■ Condition of windings
alternator is running
■■ Customer connections of Test
auxiliaries
■■ Insulation resistance of all
■■ Function of auxiliaries windings (S0/S1 test for LV)
■■ Insulation resistance of
rotor, exciter, and auxiliary
■■ Temperature sensors while
alternator is running
Cooling Rectifier
Inspect Inspect
■■ Condition of fan ■■ Diodes and varistors
10,000 Hours/2 Year Service
S0/S1 Alternator
Bearings Alternator Controls and Auxiliaries Windings Bearings
Inspect Inspect Inspect Inspect Inspect
■■ Condition of bearings ■■ Coupling arrangement ■■ Anti condensation heater ■■ Condition of windings ■■ Condition of bearings
■■ Environmental conditions
and cleanliness Test Test
■■ Complete machine damage,
■■ AVR settings while ■■ Insulation resistance of all
loose parts, and earth alternator is running windings (S0/S1 test for LV)
bonds
■■ Customer connections of
■■ Guards, screens, warning auxiliaries
and safety labels
■■ Function of auxiliaries
Test
■■ Ambient temperature (inside
and outside)
■■ Electrical nominal operating
Terminal Box conditions and excitations Cooling Rectifier Terminal Box
while alternator is running
Inspect ■■ Vibration while alternator is Inspect Inspect Inspect
■■ All alternator/customer running ■■ Condition of fan ■■ Diodes and varistors ■■ All alternator/customer
connections and cabling connections and cabling
S0/S1 Alternator 30,000 Hours/5 Year Service Kits 30,000 Hours/5 Year Service

S0/S1 Alternator
Alternator Controls and Auxiliaries Windings Bearings
For the 30,000 hour service interval Kit Number Contents
Inspect Replace Inspect Replace
we recommend replacing several
■■ Coupling arrangement ■■ Anti condensation heater ■■ Condition of windings ■■ Bearings
components in order to optimise the
A051C107 ■■ Rectifier Service Kit ■■ Environmental conditions
alternator’s performance. and cleanliness
(S1 Bearing 30,000 Hour Service Kit) ■■ NDE Bearing Kit Test Test
■■ Complete machine damage, ■■ AVR settings while ■■ Insulation resistance of all
loose parts, and earth alternator is running windings (S0/S1 test for LV)
For the S0/S1 alternator, the kits bonds
detailed in this table contain all parts ■■ Customer connections of ■■ Insulation resistance of
A054N489 ■■ Rectifier Service Kit ■■ Guards, screens, warning auxiliaries rotor, exciter and auxiliary
necessary to execute the maintenance (S0 Bearing 30,000 Hour Service Kit) ■■ NDE Bearing Kit and safety labels
■■ Function of auxiliaries
and repairs.
Test
■■ Ambient temperature (inside
Frame Part Number Description and outside)
■■ Electrical nominal operating
S0/S1 A054K278 Heater Kit UL 12V conditions and excitations Cooling Rectifier Terminal Box
while alternator is running
■■ Vibration while alternator is Inspect Replace Inspect
S0/S1 A054K280 Heater Kit UL 24V
running ■■ Condition of fan ■■ Diodes and varistors ■■ All alternator/customer
connections and cabling
S0/S1 A054K282 Heater Kit UL 115V
Test
■■ Condition of Air filter
S0/S1 A054K284 Heater Kit UL 230V
 UC22/UC27
Alternator

UC22/UC27
Alternator Commission Post Commission
6 Month Service
1,000 Hour
1 Year Service
10,000 Hours
2 Year Service
30,000 Hours
5 Year Service
 Commission
UC22/UC27 Alternator
Alternator
Inspect
■■ Alternator rating
■■ Bedplate arrangement
■■ Coupling arrangement
■■ Environmental conditions
and cleanliness
■■ Complete machine damage,
loose parts and earth bonds
■■ Guards, screens, warning
and safety labels
■■ Maintenance access
Test
■■ Ambient temperature (inside
and outside)
■■ Electrical nominal operating
conditions and excitations
while alternator is running
■■ Vibration while alternator is
running
Controls and Auxiliaries
Inspect
■■ Synchronisation settings
Test
■■ Initial AVR set up
■■ AVR settings while
alternator is running
■■ Customer connections of
auxiliaries
■■ Function of auxiliaries
■■ Synchronisation while
alternator is running
Cooling
Inspect
■■ Air flow (rate and direction
while alternator is running)
■■ Condition of fan
Test
■■ Condition of air filter
Windings
Inspect
■■ Condition of windings
■■ Customer settings for
temperature sensors
Test
■■ Insulation resistance of all
windings (UC22/UC27 test
for LV/MV)
■■ Temperature sensors while
alternator is running
Rectifier
Inspect
■■ Diodes and varistors
■■ Three phase rectifier
(if fitted)
Post Commission 250 Hours/6 Months
UC22/UC27 Alternator
Bearings Alternator
Inspect Inspect
■■ Condition of bearings ■■ Environmental conditions
■■ Customer settings for and cleanliness
temperature sensors ■■ Complete machine damage,
loose parts, and earth
bonds
Test
■■ Guards, screens, warning
■■ Temperature sensors while
and safety labels
alternator is running
Test
■■ Ambient temperature (inside
and outside)
■■ Electrical nominal operating
conditions and excitations
Terminal Box while alternator is running
■■ Vibration while alternator is
Inspect running
■■ All alternator/customer
connections and cabling
Controls and Auxiliaries Windings Bearings
Test Inspect Inspect
■■ AVR settings while ■■ Condition of windings ■■ Condition of bearings
alternator is running
■■ Function of auxiliaries Test Test
■■ Synchronisation while
■■ Insulation resistance of all ■■ Temperature sensors while
alternator is running windings (UC22/UC27 test alternator is running
for LV/MV)
■■ Insulation resistance of
rotor, exciter and PMG
■■ Temperature sensors while
alternator is running
■■ Insulation resistance of
rotor, exciter and PMG
Cooling Rectifier Terminal Box
Inspect Inspect Inspect
■■ Condition of fan ■■ Diodes and varistors ■■ All alternator/customer
connections and cabling
■■ Three phase rectifier
(if fitted)
Test
■■ Condition of air filter
 1,000 Hours/1 Year Service 10,000 Hours/2 Year Service
UC22/UC27 Alternator

Alternator
Inspect
■■ Environmental conditions
and cleanliness
■■ Complete machine damage,
loose parts, and earth
bonds
■■ Guards, screens, warning
and safety labels
Test
■■ Ambient temperature (inside
and outside)
■■ Electrical nominal operating
conditions and excitations
while alternator is running
■■ Vibration while alternator is
running
Controls and Auxiliaries Windings
Test Inspect
■■ AVR settings while ■■ Condition of windings
alternator is running
■■ Customer connections of Test
auxiliaries
■■ Insulation resistance of all
■■ Function of auxiliaries windings (UC22/UC27 test
■■ Synchronisation while for LV/MV)
alternator is running ■■ Insulation resistance of
rotor, exciter, and PMG
■■ Temperature sensors while
alternator is running
Cooling Rectifier
Inspect Inspect
■■ Condition of fan ■■ Diodes and varistors
■■ Three phase rectifier
UC22/UC27 Alternator
Bearings Alternator
Inspect Inspect
■■ Condition of bearings ■■ Coupling arrangement
■■ Environmental conditions
Test and cleanliness
■■ Complete machine damage,
■■ Temperature sensors while
alternator is running loose parts, and earth
bonds
■■ Guards, screens, warning
and safety labels
Test
■■ Ambient temperature (inside
and outside)
■■ Electrical nominal operating
Terminal Box conditions and excitations
while alternator is running
Inspect ■■ Vibration while alternator is
■■ All alternator/customer running
connections and cabling
Controls and Auxiliaries
Inspect
■■ Anti condensation heater
Test
■■ AVR settings while
alternator is running
■■ Customer connections of
auxiliaries
■■ Function of auxiliaries
■■ Synchronisation while
alternator is running
Cooling
Inspect
■■ Condition of fan
Windings Bearings
Inspect Inspect
■■ Condition of windings ■■ Condition of bearings
Test Test
■■ Insulation resistance of all ■■ Temperature sensors while
windings (UC22/UC27 test alternator is running
for LV/MV
■■ Temperature sensors while
alternator is running
Rectifier Terminal Box
Inspect Inspect
■■ Diodes and varistors ■■ All alternator/customer
■■ Three phase rectifier connections and cabling

Test (if fitted) Test (if fitted)

■■ Condition of air filter ■■ Condition of air filter

Clean Clean
■■ Air filter ■■ Air filter
UC22/UC27 Alternator 30,000 Hours/5 Year Service Kits 30,000 Hours/5 Year Service

UC22/UC27 Alternator
Alternator Controls and Auxiliaries Windings Bearings
For the 30,000 hour service interval Kit Number Contents
Inspect Replace Inspect Replace
we recommend replacing several
■■ Coupling arrangement ■■ Anti condensation heater ■■ Condition of windings ■■ Bearings
components in order to optimise the A051C212 ■■ Rectifier Service Kit
■■ Environmental conditions
alternator’s performance. (UC22 1 Bearing 30,000 Hour Service Kit) ■■ NDE Bearing Kit
and cleanliness Test Test Test
■■ Complete machine damage, ■■ AVR settings while ■■ Insulation resistance of all ■■ Temperature sensors while
loose parts, and earth alternator is running windings (UC22/UC27 test alternator is running
For the UC22/UC27 alternator, the kits A051C216 ■■ Rectifier Service Kit
bonds
■■ Customer connections of for LV/MV)
detailed in this table contain all parts (UC22 2 Bearing 30,000 Hour Service Kit) ■■ DE and NDE Bearing Kit
■■ Guards, screens, warning auxiliaries ■■ Temperature sensors while
necessary to execute the maintenance and safety labels alternator is running
■■ Function of auxiliaries
and repairs. A051C218 ■■ Rectifier Service Kit ■■ Insulation resistance of
■■ Synchronisation while
(UC27 1 Bearing 30,000 Hour Service Kit) ■■ DE and NDE Bearing Kit Test alternator is running rotor, exciter and PMG
■■ Ambient temperature (inside
and outside)
A051C222 ■■ Rectifier Service Kit ■■ Electrical nominal operating
conditions and excitations Cooling Rectifier Terminal Box
(UC27 2 Bearing 30,000 Hour Service Kit) ■■ DE and NDE Bearing Kit
while alternator is running
■■ Vibration while alternator is Inspect Replace Inspect
running ■■ Condition of fan ■■ Diodes and varistors ■■ All alternator/customer
Frame Part Number Description connections and cabling

Test
UC22/UC27 A053N107 Heater Kit UL 110-125V
■■ Condition of air filter

UC22/UC27 A053N108 Heater Kit UL 220-260V

 HC4/HC5/HC6
Alternator

HC4/HC5/HC6
Alternator Commission Post Commission
6 Month Service
1,000 Hour
1 Year Service
10,000 Hours
2 Year Service
30,000 Hours
5 Year Service
 Commission
HC4/HC5/HC6 Alternator
Alternator
Inspect
■■ Alternator rating
■■ Bedplate arrangement
■■ Coupling arrangement
■■ Environmental conditions
and cleanliness
■■ Complete machine damage,
loose parts and earth bonds
■■ Guards, screens, warning
and safety labels
■■ Maintenance access
Test
■■ Ambient temperature (inside
and outside)
■■ Electrical nominal operating
conditions and excitations
while alternator is running
■■ Vibration while alternator is
running
Controls and Auxiliaries
Inspect
■■ Synchronisation settings
Test
■■ Initial AVR and PFC set up
■■ AVR and PFC settings
while alternator is running
■■ Customer connections of
auxiliaries
■■ Function of auxiliaries
■■ Synchronisation while
alternator is running
Cooling
Inspect
■■ Air flow (rate and direction
while alternator is running)
■■ Condition of fan
Test
■■ Condition of air filter
Windings
Inspect
■■ Condition of windings
■■ Customer settings for
temperature sensors
Test
■■ Insulation resistance of all
windings (HC4/HC5/HC6
test for LV/MV)
■■ Temperature sensors while
alternator is running
Rectifier
Inspect
■■ Diodes and varistors
Post Commission 250 Hours/6 Months
HC4/HC5/HC6 Alternator
Bearings Alternator
Inspect Inspect
■■ Condition of bearings ■■ Environmental conditions
■■ Customer settings for and cleanliness
temperature sensors ■■ Complete machine damage,
loose parts, and earth
bonds
Test
■■ Guards, screens, warning
■■ Temperature sensors while
and safety labels
alternator is running
Test
■■ Ambient temperature (inside
and outside)
■■ Electrical nominal operating
conditions and excitations
Terminal Box while alternator is running
■■ Vibration while alternator is
Inspect running
■■ All alternator/customer
connections and cabling
Controls and Auxiliaries
Test
■■ AVR and PFC settings while
alternator is running
■■ Function of auxiliaries
■■ Synchronisation while
alternator is running
Cooling
Inspect
■■ Condition of fan
Test
■■ Condition of air filter
Clean
■■ Air filter
Windings Bearings
Inspect Inspect
■■ Condition of windings ■■ Condition of bearings
Test
Test
■■ Temperature sensors while
■■ Insulation resistance of all alternator is running
windings (HC4/HC5/HC6
test for LV/MV) Clean
■■ Insulation resistance of ■■ Grease exhaust and trap
rotor, exciter and PMG (Re-greasable bearings only)
■■ Temperature sensors while
alternator is running Replace
■■ Insulation resistance of ■■ Grease for re-greasable
rotor, exciter and PMG bearings
Rectifier Terminal Box
Inspect Inspect
■■ Diodes and varistors ■■ All alternator/customer
connections and cabling
 1,000 Hours/1 Year Service
HC4/HC5/HC6 Alternator
Alternator
Inspect
■■ Environmental conditions
and cleanliness
■■ Complete machine damage,
loose parts, and earth
bonds
■■ Guards, screens, warning
and safety labels
Test
■■ Ambient temperature (inside
and outside)
■■ Electrical nominal operating
conditions and excitations
while alternator is running
■■ Vibration while alternator is
running
Controls and Auxiliaries
Test
■■ AVR and PFC settings while
alternator is running
■■ Customer connections of
auxiliaries
■■ Function of auxiliaries
■■ Synchronisation while
alternator is running
Cooling
Inspect
■■ Condition of fan
Test
■■ Condition of air filter
Clean
■■ Air filter
Windings
Inspect
■■ Condition of windings
Test
■■ Insulation resistance of all
windings (HC4/HC5/HC6
test for LV/MV)
■■ Insulation resistance of
rotor, exciter, and PMG
■■ Temperature sensors while
alternator is running
Rectifier
Inspect
■■ Diodes and varistors
10,000 Hours/2 Year Service
HC4/HC5/HC6 Alternator
Bearings Alternator
Test Inspect
■■ Temperature sensors while ■■ Coupling arrangement
alternator is running ■■ Environmental conditions
and cleanliness
Replace ■■ Complete machine damage,
■■ Bearing greasee loose parts, and earth
bonds
■■ Guards, screens, warning
Clean and safety labels
■■ Grease exhaust and trap
Test
■■ Ambient temperature (inside
and outside)
■■ Electrical nominal operating
Terminal Box conditions and excitations
while alternator is running
Inspect ■■ Vibration while alternator is
■■ All alternator/customer running
connections and cabling
Controls and Auxiliaries
Inspect
■■ Anti condensation heater
Test
■■ AVR and PFC settings while
alternator is running
■■ Customer connections of
auxiliaries
■■ Function of auxiliaries
■■ Synchronisation while
alternator is running
Cooling
Inspect
■■ Condition of fan
Test
■■ Condition of air filter
Clean
■■ Air filter
Windings Bearings
Inspect Test
■■ Condition of windings ■■ Temperature sensors while
alternator is running
Test
Replace
■■ Insulation resistance of all
windings (HC4/HC5/HC6 ■■ Bearing grease
test for LV/MV)
■■ Temperature sensors while
Clean
alternator is running
■■ Grease exhaust and trap
Rectifier Terminal Box
Inspect Inspect
■■ Diodes and varistors ■■ All alternator/customer
connections and cabling
 30,000 Hours/5 Year Service

HC4/HC5/HC6 Alternator
HC4/HC5/HC6 Alternator 30,000
Kit Number Contents Alternator Controls and Auxiliaries Windings Bearings
Hours/5 Year Service Kits
A051C225 ■■ Rectifier Service Kit Inspect Replace Inspect Replace
(HC4 1 Bearing 30,000 Hour Service Kit) ■■ NDE Bearing Kit
For the 30,000 hour service interval ■■ Coupling arrangement ■■ Anti condensation heater ■■ Condition of Windings ■■ Bearings (sealed &
we recommend replacing several A051C230 ■■ Rectifier Service Kit ■■ Environmental conditions re-greasable
(HC4 2 Bearing 30,000 Hour Service Kit) ■■ DE and NDE Bearing Kit and cleanliness ■■ Bearing grease
components in order to optimise the Test Test
alternator’s performance. A051C232 ■■ Complete machine damage, ■■ AVR and PFC settings while ■■ Insulation resistance of all
■■ Rectifier Service Kit
(HC5 1 SEALED Bearing 30,000 Hour loose parts, and earth alternator is running windings (HC4/HC5/HC6 Test
■■ NDE Bearing Kit
For the HC4/HC5/HC6 alternator, Service Kit) bonds test for LV/MV)
■■ Customer connections of ■■ Temperature sensors while
the kits detailed in this table contain A051Z125 ■■ Rectifier Service Kit ■■ Guards, screens, warning auxiliaries ■■ Temperature sensors while alternator is running
■■ Re-grease NDE Bearing Kit and safety labels
all parts necessary to execute the (HC5 1 RE-GREASABLE Bearing 30,000 ■■ Function of auxiliaries alternator is running
Hour Service Kit) ■■ Cartridge and Cap
maintenance and repairs. ■■ Synchronisation while ■■ Insulation resistance of Clean
A051C234 ■■ Rectifier Service Kit Test rotor, exciter and PMG
alternator is running ■■ Grease exhaust & trap
(HC5 2 SEALED Bearing 30,000 Hour ■■ DE and NDE Bearing Kit ■■ Ambient temperature (inside
Service Kit) ■■ Cartridge and Cap (re-greasable bearings only)
and outside)
Frame Part Description A051Z131 ■■ Rectifier Service Kit ■■ Electrical nominal operating
Number (HC5 2 RE-GREASABLE Bearing 30,000 ■■ Regrease DE and NDE Bearing Kit conditions and excitations Cooling Rectifier Terminal Box
Hour Service Kit) ■■ Cartridge and Cap while alternator is running
HC4 A053M965 Heater Kit UL 220-260V ■■ Rectifier Service Kit ■■ Vibration while alternator is Inspect Replace Inspect
A051C237
(HC6 1 SEALED Bearing 30,000 Hour ■■ NDE Bearing Kit running ■■ Condition of fan ■■ Diodes and varistors ■■ All alternator/customer
Service Kit) ■■ Cartridge and Cap connections and cabling
HC4 A053M957 Heater Kit UL 110-125V
A051Z133 ■■ Rectifier Service Kit Test
(HC6 1 RE-GREASABLE Bearing 30,000 ■■ Re-grease NDE Bearing Kit
HC5/HC6 A053N002 Heater Kit UL 220-260V Hour Service Kit) ■■ Cartridge and Cap ■■ Condition of air filter

A051C243 ■■ Rectifier Service Kit

HC5/HC6 A053M968 Heater Kit Ul 110-125V (HC6 2 SEALED Bearing 30,000 Hour ■■ DE and NDE Bearing Kit Clean
Service Kit) ■■ Cartridge and Cap ■■ Air filter
A051Z137 ■■ Rectifier Service Kit
(HC6 2 RE-GREASABLE Bearing 30,000 ■■ Regrease DE and NDE Bearing Kit
Hour Service Kit) ■■ Cartridge and Cap
 S4/S5/S6
Alternator

S4/S5/S6
Alternator Commission Post Commission
6 Month Service
1,000 Hour
1 Year Service
10,000 Hours
2 Year Service
30,000 Hours
5 Year Service
 Commission
S4/S5/S6 Alternator
Alternator
Inspect
■■ Alternator rating
■■ Bedplate arrangement
■■ Coupling arrangement
■■ Environmental conditions
and cleanliness
■■ Complete machine damage,
loose parts and earth bonds
■■ Guards, screens, warning
and safety labels
■■ Maintenance access
Test
■■ Ambient temperature (inside
and outside)
■■ Electrical nominal operating
conditions and excitations
while alternator is running
■■ Vibration while alternator is
running
Controls and Auxiliaries
Inspect
■■ Synchronisation settings
Test
■■ Initial AVR and PFC set up
■■ AVR and PFC settings
while alternator is running
■■ Customer connections of
auxiliaries
■■ Function of auxiliaries
■■ Synchronisation while
alternator is running
Cooling
Inspect
■■ Air flow (rate and direction
while alternator is running)
■■ Condition of fan
Test
■■ Condition of air filter
Windings
Inspect
■■ Condition of windings
■■ Customer settings for
temperature sensors
Test
■■ Insulation resistance of all
windings
■■ Temperature sensors while
alternator is running
Rectifier
Inspect
■■ Diodes and varistors
Post Commission 250 Hours/6 Months
S4/S5/S6 Alternator
Bearings Alternator
Inspect Inspect
■■ Condition of bearings ■■ Environmental conditions
■■ Customer settings for and cleanliness
temperature sensors ■■ Complete machine damage,
loose parts, and earth
bonds
Test
■■ Guards, screens, warning
■■ Temperature sensors while and safety labels
alternator is running
Test
■■ Ambient temperature (inside
and outside)
■■ Electrical nominal operating
conditions and excitations
Terminal Box while alternator is running
■■ Vibration while alternator is
Inspect running
■■ All alternator/customer
connections and cabling
Controls and Auxiliaries
Test
■■ AVR and PFC settings while
alternator is running
■■ Function of auxiliaries
■■ Synchronisation while
alternator is running
Cooling
Inspect
■■ Condition of fan
Test
■■ Condition of air filter
Clean
■■ Air filter
Windings Bearings
Inspect Inspect
■■ Condition of windings ■■ Condition of bearings
Test
Test
■■ Temperature sensors while
■■ Insulation resistance of all alternator is running
windings
■■ Insulation resistance of Clean
rotor, exciter and PMG ■■ Grease exhaust and trap
■■ Temperature sensors while (Re-greasable bearings only)
alternator is running
■■ Insulation resistance of Replace
rotor, exciter and PMG ■■ Grease for re-greasable
bearings
Rectifier Terminal Box
Inspect Inspect
■■ Diodes and varistors ■■ All alternator/customer
connections and cabling
 1,000 Hours/1 Year Service 10,000 Hours/2 Year Service
S4/S5/S6 Alternator

Alternator
Inspect
■■ Environmental conditions
and cleanliness
■■ Complete machine damage,
loose parts, and earth
bonds
■■ Guards, screens, warning
and safety labels
Test
■■ Ambient temperature (inside
and outside)
■■ Electrical nominal operating
conditions and excitations
while alternator is running
■■ Vibration while alternator is
running
Controls and Auxiliaries
Test
■■ AVR and PFC settings while
alternator is running
■■ Customer connections of
auxiliaries
■■ Function of auxiliaries
■■ Synchronisation while
alternator is running
Cooling
Inspect
■■ Condition of fan
Windings
Inspect
■■ Condition of windings
Test
■■ Insulation resistance of all
windings
■■ Insulation resistance of
rotor, exciter, and PMG
■■ Temperature sensors while
alternator is running
Rectifier
Inspect
■■ Diodes and varistors
S4/S5/S6 Alternator
Bearings Alternator
Test Inspect
■■ Temperature sensors while ■■ Coupling arrangement
alternator is running ■■ Environmental conditions
and cleanliness
Replace ■■ Complete machine damage,
■■ Bearing grease loose parts, and earth
bonds
■■ Guards, screens, warning
Clean and safety labels
■■ Grease exhaust and trap
Test
■■ Ambient temperature (inside
and outside)
■■ Electrical nominal operating
Terminal Box conditions and excitations
while alternator is running
Inspect ■■ Vibration while alternator is
■■ All alternator/customer running
connections and cabling
Controls and Auxiliaries Windings Bearings
Inspect Inspect Test
■■ Anti condensation heater ■■ Condition of windings ■■ Temperature sensors while
alternator is running
Test Test
Replace
■■ AVR and PFC settings while ■■ Insulation resistance of all
alternator is running windings ■■ Bearing grease
■■ Customer connections of ■■ Temperature sensors while
auxiliaries alternator is running
Clean
■■ Function of auxiliaries ■■ Grease exhaust and trap
■■ Synchronisation while
alternator is running
Cooling Rectifier Terminal Box
Inspect Inspect Inspect
■■ Condition of fan ■■ Diodes and varistors ■■ All alternator/customer
connections and cabling

Test Test
■■ Condition of air filter ■■ Condition of air filter

Clean Clean
■■ Air filter ■■ Air filter
 30,000 Hours/5 Year Service

S4/S5/S6 Alternator
S4/S5/S6 Alternator 30,000
Kit Number Contents Alternator Controls and Auxiliaries Windings Bearings
Hours/5 Year Service Kits ■■ Rectifier Service Kit
A051C225 Inspect Replace Inspect Replace
(HC4/S4 1 Bearing 30,000 Hour Service Kit) ■■ NDE Bearing Kit
For the 30,000 hour service interval ■■ Coupling arrangement ■■ Anti condensation heater ■■ Condition of Windings ■■ Bearings (sealed &
A051C230 ■■ Rectifier Service Kit re-greasable
we recommend replacing several (HC4/S4 2 Bearing 30,000 Hour Service Kit) ■■ DE and NDE Bearing Kit ■■ Environmental conditions
components in order to optimise the and cleanliness Test Test ■■ Bearing grease
A051C232 ■■ Rectifier Service Kit ■■ Complete machine damage,
alternator’s performance. (HC5/ S5/S5D 1 SEALED Bearing 30,000 ■■ NDE Bearing Kit ■■ AVR and PFC settings while ■■ Insulation resistance of all
Hour Service Kit) loose parts, and earth alternator is running windings Test
For the S4/S5/S6 alternator, the A051Z125 ■■ Rectifier Service Kit bonds
■■ Customer connections of ■■ Temperature sensors while ■■ Temperature sensors while
kits detailed in this table contain (HC5 / S5 1 RE-GREASABLE Bearing ■■ Regrease NDE Bearing Kit ■■ Guards, screens, warning
30,000 Hour Service Kit ■■ Cartridge and Cap auxiliaries alternator is running alternator is running
and safety labels
all parts necessary to execute the ■■ Rectifier Service Kit ■■ Function of auxiliaries ■■ Insulation resistance of
A051C234
maintenance and repairs. (HC5 / S5 2 SEALED Bearing 30,000 Hour ■■ Sealed DE and NDE Bearing Kit ■■ Synchronisation while rotor, exciter and PMG Clean
Service Kit) ■■ Cartridge and Cap Test alternator is running ■■ Grease exhaust & trap
Frame Part Description A051Z131 ■■ Rectifier Service Kit ■■ Ambient temperature (inside (re-greasable bearings only)
(HC5 / S5 2 RE-GREASABLE Bearing ■■ Regrease DE and NDE Bearing Kit and outside)
Number 30,000 Hour Service Kit) ■■ Cartridge and Cap
■■ Electrical nominal operating
A051C237 ■■ Rectifier Service Kit conditions and excitations Cooling Rectifier Terminal Box
S4 A053M965 Heater Kit UL 220-260V
(HC6/S6/S6L1D G-H Core 1 SEALED ■■ Sealed DE and NDE Bearing Kit while alternator is running
Bearing 30,000 Hour Service Kit) ■■ Cartridge and Cap Inspect Replace Inspect
■■ Vibration while alternator is
S4 A053M957 Heater Kit UL 110-125V A051C243 ■■ Rectifier Service Kit running ■■ Condition of fan ■■ Diodes and varistors ■■ All alternator/customer
(HC6/S6/S6L1D G-H Core 2 SEALED ■■ Sealed DE and NDE Bearing Kit connections and cabling
Bearing 30,000 Hour Service Kit) ■■ Cartridge and Cap
S5/S6 A053N002 Heater Kit UL 220-260V Test
A059R029 ■■ Rectifier Service Kit
(S6L1D C-F Core 2 SEALED Bearing ■■ Sealed DE and NDE Bearing Kit ■■ Condition of air filter
S5/S6 A053M968 Heater Kit UL 110-125V 30,000 Hour Service Kit) ■■ Cartridge and Cap
A051Z133 ■■ Rectifier Service Kit
(HC6/S6 1 RE-GREASABLE Bearing 30,000 ■■ Regrease NDE Bearing Kit Clean
Hour Service Kit) ■■ Cartridge and Cap ■■ Air filter
A051Z137 ■■ Rectifier Service Kit
(HC6/S6 2 RE-GREASABLE Bearing 30,000 ■■ Regrease DE and NDE Bearing Kit
Hour Service Kit) ■■ Cartridge and Cap
 P7
Alternator

P7
Alternator Commission Post Commission
6 Month Service
1,000 Hour
1 Year Service
10,000 Hours
2 Year Service
30,000 Hours
5 Year Service
 Commission Post Commission 250 Hours/6 Months
P7 Alternator

P7 Alternator
Alternator Controls and Auxiliaries Windings Bearings Alternator Controls and Auxiliaries Windings Bearings
Inspect Inspect Inspect Inspect Inspect Test Inspect Inspect
Test
■■ Alternator
Generator rating
Rating ■■ Synchronisation
Synchronization Settngs
settings ■■ Condition of windings
Windings ■■ Condition of bearings
Bearings ■■ Environmental conditions
Conditions ■■ AVR and
&PFC settings
PFC while
settings while ■■ Condition of windings
Windings ■■ Temperature
Condition of bearings
Sensors while
P0/P1

P0/P1
■■ Bedplate arrangement
Arrangement ■■ Customer settings
Settngs for ■■ Customer settings
settngs for
for and cleanliness
Cleanliness generator is running
alternator generator is running
temperature sensors temperature sensors ■■ Complete machine damage, ■■ Function of auxiliaries Test
■■ Coupling arrangement
Arrangement Test Test
loose parts, and
& earth
earth
bonds ■■ Synchronization
Synchronisation while ■■ Temperature sensors while
■■ Environmental conditions
Conditions ■■ Initial AVR and
& PFC
PFC
setset
upup ■■ Insulation resistance of all
and cleanliness
Cleanliness Test Test ■■ bonds
Guards, Screens, Warning generator is running
alternator (PI test
windings (P7 testfor
forMH/VH)
LV/MV)
alternator is running
■■ AVR and
&PFCPFCsettngs
settings
while and Safety
■■ Guards, Labelswarning
screens,
■■ Complete machine damage, generator
settings while
is running
alternator is ■■ Insulation resistance of all ■■ Temperature sensors
Sensors while
while and safety labels ■■ Insulation resistance of Clean
loose parts and earth bonds running connections of
■■ Customer windings (P7 testfor
(PI test forMH/VH)
LV/MV) alternator
generator is running rotor, exciter and PMG ■■ Grease exhaust and trap
■■ Guards, screens,
Screens, warning
Warning ■■ auxiliaries
Customer connections of ■■ Temperature sensorsof
Insulation resistance while Test ■■ Temperature sensors while (Re-greasable bearings only)
Test
and safety
Safety labels
Labels ■■ auxiliaries
Function of auxiliaries alternator
rotor, exciter
is running
and PMG ■■ Ambient Temperature (inside generator is running
alternator
and outside)
■■ Ambient temperature (inside Replace
■■ Maintenance access
Access ■■■ Synchronization
■ Function of auxiliaries
while ■■ Temperature sensors while
and outside)
■■ Synchronisation
generator is running
while generator is running ■■ Electrical Nominal Operating ■■ Grease for re-greasable
alternator is running Conditionsnominal
■■ Electrical and Excitations
operating bearings
Test while generator
conditions is running
and excitations
■■ Ambient Temperature
temperature (inside
(inside Cooling Rectifier Terminal Box while alternator
■■ Vibration is running
while generator Cooling Rectifier Terminal Box
and outside) is runningwhile alternator is
■■ Vibration
■■ Electrical nominal
Nominal operating
Operating Inspect Inspect Inspect running Inspect Inspect Inspect
Conditions and
conditions and excitations
Excitations ■■ Air flow
Flow(rate
(rateand
anddirection
direction ■■ Diodes and varistors ■■ All alternator/customer
generator/customer ■■ Condition of fan ■■ Diodes and varistors ■■ All alternator/customer
generator/customer
while alternator
generator is running while alternator
generator is running) ■■ connections
connections andand cabling
cabling connections and cabling
■■ Vibration while alternator
generator is ■■ Condition of fan
is running
running Test
■■ Condition of air
Air filter
filter
Test
■■ Condition of air
Air filter
filter Clean
■■ Air filter
 Commission
1,000 Hours/1 Year Service Post Commission
10,000 Hours/2 Year
250Service
Hours/6 Months
P7 Alternator

P7 Alternator
Alternator Controls and Auxiliaries Windings Bearings Alternator Controls and Auxiliaries Windings Bearings
Inspect Inspect
Test Inspect Inspect Inspect Test
Inspect Inspect Inspect
Test
■■ Generator
Environmental
Rating
conditions ■■ Synchronization Settngs
AVR and PFC settings while Windings
■■ Condition of windings ■■ Condition of bearings
Bearings ■■ Environmental Conditions
Coupling arrangement ■■ AVR &PFC settingsheater
Anti condensation while ■■ Condition of windings
Windings ■■ Temperature
Condition of bearings
Sensors while
P0/P1

P0/P1
■■ and cleanliness
Bedplate Arrangement alternator is running ■■ Customer Settngs for ■■ Customer settngs for ■■ and Cleanlinessconditions
Environmental generator is running generator is running
Testtemperature sensors Test
■■■ Complete
■ machine damage,
Coupling Arrangement ■■ Customer connections of
Test Testtemperature sensors ■■ Complete machine damage,
and cleanliness ■ ■ Function of auxiliaries
Test Test
loose parts, and earth
■■ bonds
Environmental Conditions
auxiliaries
■■ Initial AVR & PFC set up ■■ Insulation resistance of all
■■ Temperature sensors while ■■ loose parts,
Complete & earthdamage,
machine bonds
■■■ Synchronization
■ while while
AVR and PFC settings ■■ Insulation resistance of all
■■ Temperature sensors while
■■ Function of auxiliaries alternator is running ■■ Guards, Screens,
loose parts, Warning
and earth generator is
is running
running alternator is running
and Cleanliness ■■ AVR &PFC settngs while Testwindings (P7 test for LV/MV) Test alternator windings (P7 testfor
(PI test forMH/VH)
LV/MV)
■■ Guards, screens, warning ■■ Synchronisation while and Safety Labels
bonds
■■ Complete
and safetymachine
labels damage, generator is running ■■ Insulation resistance of all Clean
■■ Temperature Sensors while ■■ Customer connections of ■■ Insulation
Temperature sensorsofwhile
resistance Clean
loose parts and earth bonds alternator is running windings
rotor, (PI test
exciter, andfor
PMGMH/VH) generator is running ■■ Guards, screens, warning auxiliaries alternator is running
rotor, exciter and PMG
■■ Customer connections of ■■ Grease exhaust and trap ■■ Grease exhaust and trap
■■ Guards, Screens, Warning auxiliaries ■■ Insulation
Temperatureresistance
sensorsofwhile (Re-greasable bearings only) Testand safety labels ■■ Function of auxiliaries ■■ Temperature sensors while (Re-greasable bearings only)
Testand Safety Labels rotor, exciter
alternator and PMG
is running ■■ Ambient Temperature (inside generator is running
■■ Function of auxiliaries ■■ Synchronisation while
■■■ Maintenance
■ Ambient temperature
Access (inside ■■ Temperature sensors while Replace Testand outside) alternator is running Replace
and outside) ■■ Synchronization while
generator is running generator is running ■■ Grease for re-greasable ■■ Electrical Nominal Operating
Ambient temperature (inside ■■ Grease for re-greasable
■■ Electrical nominal operating bearings Conditions
and outside)and Excitations bearings
Testconditions and excitations
■■ while generator
Electrical is operating
nominal running
while alternator
■■ Ambient is running
Temperature (inside Cooling Rectifier Terminal Box ■■ Vibration
conditionswhile
and generator
excitations Cooling Rectifier Terminal Box
and outside)
■■ Vibration while alternator is is running
while alternator is running
■■ running
Electrical Nominal Operating Inspect Inspect Inspect ■■ Vibration while alternator is Inspect Inspect Inspect
Conditions and Excitations ■■ Air
Condition
Flow (rate
of fan
and direction ■■ Diodes and varistors ■■ All alternator/customer
generator/customer running ■■ Condition of fan ■■ Diodes and varistors ■■ All alternator/customer
generator/customer
while generator is running while generator is running) ■■ connections
connections andand cabling
cabling connections and cabling
■■ Vibration while generator ■ ■ Condition of fan
is running Test Test
■■ Condition of air filter ■■ Condition of air
Air filter
filter
Test
■ ■ Condition of Air filter
Clean Clean
■■ Air filter ■■ Air filter
P7 Alternator 30,000 Hours/5 Year Service Kits Post Commission
30,000 Hours/5 Year
250Service
Hours/6 Months

P7 Alternator
Alternator Controls and Auxiliaries Windings Bearings
For the 30,000 hour service interval Kit Number Contents
Inspect Replace
Test Inspect Replace
Test
we recommend replacing several
■■ Environmental
Coupling arrangement
Conditions Anti &PFC
■■ AVR condensation
settings heater
while ■■ Condition of windings
Windings ■■ Temperature
Bearings (Sealed & while
Sensors
components in order to optimise the A051C251 ■■ Rectifier Service Kit

P0/P1
■■ and Cleanlinessconditions
Environmental generator is running re-greasable)
generator is running
alternator’s performance. (P7 1 Bearing 30,000 Hour Service Kit) ■■ (A-G) NDE Bearing Kit
■■ Complete
and cleanliness
machine damage, ■ ■ Function of auxiliaries ■■ Bearing grease
Test Test
For the P7 alternator, the kits detailed ■■ loose parts,
Complete & earthdamage,
machine bonds
■■■ Synchronization
■ while while
AVR and PFC settings ■■ Insulation resistance of all
A051Z145 ■■ Rectifier Service Kit ■■ Guards,
loose parts,
Screens,
and earth
Warning generator is
is running
running
in this table contain all parts necessary alternator windings (P7 testfor
(PI test forMH/VH)
LV/MV) Test
(P7 1 SEALED Bearing 30,000 Hour ■■ NDE Bearing Kit and Safety Labels
bonds
to execute the maintenance and ■■ Customer connections of ■■ Insulation
Temperature sensorsofwhile
resistance ■■ Temperature sensors while
Service Kit) ■■ Cartridge and Cap ■■ Guards, screens, warning
repairs. auxiliaries alternator is running
rotor, exciter and PMG alternator is running
Testand safety labels ■■ Function of auxiliaries ■■ Temperature
Insulation resistance
sensorsofwhile
A051C255 ■■ Rectifier Service Kit ■■ Ambient Temperature (inside ■■ Synchronisation while rotor, exciter
generator and PMG
is running Clean
(P7 2 BRG 30,000 Hour Service Kit, A-E) ■■ (A-E) DE and NDE Bearing Kit Testand outside) alternator is running ■■ Grease exhaust & trap
■■ Electrical Nominal Operating
Ambient temperature (inside (re-greasable bearings only)
Conditions
and outside)and Excitations
A051C257 ■■ Rectifier Service Kit ■■ while generator
Electrical is operating
nominal running
■■ Vibration
conditionswhile
and generator
excitations Cooling Rectifier Terminal Box
(P7 2 BRG 30,000 Hour Service Kit, F-G) ■■ (F-G) DE and NDE Bearing Kit
is running
while alternator is running
■■ Vibration while alternator is Inspect Inspect
Replace Inspect
running ■■ Condition of fan ■■ Diodes and varistors ■■ All alternator/customer
generator/customer
Frame Part Number Description connections and cabling

Test
P7 A-F A053N003 Heater Kit UL 220-260V
■■ Condition of air
Air filter
filter

P7 A-F A053M969 Heater Kit UL 110-125V

Clean

P7 G-H A053N109 Heater Kit UL 220-260V ■■ Air filter

P7 G-H A053M999 Heater Kit UL 110-125V

 S7
Alternator

S7
Alternator Commission Post Commission
6 Month Service
1,000 Hour
1 Year Service
10,000 Hours
2 Year Service
30,000 Hours
5 Year Service
 Commission
S7 Alternator
Alternator
Inspect
■■ Alternator rating
■■ Bedplate arrangement
■■ Coupling arrangement
■■ Environmental conditions
and cleanliness
■■ Complete machine damage,
loose parts and earth bonds
■■ Guards, screens, warning
and safety labels
■■ Maintenance access
Test
■■ Ambient temperature (inside
and outside)
■■ Electrical nominal operating
conditions and excitations
while alternator is running
■■ Vibration while alternator is
running
Controls and Auxiliaries
Inspect
■■ Synchronisation settings
Test
■■ Initial AVR and PFC set up
■■ AVR and PFC settings
settings while alternator is
running
■■ Customer connections of
auxiliaries
■■ Function of auxiliaries
■■ Synchronisation while
alternator is running
Cooling
Inspect
■■ Air flow (rate and direction
while alternator is running)
■■ Condition of fan
Test
■■ Condition of air filter
Windings
Inspect
■■ Condition of windings
■■ Customer settings for
temperature sensors
Test
■■ Insulation resistance of all
windings (P7 test for LV/MV)
■■ Temperature sensors while
alternator is running
Rectifier
Inspect
■■ Diodes and varistors
Post Commission 250 Hours/6 Months
S7 Alternator
Bearings Alternator
Inspect Inspect
■■ Condition of bearings ■■ Environmental conditions
■■ Customer settings for and cleanliness
temperature sensors ■■ Complete machine damage,
loose parts, and earth
bonds
Test
■■ Guards, screens, warning
■■ Temperature sensors while and safety labels
alternator is running
Test
■■ Ambient temperature (inside
and outside)
■■ Electrical nominal operating
conditions and excitations
Terminal Box while alternator is running
■■ Vibration while alternator is
Inspect running
■■ All alternator/customer
connections and cabling
Controls and Auxiliaries
Test
■■ AVR and PFC settings while
alternator is running
■■ Function of auxiliaries
■■ Synchronisation while
alternator is running
Cooling
Inspect
■■ Condition of fan
Test
■■ Condition of air filter
Clean
■■ Air filter
Windings Bearings
Inspect Inspect
■■ Condition of windings ■■ Condition of bearings
Test
Test
■■ Temperature sensors while
■■ Insulation resistance of all alternator is running
windings (P7 test for LV/MV)
■■ Insulation resistance of Clean
rotor, exciter and PMG ■■ Grease exhaust and trap
■■ Temperature sensors while (Re-greasable bearings only)
alternator is running
Replace
■■ Grease for re-greasable
bearings
Rectifier Terminal Box
Inspect Inspect
■■ Diodes and varistors ■■ All alternator/customer
connections and cabling
 1,000 Hours/1 Year Service
S7 Alternator
Alternator
Inspect
■■ Environmental conditions
and cleanliness
■■ Complete machine damage,
loose parts, and earth
bonds
■■ Guards, screens, warning
and safety labels
Test
■■ Ambient temperature (inside
and outside)
■■ Electrical nominal operating
conditions and excitations
while alternator is running
■■ Vibration while alternator is
running
Controls and Auxiliaries
Test
■■ AVR and PFC settings while
alternator is running
■■ Customer connections of
auxiliaries
■■ Function of auxiliaries
■■ Synchronisation while
alternator is running
Cooling
Inspect
■■ Condition of fan
Test
■■ Condition of air filter
Clean
■■ Air filter
Windings
Inspect
■■ Condition of windings
Test
■■ Insulation resistance of all
windings (P7 test for LV/MV)
■■ Insulation resistance of
rotor, exciter, and PMG
■■ Temperature sensors while
alternator is running
Rectifier
Inspect
■■ Diodes and varistors
10,000 Hours/2 Year Service
S7 Alternator
Bearings Alternator
Inspect Inspect
■■ Condition of bearings ■■ Coupling arrangement
■■ Environmental conditions
Test and cleanliness
■■ Temperature sensors while ■■ Complete machine damage,
alternator is running
loose parts, and earth
bonds
Clean
■■ Guards, screens, warning
■■ Grease exhaust and trap and safety labels
(Re-greasable bearings only)
Replace Test
■■ Grease for re-greasable ■■ Ambient temperature (inside
bearings and outside)
■■ Electrical nominal operating
Terminal Box conditions and excitations
while alternator is running
Inspect ■■ Vibration while alternator is
■■ All alternator/customer running
connections and cabling
Controls and Auxiliaries
Inspect
■■ Anti condensation heater
Test
■■ AVR and PFC settings while
alternator is running
■■ Customer connections of
auxiliaries
■■ Function of auxiliaries
■■ Synchronisation while
alternator is running
Cooling
Inspect
■■ Condition of fan
Test
■■ Condition of air filter
Clean
■■ Air filter
Windings Bearings
Inspect Inspect
■■ Condition of windings ■■ Condition of bearings
Test
Test
■■ Temperature sensors while
■■ Insulation resistance of all alternator is running
windings (P7 test for LV/MV)
■■ Temperature sensors while Clean
alternator is running
■■ Grease exhaust and trap
(Re-greasable bearings only)
Replace
■■ Grease for re-greasable
bearings
Rectifier Terminal Box
Inspect Inspect
■■ Diodes and varistors ■■ All alternator/customer
connections and cabling
S7 Alternator 30,000 Hours/5 Year Service Kits 30,000 Hours/5 Year Service

S7 Alternator
Alternator Controls and Auxiliaries Windings Bearings
For the 30,000 hour service interval Kit Number Contents
Inspect Replace Inspect Replace
we recommend replacing several
A051C251 ■■ Rectifier Service Kit ■■ Coupling arrangement ■■ Anti condensation heater ■■ Condition of windings ■■ Bearings (Sealed &
components in order to optimise the re-greasable)
(P7/S7 1 RE-GREASABLE Bearing 30,000 ■■ NDE Bearing Kit ■■ Environmental conditions
alternator’s performance. Hour Service Kit) and cleanliness ■■ Bearing grease
■■ Cartridge and Cap Test Test
For the S7 alternator, the kits detailed ■■ Complete machine damage, ■■ AVR and PFC settings while ■■ Insulation resistance of all
A051Z145 ■■ Rectifier Service Kit loose parts, and earth
in this table contain all parts necessary alternator is running windings (S7 test for LV) Test
(P7/S7 1 SEALED Bearing 30,000 HourService ■■ NDE Bearing Kit bonds
to execute the maintenance and ■■ Customer connections of ■■ Temperature sensors while ■■ Temperature sensors while
Kit) ■■ Cartridge and Cap ■■ Guards, screens, warning
repairs. auxiliaries alternator is running alternator is running
and safety labels
■■ Rectifier Service Kit ■■ Function of auxiliaries ■■ Insulation resistance of
A051C255
■■ Synchronisation while rotor, exciter and PMG Clean
(P7 A-E core/S7 C-F core 2 RE-GREASABLE ■■ DE Bearing Kit Test alternator is running ■■ Grease exhaust & trap
Bearing 30,000 Hour Service Kit) ■■ Cartridge and Cap ■■ Ambient temperature (inside (re-greasable bearings only)
and outside)
A051C257 ■■ Rectifier Service Kit
■■ Electrical nominal operating
(P7 F-G core/S7 G-J core 2 RE-GREASABLE ■■ DE Bearing Kit conditions and excitations Cooling Rectifier Terminal Box
Bearing 30,000 Hour Service Kit) ■■ Cartridge and Cap while alternator is running
■■ Vibration while alternator is Inspect Replace Inspect
running ■■ Condition of fan ■■ Diodes and varistors ■■ All alternator/customer
Frame Part Number Description connections and cabling

Test
S7 C-G A053N003 Heater Kit UL 220-260V
■■ Condition of air filter

S7 C-G A053M969 Heater Kit UL 110-125V

Clean

S7 H-J A053N109 Heater Kit UL 220-260V ■■ Air filter

S7 H-J A053M999 Heater Kit UL 110-125V

 P80
Alternator

P80
Alternator Commission Post Commission
6 Month Service
1,000 Hour
1 Year Service
10,000 Hours
2 Year Service
30,000 Hours
5 Year Service
 Commission
P80 Alternator
Alternator
Inspect
■■ Alternator rating
■■ Bedplate arrangement
■■ Coupling arrangement
■■ Environmental conditions
and cleanliness
■■ Complete machine damage,
loose parts and earth bonds
■■ Guards, screens, warning
and safety labels
■■ Maintenance access
Test
■■ Ambient temperature (inside
and outside)
■■ Electrical nominal operating
conditions and excitations
while alternator is running
■■ Vibration while alternator is
running
Controls and Auxiliaries
Inspect
■■ Synchronisation settings
Test
■■ Initial AVR and PFC set up
■■ AVR and PFC settings
settings while alternator is
running
■■ Customer connections of
auxiliaries
■■ Function of auxiliaries
■■ Synchronisation while
alternator is running
Cooling
Inspect
■■ Air flow (rate and direction
while alternator is running)
■■ Condition of fan
Test
■■ Condition of air filter
Windings
Inspect
■■ Condition of windings
■■ Customer settings for
temperature sensors
Test
■■ Insulation resistance of
all windings (P80 test for
MV/HV)
■■ Temperature sensors while
alternator is running
Rectifier
Inspect
■■ Diodes and surge
suppressors
Post Commission 250 Hours/6 Months
P80 Alternator
Bearings Alternator
Inspect Inspect
■■ Condition of bearings ■■ Environmental conditions
■■ Customer settings for and cleanliness
temperature sensors ■■ Complete machine damage,
loose parts, and earth
bonds
Test
■■ Guards, screens, warning
■■ Temperature sensors while
and safety labels
alternator is running
Test
■■ Ambient temperature (inside
and outside)
■■ Electrical nominal operating
conditions and excitations
Terminal Box while alternator is running
■■ Vibration while alternator is
Inspect running
■■ All alternator/customer
connections and cabling
Controls and Auxiliaries
Test
■■ AVR and PFC settings while
alternator is running
■■ Function of auxiliaries
■■ Synchronisation while
alternator is running
Cooling
Inspect
■■ Condition of fan
Test
■■ Condition of air filter
Clean
■■ Air filter
Windings
Inspect
■■ Condition of windings
Test
■■ Insulation resistance of
all windings (P80 test for
MV/HV)
■■ Insulation resistance of
rotor, exciter and PMG
■■ Temperature sensors while
alternator is running
Rectifier
Inspect
■■ Diodes and surge
suppressors
Bearings
Inspect
■■ Condition of bearings
Test
■■ Temperature sensors while
alternator is running
Clean
■■ Grease exhaust and trap
(Re-greasable bearings only)
Replace
■■ Grease for re-greasable
bearings
Terminal Box
Inspect
■■ All alternator/customer
connections and cabling
 1,000 Hours/1 Year Service
P80 Alternator
Alternator
Inspect
■■ Environmental conditions
and cleanliness
■■ Complete machine damage,
loose parts, and earth
bonds
■■ Guards, screens, warning
and safety labels
Test
■■ Ambient temperature (inside
and outside)
■■ Electrical nominal operating
conditions and excitations
while alternator is running
■■ Vibration while alternator is
running
Controls and Auxiliaries
Test
■■ AVR and PFC settings while
alternator is running
■■ Customer connections of
auxiliaries
■■ Function of auxiliaries
■■ Synchronisation while
alternator is running
Cooling
Inspect
■■ Condition of fan
Test
■■ Condition of air filter
Clean
■■ Air filter
Windings
Inspect
■■ Condition of windings
Test
■■ Insulation resistance of
all windings (P80 test for
MV/HV)
■■ Insulation resistance of
rotor, exciter, and PMG
■■ Temperature sensors while
alternator is running
Rectifier
Inspect
■■ Diodes and surge
suppressors
10,000 Hours/2 Year Service
P80 Alternator
Bearings Alternator
Inspect Inspect
■■ Condition of bearings ■■ Coupling arrangement
■■ Environmental conditions
Test and cleanliness
■■ Temperature sensors while ■■ Complete machine damage,
alternator is running
loose parts, and earth
bonds
Clean
■■ Guards, screens, warning
■■ Grease exhaust and trap and safety labels
(Re-greasable bearings only)
Replace Test
■■ Grease for re-greasable ■■ Ambient temperature (inside
bearings and outside)
■■ Electrical nominal operating
Terminal Box conditions and excitations
while alternator is running
Inspect ■■ Vibration while alternator is
■■ All alternator/customer running
connections and cabling
Controls and Auxiliaries Windings Bearings
Inspect Inspect Inspect
■■ Anti condensation heater ■■ Condition of windings ■■ Condition of bearings
Test
Test Test
■■ Temperature sensors while
■■ AVR and PFC settings while ■■ Insulation resistance of alternator is running
alternator is running all windings (P80 test for
MV/HV)
■■ Customer connections of Clean
auxiliaries ■■ Temperature sensors while
■■ Grease exhaust and trap
■■ Function of auxiliaries alternator is running (Re-greasable bearings only)
■■ Synchronisation while
alternator is running Replace
■■ Grease for re-greasable
bearings
Cooling Rectifier Terminal Box
Inspect Inspect Inspect
■■ Condition of fan ■■ Diodes and surge ■■ All alternator/customer
suppressors connections and cabling
Test
■■ Condition of air filter
Clean
■■ Air filter
P80 Alternator 30,000 Hours/5 Year Service Kits
For the 30,000 hour service interval Kit Number
we recommend replacing several
components in order to optimise the
A051C282
alternator’s performance.
(P80 1 Bearing 30,000 Hour Service Kit)
For the P80 alternator, the kits detailed
in this table contain all parts necessary A051C285
to execute the maintenance and (P80 2 Bearing 30,000 Hour Service Kit)
repairs.
A051C291
(P80 2 Bearing 30,000 Hour Service Kit)
Frame Part Number
P80 45-1029
30,000 Hours/5 Year Service
P80 Alternator
Alternator
Contents
Inspect
■■ Coupling arrangement
■■ Rectifier Service Kit ■■ Environmental conditions
and cleanliness
■■ NDE Bearing Kit
■■ Complete machine damage,
loose parts, and earth
bonds
■■ Rectifier Service Kit ■■ Guards, screens, warning
■■ Bearing Kit Frame R, S, & T and safety labels
Test
■■ Ambient temperature (inside
■■ Rectifier Service Kit
and outside)
■■ Bearing Kit Frame X, Y, & Z
■■ Electrical nominal operating
conditions and excitations
while alternator is running
■■ Vibration while alternator is
running
Description
Heater Kit UL
Controls and Auxiliaries
Replace
■■ Anti condensation heater
Test
■■ AVR and PFC settings while
alternator is running
■■ Customer connections of
auxiliaries
■■ Function of auxiliaries
■■ Synchronisation while
alternator is running
Cooling
Inspect
■■ Condition of fan
Test
■■ Condition of air filter
Windings
Inspect
■■ Condition of windings
Test
■■ Insulation resistance of
all windings (P80 test for
MV/HV)
■■ Temperature sensors while
alternator is running
■■ Insulation resistance of
rotor, exciter and PMG
Rectifier
Replace
■■ Diodes and surge
suppressors
Bearings
Replace
■■ Bearings (sealed &
re-greasable)
■■ Bearing grease
Test
■■ Temperature sensors while
alternator is running
Clean
■■ Grease exhaust & trap
(re-greasable bearings only)
Terminal Box
Inspect
■■ All alternator/customer
connections and cabling
Guaranteed
We guarantee that every product we produce
matches the quality, robustness, and proven
performance you expect from the STAMFORD range.
Built to our quality assured standards, STAMFORD
products benefit from a global support network,
extensive research and development, and world-
leading expertise.
Where people need power, businesses rely on
genuine STAMFORD alternators. Proven expertise
in design, development, manufacturing, customer
support and servicing, ensures quality in every aspect
of our business.
Visit genuine-stamford.com to find out how we
are protecting our customers and their businesses
against the dangers of illegal, counterfeit and
imitation products and taking action.
The Power of More™
Selecting the right alternator for the right What this means to you:
application in today’s complex world is ■■ 24 hour response to service emergencies,
our goal - making your life simpler. We 7 days a week
understand the performance requirements
■■ Trained engineers available locally,
that each application and operating
speaking the local language
environment demands. Our knowledgeable
and experienced Customer Engineers align ■■ Commissioning of alternators onsite
individual customers’ power needs with the ■■ Onsite bearing maintenance and bearing
most suitable alternator specification. condition monitoring
We take pride in our global reputation for ■■ Onsite insulation integrity checks
Technical Support and After Sales Service, ■■ AVR and accessories set up onsite
continually adding new, trained engineers in ■■ Extensive aftermarket distribution for
locations near to our customers, worldwide. genuine STAMFORD parts
Cummins engineers are experienced
professionals trained in electrical, electronic
and mechanical engineering and are ready
to help at any point in the STAMFORD
alternator lifecycle, minimising risk of
unexpected downtime.
Applications Support Email:
applications@cummins.com
Customer Service Help Desk:
Phone: +44 (0)1780 758690 (24 hours)

Service Contacts:
Americas: cgta.service@cummins.com
Phone: +1-800-367-2764

EMEA: emea.service@cummins.com
Phone: +441780 758690

APAC: APAC.service@cummins.com
Phone: +65 63053155

China: CGT.China.service@cummins.com
stamford-avk@cummins.com
Phone: +86 400 88 12390

Copyright 2019, Cummins Generator Technologies Ltd. All rights reserved.

Cummins and the Cummins logo are registered trade marks of Cummins Inc.
India: v.devarajan@cummins.com AvK and STAMFORD are registered trade marks of Cummins Generator Technologies Ltd.
Phone: +91 (0) 20 67067639
Part No. PG_SSG_P_EN_AF Rev.05