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    S SSB29 - Alternator Cables PM: WARNING: This Equipment Contains Hazardous Voltages

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    Mohan Preeth
    This document provides instructions for performing preventative maintenance on alternator cables to prevent wear and chaffing. It involves using heat shrink tubing and tape to insulate the main stator and auxiliary leads where they are showing signs of damage or wear. The procedure takes an estimated 2 hours and should only be performed by trained technicians, as it involves working on hazardous high-voltage systems. Safety precautions like lockout/tagout and verifying the system is safe to work on must be followed.

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    © All Rights Reserved
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    S SSB29 - Alternator Cables PM: WARNING: This Equipment Contains Hazardous Voltages

    Uploaded by

    Mohan Preeth
    37 views3 pages
    This document provides instructions for performing preventative maintenance on alternator cables to prevent wear and chaffing. It involves using heat shrink tubing and tape to insulate the main stator and auxiliary leads where they are showing signs of damage or wear. The procedure takes an estimated 2 hours and should only be performed by trained technicians, as it involves working on hazardous high-voltage systems. Safety precautions like lockout/tagout and verifying the system is safe to work on must be followed.

    Original Description:

    Alternator cable hitachi

    Original Title

    SSB29_AlternatorCables_PM

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    This document provides instructions for performing preventative maintenance on alternator cables to prevent wear and chaffing. It involves using heat shrink tubing and tape to insulate the main stator and auxiliary leads where they are showing signs of damage or wear. The procedure takes an estimated 2 hours and should only be performed by trained technicians, as it involves working on hazardous high-voltage systems. Safety precautions like lockout/tagout and verifying the system is safe to work on must be followed.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    37 views3 pages

    S SSB29 - Alternator Cables PM: WARNING: This Equipment Contains Hazardous Voltages

    Uploaded by

    Mohan Preeth
    This document provides instructions for performing preventative maintenance on alternator cables to prevent wear and chaffing. It involves using heat shrink tubing and tape to insulate the main stator and auxiliary leads where they are showing signs of damage or wear. The procedure takes an estimated 2 hours and should only be performed by trained technicians, as it involves working on hazardous high-voltage systems. Safety precautions like lockout/tagout and verifying the system is safe to work on must be followed.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 3

    s AC TRUCK SERVICE BULLETIN-PM-SSB29

    5/18/2007

    SSB29 – Alternator Cables PM


    Description of Modification
    In order to prevent cable wear and chaffing, preventative maintenance is recommended to better insulate the Alternator’s
    Main Stator Leads. This preventative maintenance is recommended for older version Alternators displaying damage to Main
    Stator Leads or signs of wear and chaffing. While inspecting Main Stator Leads it is recommended that Auxiliary Leads are
    inspected and maintained as well.

    Overview
    The following procedure describes the necessary steps to modify affected cables so that they are more resistant to wear and
    chaffing due to shock and vibration.

    Time to Install
    The estimated completion time is 2 hours. This estimate assumes all required tools and materials are readily available and the
    procedure has been reviewed prior to beginning.

    Tools Required
    • Heat Gun
    • Tools required in regular work on the drive system

    Materials Required
    • Commercially available, industrial grade, electrically insulated Heat Shrink with minimum insulation rating of 3Kv,
    such as 3M, ITCSN Heat Shrinkable Cable Sleeves
    o Cable Dimensions
    ƒ Main Stator Leads (6) - 4/0 awg, (0.91” insulation OD)
    ƒ Auxiliary Leads (3) - 2 awg, (0.66” insulation OD)
    • Commercially available, industrial grade, heat resistant Tie Wraps (ensure sufficient lengths, minimum 1 foot, and
    tensile strength)
    • Commercially available, industrial grade, heat resistant Electrical Insulation Tape with minimum insulation rating
    of 3kv

    Skills Required
    Understanding of all safety procedures involving work on drive system components

    Familiarity With
    Working on the Siemens AC Haul Truck drive system

    WARNING: This Equipment Contains Hazardous Voltages

    All warnings and hazard labels have to be read and obeyed carefully before any kind of installation,
    commissioning, service or repair action is taken. Violating these instructions can cause severe damages
    to the machine or cause the death of the operator or service personnel!

    WARNING: !!! VERIFY THAT THE SYSTEM IS SAFE TO WORK ON!!!


    o Shut the engine off using proper shutdown procedure, key off
    o Lock Out / Tag Out procedures for site should be strictly followed
    o Allow the system to completely power down
    o Wait 5 minutes before opening the cabinet doors
    o Use a high voltage probe to measure the DC bus to ground
    o After confirming that the system is safe to work , begin work

    WARNING: This procedure is meant for individuals who already have a high level of experience working on the
    Siemens AC Haul Truck drive system. To ensure work is done safely only Siemens trained technicians or
    those specifically trained by Siemens Engineers should perform the following.

    Rev 1 1 of 3
    s AC TRUCK SERVICE BULLETIN-PM-SSB29
    5/18/2007

    Procedure

    Warning
    This procedure requires work performed at heights. Observe and follow all proper safety requirements!

    Note
    Torque all electrical connections and mounting bolts based on the size and grade of the hardware used

    1. Completely remove top cover from Main Rectifier to inspect Main Stator Leads
    • Remove bolts fastening Main Rectifier Cover using correctly sized socket
    • Remove bolts holding Main Rectifier cover to Blower Housing using two correctly sized wrenches
    • Keep all bolts, nuts, and washers in safe place while performing work, do not allow them to fall into Alternator
    • Take Main Rectifier cover and place in secure location

    2. Remove fasteners holding Main Stator Leads to Main Rectifier


    • If leads are missing labels, be sure to label first before removing fasteners and covering with heat shrink. Use Figure
    2 as reference.
    • Remove bolts securing leads to Main Rectifier using wrench and socket. There should be two leads per phase
    marked one, two and three. Remove any tie wraps securing leads so they may be covered with heat shrink.

    3. Cover each lead with insulated heat shrink


    • Inspect Main Stator Leads for signs of damage and where they could possibly wear or chaff. These sections must be
    covered by insulated heat shrink.
    • Cover leads in appropriate places and use heat gun to secure heat shrink, Figure 1 shows leads entirely covered
    • If Stator Lead labels are covered by Heat Shrink, apply new labels accordingly (See labels on leads in Figure 2)
    • Inspect Auxiliary Leads and determine if insulation is necessary
    • Use insulated electrical tape to cover any damaged areas or locations where the cables are wearing and chaffing.
    • Watch for rubbing between Main Stator Leads and Auxiliary Leads and insulate accordingly

    Caution
    Correct safety measures must be followed while using Heat Gun; may cause burns.

    Note
    Be careful not to overheat Stator Leads or Heat Shrink while using Heat Gun

    Figure 1. Heat Shrink on Stator Leads.


    Figure 2. Stator Lead connections to Main Rectifier.

    Rev 1 2 of 3
    s AC TRUCK SERVICE BULLETIN-PM-SSB29
    5/18/2007
    4. Connect stator leads back to Main Rectifier
    • When all cables requiring maintenance have been insulated, connect back to the Main Rectifier appropriately
    • Install fasteners that were removed in step 2

    5. Tightly secure leads with Tie Wraps


    • Using Tie Wraps, sufficiently secure Main Stator Leads and Auxiliary Leads to prevent shifting and vibration,
    remember to crisscross tie wraps to prevent shifting
    • Using Figure 2 note the use of support bars as tie points for cables

    Note
    Not all Rectifier Enclosures are the same as in Figure 2. Use example provided and modify for availability of tie
    points. Remember to securely fasten leads so that they do not have the ability to shift or vibrate.

    6. Install Alternator top cover on Main Rectifier and blower housing


    • Perform Step 1 in reverse, making sure all bolts are secure and not missing
    • If any hardware is missing replace immediately!

    Rev 1 3 of 3

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