Mantenimiento 5GTA39

GE Transportation
5GTA39 Alternator
Maintenance
Document No. GEK-91723, Rev. A
GEK-91723A
5GTA39 Alternator Maintenance
© 2012 General Electric Company. All rights reserved. The information contained in this publication is the property of
General Electric Company and is disclosed in confidence. This publication is intended for use by GE customers solely
for purposes of operating and performing routine maintenance of purchased or licensed GE products, and it shall
not be reproduced, redistributed, retransmitted, translated, abridged, adapted, condensed, revised or otherwise
modified, in any form, in whole or in part, or used for any other purpose, or disclosed to third parties, without the
express written consent of GE. However, if a GE customer ("Customer") requires additional copies of this publication
or portions thereof for internal use, GE hereby grants to Customer a limited right to reproduce this publication, in
whole or in part, and Customer agrees to use such authorized copies ("Copies") solely for its intended purposes. Any
Copies made under this limited reproduction right shall contain this notice and any other legal notices appearing in
this publication. The Customer shall be responsible for complying with U.S. export control laws with respect to distri-
bution of all Copies.
GE and Customer agree that the information contained herein does not purport to cover all details or variations in
GE products or to provide for every possible contingency with installation, operation or maintenance. Should further
information be desired or should particular problems arise that are not covered sufficiently for the user's purposes,
the matter should be referred to General Electric Company. Any applicable Federal, State or local regulations or
company safety or operating rules must take precedence over any information or instructions given in the Technical
Documentation. GE has no obligation to keep the material up to date after the original publication.
GENERAL ELECTRIC COMPANY EXPLICITLY DISCLAIMS ALL WARRANTIES OF ACCURACY, MERCHANTABILITY OR FIT-
NESS FOR ANY PURPOSE IN CONNECTION WITH THIS PUBLICATION AND USE THEREOF.
If you are not an authorized recipient of this publication, you are hereby notified that any perusal, use, distribution,
copying or disclosure is strictly prohibited. If you have received this publication in error, please immediately return to
GE at the following address: GE Transportation, Technical Publications Department, Building 14, 2901 East Lake Rd.,
Erie, PA 16531.
Revision History
Rev Date By Description
NEW Jun-2008 PAB Initial release of publication.
A Dec-2012 AMB Replaced the stator field resistance limit and the tertiary field resistance in
Table 4 per Workflow 81649779.
ii GE Proprietary and Confidential Information

GEK-91723A
TABLE OF CONTENTS
Section Page
1. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2. RELATED PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3. SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4. MODEL DIFFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5. REMOVAL AND REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5.1. ALTERNATOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5.2. CLEANING ALTERNATOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.3. INSPECTION AND TEST PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.4. ALTERNATOR COMPONENT RECONDITIONING OR REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.5. ALTERNATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.6. ALTERNATOR ROTATIONAL TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6. SUMMARY DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.1. ALTERNATOR DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.2. ALTERNATOR COMPONENT IDENTIFICATION BY MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.3. TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.4. DIMENSIONAL INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
GE Proprietary and Confidential Information iii

GEK-91723A
LIST OF FIGURES
Figure Page
1 5GTA39 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Alternator Engine Connection End Frame Adapter Sling Positioning . . . . . . . . . . . . . . . . . 6
3 Alternator in the Shaft Horizontal Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Alternator in the Shaft Vertical Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Preparing to Lift the Rotor Assembly and Frame Head from the Stator Assembly. . . . . 9
6 Attachment Points for Two Hoists to Frame Head (Viewed From Above) . . . . . . . . . . . . . 11
7 Rotor Bearing Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
8 Preparation for Collector Ring Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
9 Rotor Coil Components and Mounting Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10 Rotor Balance Weight Attachment Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
11 Alternator Impeller Hub Alignment and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
12 Bearing Assembly Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
13 Routing and Securing Brush Holder Cables and Speed Sensor Cable . . . . . . . . . . . . . . . . 43
14 5GTA39A1, 5GTA39A2, and 5GTA39B1 Component Identification (Part 1 of 2) . . . . . . . . 49
15 5GTA39A1, 5GTA39A2, and 5GTA39B1 Component Identification (Part 2 of 2) . . . . . . . . 50
16 5GTA39B2 Component Identification (Part 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
17 5GTA39B2 Component Identification (Part 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
18 5GTA39C1 Component Identification (Part 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
19 5GTA39C1 Component Identification (Part 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
20 5GTA39C2 and 5GTA39C3 Component Identification (Part 1 of 2) . . . . . . . . . . . . . . . . . . . . 55
21 5GTA39C2 and 5GTA39C3 Component Identification (Part 2 of 2) . . . . . . . . . . . . . . . . . . . . 56
22 5GTA39D1 and 5GTA39D2 Component Identification (Part 1 of 2) . . . . . . . . . . . . . . . . . . . 57
23 5GTA39D1 and 5GTA39D2 Component Identification (Part 2 of 2) . . . . . . . . . . . . . . . . . . . 58
24 Torque Values, Part 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
27 Alternator Rotor Shaft Dimensional Inspection Criteria. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
28 Bearing Housing Dimensional Inspection Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
29 Bearing Cap Dimensional Inspection Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
30 Rotor Shaft Collar Dimensional Inspection Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
31 Flinger Critical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
iv GE Proprietary and Confidential Information

GEK-91723A
1. GENERAL INFORMATION
1.1. INTRODUCTION
This publication covers the repair and overhaul procedures (disassembly, inspection, reassembly, and testing) for the
General Electric OHV 5GTA39 Traction Alternator, shown in Figure 1, used in electric drive mining trucks.
Figure 1. 5GTA39 Alternator
Revisions are indicated by margin bars.
GE Proprietary and Confidential Information 1

GEK-91723A
1.2. RELATED PUBLICATIONS
When using related publication, always use the highest letter version of the publication. Publications containing
additional information on the 5GTA39 Alternator are:
Table 1. Related Publications
Publication Title Publication Number

Planned Maintenance GEK-91739
AC OHV Drive System Pedigree File GEK-91703
OHV Rotating Equipment Overhaul Tool Guide GEK-91747
1.3. SAFETY INFORMATION
Safety precautions, which must be observed when working on this equipment, appear throughout this publication.
WARNINGS indicate the potential for personal injury, and CAUTIONS indicate the potential for equipment damage.
1.4. MODEL DIFFERENCES
For 5GTA39 model differences, refer to the AC OHV Drive System Pedigree File publication shown in section
1.2., RELATED PUBLICATIONS in this publication.
2. CONTROLS AND INDICATORS

Not applicable.
3. FUNCTIONAL DESCRIPTION
The 5GTA39 Traction Alternator is a salient-pole, three-phase, Y-connected, AC alternator mounted solidly to a diesel
engine and driven by the engine crankshaft. The alternator provides electrical power for propulsion and control sys-
tems of an Off-Highway vehicle.
The alternator is a single-bearing, self-excited machine, the rotor of which is bolted directly to the engine crankshaft
through an adapter plate and a flex plate. Alternator rotor weight is supported on the outboard end (collector ring
end) with a ball bearing and on the drive end by the engine crankshaft.
Cooling air is supplied by an in-line integral blower. This blower consists of a fan bolted directly to the fan hub, which
is mounted on the rotor shaft outboard of the alternator bearing. The blower housing is made of fiberglass to mini-
mize weight.
4. SCHEDULED MAINTENANCE
Refer to section 1.2., RELATED PUBLICATIONS in this publication for the Planned Maintenance publication.
5. REMOVAL AND REPLACEMENT

The Alternator weighs approximately 10800 lbs. (4900 kg). Use appropriate lifting
WARNING devices for this weight. Failure to do so may result in injury or death.
2 GE Proprietary and Confidential Information

GEK-91723A
Lift the alternator using the three lifting lugs on the stator assembly. Do not attempt
CAUTION to lift the alternator by the fiberglass housing. Damage to the fiberglass housing will
result if excessive loads are placed on the housing.
Do not use standard hardware to replace alternator hardware during overhaul. Most
CAUTION hardware (bolts, nuts, washers, etc.) is special application hardware. Use only parts
ordered from the Parts Catalogue for the alternator. Failure to use correct hardware
may result in alternator damage and premature failure.
When removing hardware (bolts, nuts, and washers) that will be reused, mark the
CAUTION hardware by tag or small box to ensure the correct hardware is installed in the correct
location when assembling the alternator. Failure to install the correct hardware in the
correct location may cause premature failure of the alternator.
5.1. ALTERNATOR DISASSEMBLY

Ensure fiber shims are between the rotor and the stator components to prevent
CAUTION bearing misalignment during disassembly. Shims material should be 15 X 4 X 0.140
inches (381 X 102 X 3.56 mm). The shims should be installed for alternator shipping.
5.1.1. Blower Housings and Traction Motor/Control Impeller Removal
NOTE: Unless otherwise noted, the numbers in parentheses refer to items in Figure 22 found in section
6.2., ALTERNATOR COMPONENT IDENTIFICATION BY MODEL in this publication.
The alternator should be in the shaft horizontal position as shipped. The blower outlet air housing (42), impeller blade
(43), and blower inlet air housing (38) should be removed at this time. To remove these components:
1. To remove the air outlet housing (42):
a. Secure the air outlet housing (42) on a lifting device with a lifting strap or sling that will not damage the
housing. Take the slack out of the lifting strap or sling with the lifting device.
The blower air outlet housing weighs approximately 125 lbs. (56.7 kg). Use appropriate
WARNING lifting devices for this weight. Failure to do so may result in injury or death.
b. Remove the bolts (40), nuts (41), and washers from around the outlet housing. Mark and store the bolts, nuts,
and washers for use during alternator assembly.
c. Sealer between the outlet and inlet housings (42 and 38)may hold the housing pieces together. Use a thin
bladed tool (putty knife) between the housings to separate the sealer. Do not use pry bars, which may dam-
age the fiberglass housings.
d. Lift the outlet housing away from the alternator and store in a secure location to prevent damage to the
fiberglass.
2. To remove the impeller blade (43):
a. Secure the impeller blade (43) on a lifting device with a lifting strap or sling that will not damage the impeller.
Take the slack out of the lifting strap or sling with the lifting device.

GEK-91723A
The impeller blade weighs approximately 170 lbs. (77 kg). Use appropriate lifting
b. Remove the bolts (45) securing the impeller blade (43) to the impeller drive hub (44). Mark and store the bolts
for use during assembly.
c. Install two guide pins (0.50-13 x 4 inch all thread or bolt with the head removed) at the 3 o’clock and 9
o’clock positions (opposite sides) in the impeller blade mounting holes. The guide pins will thread into the
threaded holes of the impeller drive hub.
d. If the impeller blade (43) is not loose on the impeller drive hub (44), three jack out bolts can be threaded into
the three equally spaced threaded holes in the impeller blade. Thread three 0.50-13 x 6 (with at least 3.5
inches of thread) jack out bolts into the threaded holes of the impeller blade.
e. Moving around the three jack out bolts, apply even pressure by threading the jack out bolts in until the
impeller is loose from the impeller drive hub (44).
f. A dowel pin is located between the impeller and drive hub. When removing the impeller, the dowel pin may
remain with the drive hub or pull out with the impeller. After separating the drive hub and impeller, remove
the dowel pin and mark for installation during assembly.
g. Lift the impeller blade (43) away from the alternator, remove the jack out bolts, and store the impeller blade
in a protect area to prevent damage.
h. Remove the guide pins from the impeller drive hub.
3. To remove the air inlet housing (38):
a. Secure the air inlet housing (38) on a lifting device with a lifting strap or sling that will not damage the air
inlet housing. Take the slack out of the lifting strap or sling with the lifting device.
The blower air inlet housing weighs approximately 295 lbs. (135 kg). Use appropriate
b. Remove the bolts and washers (39) securing the inlet housing to the frame head (37).
c. Sealer between the inlet housings (38) and the frame head (37)may hold the inlet housing and frame head
together. Use a thin bladed tool (putty knife) between the inlet housing and the frame head to separate the
sealer. Do not use pry bars, which may damage the fiberglass housing.
d. Lift the inlet housing away from the alternator and store in a secure location to prevent damage to the
fiberglass.
5.1.2. Traction Motor/Control Impeller Drive Hub Removal
NOTE: The impeller drive hub must be removed at this time to allow the alternator to be turned to the shaft ver-
tical position.
To remove the impeller drive hub (44):

GEK-91723A
1. Assemble the impeller drive hub removal tool on the rotor shaft and drive hub as shown in publication GEK-
91747, OHV ROTATING EQUIPMENT OVERHAUL TOOL GUIDE listed in section 1.2., RELATED PUBLICATIONS in
this publication.
When removing the impeller drive hub, hydraulic fluid may leak from the tooling
WARNING assembly causing slippery floors. Place a container under the impeller drive hub to
contain any leaking hydraulic fluid. Failure to do so may result in injury on oil covered
floors.
2. Pump the manual hydraulic pump until the drive hub has loosened from the rotor shaft fit. The back plate of the
tool assembly will prevent the drive hub from ejecting and falling when the drive hub is forced from the rotor
shaft fit.
3. Remove the impeller drive hub removal tool assembly components and store the drive hub in a secure location
until assembly of the alternator.
4. Disassemble the impeller drive hub removal tool from the alternator.
5.1.3. Frame Adapter Removal
Before turning the alternator to the shaft vertical position, the frame adapter (13) should be removed. To remove the
frame adapter:
1. Lace a lifting sling or cable through two upper adjacent windows or slots as shown in Figure 2 in the frame
adapter (13) in the center of the frame adapter. Attach the sling or cable to a hoist and take the slack out of the
sling.
2. Thread a 0.625-11 eyebolt into the upper tapped hole of the engine adapter outer bolt circle as shown in Figure
2. This will allow the rotor to be lifted slightly off the frame adapter. Lace a lifting sling or cable through the eye-
bolt. Attach the sling or cable to a second hoist (not the hoist lifting the frame adapter). Lift the rotor assembly
slightly so the frame adapter is not supporting the weight of the rotor. Do not lift the alternator with the eyebolt.
3. Remove (and mark for reuse) the mounting bolts and washers (14) from the backside of the frame adapter.
4. Lift the frame adapter away from the alternator and secure in a safe location.
5. Remove the sling from the frame adapter.
5.1.4. Install the Stator Support Posts
Install four equally spaced rotor support post assemblies (post, stud, and nut) through the mounting holes of the
frame adapter bolts (14) as shown in Figure 3. Snug the support post nut with a wrench. This will maintain the proper
height of the stator with the rotor height when the alternator is turned to the shaft vertical position.

GEK-91723A
5.1.5. Rotating the Alternator from the shaft Horizontal Position to the Shaft Vertical Posi-
tion
To continue with the alternator disassembly, the alternator must be in the shaft vertical position. To rotate the alter-
nator from the shaft horizontal position, Figure 3, to the shaft vertical position, Figure 4.
1. Install the Rotor End Swivel Hoist Ring Assembly on the end of the rotor shaft as shown in publication GEK-
this publication
The alternator assembly weighs approximately 9500 lbs (4310 kg). Use appropriate lift-
WARNING ing devices for this weight. Failure to do so may result in injury or death.
T20
T19
Figure 2. Alternator Engine Connection End Frame Adapter Sling Positioning

GEK-91723A
2. With the swivel hoist ring attached to the rotor end, prepare to lift the alternator with two hoists. Attach the hoist
cables as shown in Figure 3.
3. Lift the alternator evenly with both hoists.
4. When the alternator is approximately 3 feet (1 meter) of the floor, begin lifting the rotor end of the alternator and
lowering the engine connection end of the alternator. Position the hoist to remain over the center of the load for
the hoist.
5. When the alternator has been turned to the shaft vertical position (Figure 4), lower both hoists until the alterna-
tor has settled on the floor.
Figure 3. Alternator in the Shaft Horizontal Position

GEK-91723A
Figure 4. Alternator in the Shaft Vertical Position
5.1.6. Separate the Rotor and Stator Assemblies
The rotor assembly, with the frame head, will be separated from the stator assembly. The rotor assembly will be
lifted vertically out of the stator assembly. To remove the rotor assembly and frame head from the stator assembly:
1. Remove the power cable cover (25). To remove the power cable cover:
a. If the six power cables (27) run through the cover, loosen the cable bushing (26) to allow the cover to slide off
the cables.
b. Remove the four cover mounting bolts and washers (and mark for reuse) located on each end of the half
moon cover.
c. Lift the cover off to gain access to the cable-to-bus connection by feeding the power cables through the
cable bushings if power cables run through the cover.
d. Remove (and mark for reuse) the bolts and washers (29) that secure the power cables (29) to the copper bus
bar and remove the power cables.
2. Remove (and mark for reuse) the six bolts, washers (31), and tap blocks (32) securing the stator field connections
to the power cable connection points.

GEK-91723A
3. Remove the brush access covers. Unlatch the six brush hold down springs (59). Remove the six brushes from the
brush boxes.
4. Remove (and mark for reuse) the six brush holder stud mounting bolts and washers (63). Cut any cable ties hold-
ing the brush holder cables to hold down rails or staples.
5. Loosen the cable bushings on the cable to the brush holders. Feed the cable through the frame head. Remove
the brush holders and cables from the frame head.
6. Unlock and remove the speed sensor cable (57) from the speed sensor (54). Remove the speed sensor cable from
the frame head.
7. Loosen the lock nut on the speed sensor (54). Remove the speed sensor.
8. Attach a hoist to the swivel hoist ring on the end of the rotor shaft (Figure 5). Take the slack from the cable but do
not lift the alternator.
The rotor assembly and frame head weigh approximately 3460 lbs. (1570 kg). Use
WARNING appropriate lifting devices for this weight. Failure to do so may result in injury or
death.
Figure 5. Preparing to Lift the Rotor Assembly and Frame Head from the Stator Assembly

GEK-91723A
9. Remove (and mark for reuse) the frame head mounting bolts as shown in Figure 5.
10. The frame head may need to be pushed out of the rabbit fit in the stator frame. There are three equally spaced
tapped jack out holes in the stator frame on the same bolt circle as the mounting holes of the frame head.
Thread three 0.625-11 x 1.75 full thread bolts (or longer bolts with 1.75 inches of thread) in the frame head jack
out holes of the stator. Evenly turn the jack out bolts until the frame head is loose from the stator.
11. Lift the rotor assembly and frame head from the stator assembly. When the rotor and frame head assembly is
clear of the stator assembly, move the assemblies to an open location where additional work will be performed.
5.1.7. Frame Head Removal
The frame head (37) and rotor assembly will be separated. The frame head will be lifted vertically off the rotor
assembly. To remove the frame head:
1. Install two frame head eyebolt lifting assemblies into the open brush holder mounting holes (Figure 6) of the
frame head as shown in publication GEK-91747, OHV ROTATING EQUIPMENT OVERHAUL TOOL GUIDE listed in
section 1.2., RELATED PUBLICATIONS in this publication.
The frame head weighs approximately 1470 lbs. (670 kg). Use appropriate lifting
2. Attach the two lifting lugs of the frame head to the first hoist (Figure 6). Attach the eyebolts to the second hoist.
3. Take the slack out of the lifting slings or cables of the two hoists attached to the frame head. Do not lift the
frame head at this time.
4. Remove the six bearing housing mounting bolts (53) From the inner bolt circle of the frame head.
5. Thread three 0.625-11 x 1.75 full thread bolts (or longer bolts with 1.75 thread) into the frame head jack out
tapped holes on the same bolt circle as the bearing housing mounting bolts.
6. Evenly thread the jack out bolts in the frame head until the frame head is clear of the bearing housing fit.
7. Lift the frame head evenly with the two hoists. Damage to the frame head or rotor components may occur if the
frame head is lifted unevenly.
8. Move the frame head to a secure area for later alternator assembly.
9. Remove the hoist cables or slings.

GEK-91723A
Figure 6. Attachment Points for Two Hoists to Frame Head (Viewed From Above)
5.1.8. Rotor Bearing Housing Assembly Removal
The rotor bearing assembly (Figure 7) is accessible after the frame head has been removed. The bearing housing
assembly includes the bearing cap (46), the bearing housing (52), the outboard sleeve (50), and the bearing, (51). To
disassembly rotor bearing components:
1. Remove the bearing cap (46). To remove the bearing cap:
a. Remove the six bearing cap bolts and washers (48).
b. The bearing cap (46) will be tight to the fit of the bearing housing (52). Thread two 0.625-11 x 3 jack out bolts
into the two threaded holes in the bearing cap (180° apart).

GEK-91723A
The bearing cap weighs approximately 40 lbs. (18 kg). Use appropriate lifting devices
WARNING appropriate for this weight. Failure to do so may result in injury.
c. Evenly tighten the two jack out bolts until the bearing cap is free of the bearing housing fit.
d. The outer shaft seal (47) should remain in the bearing cap during cap removal. If the seal remains on the
outer sleeve after cap removal, pull the seal and discard.
e. Remove the jack out bolts from the bearing cap. The outer shaft seal may be in the internal bearing cap fit.
Remove the seal and discard. Store the bearing cap in a secure area for use in later processes.
2. Assemble the bearing housing removal tool over the rotor shaft and onto the bearing housing as shown in pub-
lication GEK-91747, OHV ROTATING EQUIPMENT OVERHAUL TOOL GUIDE listed in section 1.2., RELATED PUBLI-
CATIONS in this publication.
The bearing housing assembly weighs approximately 89 lbs. (40 kg). The bearing
WARNING assembly includes the bearing housing weighing approximately 62 lbs. (28 kg), the
bearing weighing approximately 20 lbs. (9 kg), and the outboard sleeve weighing
approximately 7 lbs. (3 kg). Use appropriate lifting devices for these weights. Failure to
do so may result in injury.
Figure 7. Rotor Bearing Assembly

GEK-91723A
3. Tighten the bearing housing removal tool assembly center bolt. This will pull the bearing housing assembly
toward the end of the rotor shaft.
4. When the bearing has moved up the rotor shaft and is at the loose fit, remove the bearing housing assembly
components.
5. To remove the bearing from the bearing housing, use a wooden block against the bearing and gently tap the
wooden block with a mallet. Move around the bearing to ensure it does not jam in the bearing housing. Discard
the bearing and store the other components for later assembly of the alternator.
6. The inboard shaft seal (Figure 7) will be in the bearing housing inboard slot. Remove the seal and discard.
5.1.9. Rotor Shaft Speed Sensor Hub Removal
The speed sensor hub (55) and other inboard rotor components do not have to be removed unless damage or wear
is measured or observed. To remove the speed sensor hub:
1. Assemble the speed sensor hub removal tool assembly over the rotor and hub as shown in publication GEK-
this publication.
2. Tighten the speed sensor hub (55) removal tool assembly center bolt. This will pull the speed sensor hub (Figure
7) toward the end of the rotor shaft.
3. When the speed sensor hub has moved to a looser rotor shaft fit, remove the tool assembly and the hub. Store
the speed sensor hub for later assembly of the alternator.
5.1.10. Alternator Impeller Removal
The alternator impeller (66) and other inboard rotor components do not have to be removed unless damage or wear
is measured or observed. To remove the impeller:
The alternator impeller weighs approximately 55 lbs. (24 kg). Use appropriate lifting
WARNING devices for this weight. Failure to do so may result in injury.
1. Remove and mark for later use the fifteen impeller mounting bolts and washers (67).
2. The impeller may be tight in the fit to the impeller hub. Thread three 0.50-13 X 2.5 full thread jack out bolts into
the three equally spaced tapped jack out holes on the same bolt circle as the impeller mounting bolt holes.
3. Evenly tighten the three jack out bolts until the impeller (66) is free of the impeller hub fit. There is a dowel pin
between the impeller and the impeller hub.
4. Remove the three jack out bolts in the impeller holes and thread three 0.50-13 eyebolts in place of the jack out
bolts.

GEK-91723A
5. Attach a lifting device to the three eyebolts and lift the impeller over the end of the rotor shaft.
6. A dowel pin may be in the impeller or in the impeller hub. If the dowel pin is loose, remove and mark the dowel
pin for reuse. If the dowel pin is not loose, drive the pin out when the impeller is clear of the rotor.
7. Store the impeller in a secure area for use during alternator assembly.
5.1.11. Collector Ring Assembly Removal
The collector ring assembly (69) and other inboard rotor components do not have to be removed unless damage or
excessive wear is measured or observed. Refer to section 6.1.2., ELECTRICAL TESTING ALTERNATOR DATA in this pub-
lication for minimum reuse criteria. To remove the collector ring assembly:
1. Cut and remove the lock wire on the two cleat block bolts (Figure 8). Remove the bolts, cleat and bar.
2. Cut the banding and tape around the collector ring assembly and the impeller hub (Figure 8) securing the F1 and
F2 copper bars.
The copper straps and bars are heated during the brazing process and may cause
WARNING burns. Follow procedures and use safety equipment for handling heated components.
Failure to do so may result in injury.
3. Using brazing tongs, as shown in publication GEK-91747, OHV ROTATING EQUIPMENT OVERHAUL TOOL GUIDE
listed in section 1.2., RELATED PUBLICATIONS in this publication, heat and separate (Figure 8) the copper bar con-
nections to the collector rings F1 and F2.
4. Install the collector ring removal tool assembly as shown in publication GEK-91747, OHV ROTATING EQUIP-
MENT OVERHAUL TOOL GUIDE listed in section 1.2., RELATED PUBLICATIONS in this publication.
5. Tighten the shaft center bolt of the collector ring assembly removal tool. The collector ring assembly will move
6. When the collector ring assembly is free of the rotor shaft fit, lift the assembly and tool clear of the rotor shaft. A
new collector ring assembly is required after removing a collector ring. The removed collector ring assembly
should be discarded.
7. Remove the tool assembly from the collector ring assembly. Portions of the removal tool are used in other
removal procedures.

GEK-91723A
Figure 8. Preparation for Collector Ring Assembly Removal
5.1.12. Alternator Impeller Drive Hub Removal

GEK-91723A
The alternator impeller drive hub (68) and other inboard rotor components do not have to be removed unless dam-
age or wear is measured or observed. To remove the alternator impeller drive hub:
1. Install the alternator impeller drive hub removal tool assembly as shown in publication GEK-91747, OHV ROTAT-
ING EQUIPMENT OVERHAUL TOOL GUIDE listed in section 1.2., RELATED PUBLICATIONS in this publication.
2. Tighten the shaft center bolt of the alternator impeller drive hub removal tool assembly. The drive hub will move
3. When the drive hub is free of the rotor shaft fit, remove the drive hub and removal tool assembly. The impeller
hub is an integral part of the collector ring assembly mounting process. A new impeller hub is required after
removal from the rotor shaft. The impeller hub should be discarded.
4. Remove the tool assembly from the drive hub.
5.1.13. Rotor Shaft and Rotor Yoke Separation
The rotor shaft (1) and rotor yoke (2) do not have to be separated unless the rotor yoke, rotor shaft, collector ring
assembly (69), or rotor field coil (8) require replacement. Verify the need to disassemble these components with the
GE Representative. To separate the rotor shaft and the rotor yoke:
1. Position the rotor yoke/shaft assembly in the shaft vertical orientation.
2. Remove the fifteen bolts and washers (70) securing the rotor shaft to the rotor yoke. If the rotor shaft (1) will not
be reused, cut the lock wire, remove the two bolts, and remove the balance weight. The balance weight can be
used on the replacement rotor shaft.
3. Thread three 0.625-11 x 3 in. bolts into the shaft jack out tapped holes on the shaft-to-yoke mounting bolt circle.
4. Assemble the adapter plate and swivel hoist ring on the end of the rotor shaft as shown in publication GEK-
this publication.
The rotor shaft weighs approximately 320 lbs. (146 kg). Use appropriate lifting devices
WARNING for this weight. Failure to do so may result in injury.
5. Attach the swivel hoist ring to a lifting device. Apply tension to the swivel hoist but do not lift the rotor yoke/shaft
assembly from the floor.
6. Evenly tighten the three jack out bolts until the rotor shaft is free of the yoke fit. Previous varnish treatments may
prevent the rotor shaft from easily separating from the rotor yoke. Heat and score varnish between the shaft
and yoke.
7. Lift the rotor shaft from the rotor yoke.
5.2. CLEANING ALTERNATOR COMPONENTS

Cleaning agents may be toxic and/or flammable. They can cause serious or fatal injury
WARNING if used without proper precautions. For safety:

GEK-91723A
• Do not inhale fumes.
• Use only in adequately ventilated areas.
• Avoid contact of cleaning agent with the skin.
• Do not expose cleaning agent to flame or sparks.
• Observe warning and caution statements issued by the manufacturer of the clean-
ing agent.
The following sections describe various cleaning procedures. Due to frequent changes in cleaning fluids and solu-
tions, ensure the cleaning fluid or solution will not harm alternator nonmetallic material (such as coil insulation, res-
ins, or rubber) or metallic material (such as copper, bronze, steel, or aluminum). Contact the local GE Representative if
there are questions.
5.2.1. Vapor Degreaser
1. Bring the cleaning solution to a boil and allow the vapor line in the tank to rise to the condenser coils at the top
of the tank.
2. Keep the temperature of the vaporized cleaning solution at about 120° C (248° F).
Introduce the apparatus to the cleaning vapor intermittently. Do not allow an electri-
CAUTION cally insulated part to remain in the cleaning vapor more than 15 minutes as pro-
longed exposure to the vapor may damage the insulation.
3. Lower the part to be cleaned into the vapor-laden atmosphere so the vapor will condense on the apparatus.
4. To speed the removal of heavy dirt accumulations, spray the hot solution directly from the tank onto the appa-
ratus being cleaned. The temperature of the solution must be below its boiling point.
5. Remove the cleaned part from the degreaser; drain and cool the part.
5.2.2. Liquid Cleaner
1. When cleaning insulated electrical parts, use a quick drying cleaner that will not leave an oily deposit. Dip a
clean, lint free cloth into the cleaner and wipe off the part. Do not dip insulating materials in liquid cleaner.
2. When cleaning anti-friction bearings and metal parts use a cleaner that will leave an oil film on finished sur-
faces. Kerosene, petroleum spirits or other petroleum base cleaners are satisfactory.
3. When cleaning shafts, pinions and gears (prior to reassembly), use a quick drying nonoily cleaner.
5.2.3. Steam Cleaning
NOTE: Care must be taken in the selection of detergents used in conjunction with steam cleaning. Cleaning
agents are usually alkaline and not chemically neutral. Satisfactory results have been obtained with the proper
use of Navee 42* and Superlode**.

GEK-91723A
Alternator stator coils are installed with KAPTON*** insulation. Do not use alkali
CAUTION cleaning compounds (commonly used with steam cleaning equipment) to clean the
stator coils. Alkali solutions have an adverse affect on this type insulation. Steam will
not affect KAPTON if no alkali is present in the cleaning equipment.
NOTE: Do not use caustic compounds because of their effect on the organic insulation materials.
1. Suspend the apparatus so that it is accessible from all directions of flow from the hose.
2. Dilute detergent according to manufacturer’s instructions and heat to 65 to 80° C (150 to 175° F).
NOTE: The detergents noted above have been used at full strength without any apparent effects on insulation or
varnish. However, it is recommended that full strength be used only when heavy accumulation of contaminants
must be removed.
3. Spray on detergent and allow 5 to 20 minutes for detergent to penetrate accumulated contaminants.
NOTE: Ensure air holes in stator core are cleaned thoroughly. Scrape out build up if necessary.
4. Thoroughly wash off detergents with steam and hot water: recommended pressure 120 psi (827 kPa) at temper-
ature of 160°C (320°F).
5. Air blow with clean, dry, compressed air (if necessary).
NOTE: After cleaning, the rotor and stator must be thoroughly flushed in a clean hot water tank. Observe the fol-
lowing:
• Do not immerse collector rings in water.

• The cleaning agent is alkaline (contains sodium phosphates, silicates or sodium carbonate, sodium hydrox-
ide and wetting agents). If not thoroughly rinsed, the lack of chemical neutrality results in a residue (gener-
ally a dry powder) that will absorb water in normal service and cause electrical leakage paths to ground.
• The water tank should have a filtration system to remove solid particles and a pH control to monitor the
alkalinity of water. The water should be kept below its boiling point and be agitated. If the water tank does
not have pH control, the pH level can be tested with pH paper, which can be obtained from a laboratory sup-
ply house. When testing water, the color indicated by the paper should be yellow-green (pH of 7 - neutral).
Table 2. PH Balance Check
Acid Neutral Base-Alkaline

5-6 7 8 9 10 11
Orange Yellow-Green Green Ive-Green Blue Purple
6. Immerse the rotor (collector rings up) or the stator in hot water for approximately 20 seconds; raise and
immerse again for 20 seconds.
7. Move the rotor or stator to a ventilated oven and bake for 8 to 12 hours at 125°C (257°F).
8. Perform megohmmeter and high-potential tests; use appropriate values listed in section 6.1.2., ELECTRICAL
TESTING ALTERNATOR DATA in this publication.

GEK-91723A
9. If the rotor or stator does not meet testing standards, bake for an additional two to four hours and repeat the
tests. If the tests still fail, troubleshoot to determine the exact source of the ground.
5.3. INSPECTION AND TEST PROCEDURES
Inspection and test procedures include visual, dimensional measurement, and meter readings (ohm, amp, volt). The
following sections describe the inspection and test procedures to determine reusability of alternator components.
Some components failing the inspection and test procedures may be repaired as described in section
5.4., ALTERNATOR COMPONENT RECONDITIONING OR REPAIR in this publication. Components failing inspection and
test procedures and not listed in this section should be replaced.
5.3.1. Visual Inspection of the Alternator Components
The alternator components should be visually inspected prior to advancing into more detailed inspections. Visually
inspect the components for:
1. Electrical insulation breakdown on stator and rotor fields, cables, bus bars, and speed sensor control wires. Visu-
ally inspect the insulation and electrical connections for signs of impact, erosion damage from debris in the
cooling air, rubbing, stiffening rubber insulation, electrical arcing, and cut or slicing damage. Repair or replace-
ment is required if damage is found. Refer to the local GE Representative with any questions.
2. Fiberglass housing damage. Inspect the fiberglass housings (inlet and outlet) for impact damage, impeller rub-
bing, erosion damage from airborne debris, and stress fractures or cracks. Inspect around the mounting holes of
the fiberglass housings carefully for cracks propagating from the mounting holes. Repair or replacement is
required if damage is found. Refer to the local GE Representative with any questions.
3. Impeller (both the traction motor/control and alternator) damage. Visually inspect the impellers and impeller
mounting plates for blade damage from impact, wear from airborne debris, cracks, rubbing, loose mounting riv-
ets, and drive pin bore for elongation. Repair or replacement is required if damage is found. Refer to the local GE
Representative with any questions.
4. Impeller drive hubs and pins (both the traction motor/control and alternator) damage. Visually inspect the hubs
and pins for cracks, impact damage, erosion from airborne debris, rotor shaft bore for gouged metal, thread
damage to the tapped impeller mounting holes, drive pin bore for elongation, and corrosion of metal. Repair or
replacement is required if damage is found. Refer to the local GE Representative with any questions.
5. Rotor shaft and shaft components (bearing housing, bearing cap, collars, and flinger) for damage. Inspect the
components and rotor shaft for impact damage, erosion from airborne debris, severe scrapping or scuff marks,
metal corrosion or etching, or thread damage in tapped holes. Repair or replacement is required if damage is
found. Refer to the local GE Representative with any questions.
6. Collector ring assembly mechanical or electrical damage. Inspect the insulation between the steel rings for loos-
ening, burnt, flaking, or cuts. Ensure the steel rings are securely mounted to the collector ring hub. Inspect the
steel rings surfaces for grooving wear, etching, or corrosion damage.
7. In general, look for obvious wear on any alternator component. Refer to the GE Representative for additional
information.
5.3.2. Stator and Rotor Electrical Tests
NOTE: Values of volts, milliampere, impedance, and resistance are listed in section 6.1.2., ELECTRICAL TESTING
ALTERNATOR DATA in this publication.

GEK-91723A
5.3.2.1. Megohmmeter Tests
The main stator fields, tertiary field, and rotor coils are tested with a megohmmeter to ensure electrical connections
and circuit integrity above ground. If these components have are wet or have not been cleaned, follow the cleaning
and baking instructions in section 5.2., CLEANING ALTERNATOR COMPONENTS in this publication. To test with the
fields with a megohmmeter:
High voltage is used during electrical testing. Ensure personnel are clear of the test
WARNING area and follow safety procedures during testing. Failure to do so may result in injury
or death.
1. Megohmmeter test the main stator fields (T1, T2, and T3). To check these fields:
a. Ensure the main stator leads (T1, T2, and T3) are insulated or isolated from ground and clear of personnel
during testing.
b. One lead of each stator field is connected internally and testing any lead will test all three stator fields.
Apply a 500 volt megohmmeter test between the main stator field T1, T2, or T3 lead or connection and a
cleaned ground connection on the stator frame. The ohm value should equal or exceed the ohm value listed
in section 6.1.2., ELECTRICAL TESTING ALTERNATOR DATA.
c. If the ohm reading is lower than the listed value, the stator can be cleaned and thoroughly dried as
described in section 5.2., CLEANING ALTERNATOR COMPONENTS in this publication. Test again after cleaning
and drying the stator.
2. Megohmmeter test the tertiary fields (T15 and T16). To check this field:
a. Ensure the tertiary leads (T15 and T16) are insulated or isolated from ground and clear of personnel during
testing.
b. The tertiary field leads are from the same tertiary field and the tertiary field is completely tested by con-
necting to either lead. Apply a 500 volt megohmmeter test between the tertiary field T15 or T16 lead or con-
nection and a cleaned ground connection on the stator frame. The ohm value should equal or exceed the
ohm value listed in section 6.1.2., ELECTRICAL TESTING ALTERNATOR DATA in this publication.
c. If the ohm reading is lower than the listed value, the stator can be cleaned and thoroughly dried as
described in section 5.2., CLEANING ALTERNATOR COMPONENTS in this publication. Test again after cleaning
and drying the stator.
3. Megohmmeter test the rotor coils (F1 and F2). To check these coils:
a. The rotor coils are connected in series and all coils are checked by testing either through F1 or F2 lead.
Apply a 500 volt megohmmeter test between the rotor coils lead F1 or F2 (collector ring assembly steel
rings) and a cleaned ground connection on the rotor yoke frame (Item 2, Figure 22). The ohm value should
equal or exceed the ohm value listed in section 6.1.2., ELECTRICAL TESTING ALTERNATOR DATA in this publi-
cation.
b. If the ohm reading is lower than the listed value, the rotor can be cleaned and thoroughly dried as described
in section 5.2., CLEANING ALTERNATOR COMPONENTS in this publication. Test again after cleaning and dry-
ing the rotor.

GEK-91723A
5.3.2.2. Impedance Tests
NOTE: The rotor must be removed from the stator for this impedance test.
Measure the impedance of the rotor coils, both individually or assembled, using the following procedure that gives
the results in terms of voltage drops. Voltage drop is a direct reflection of the amount of impedance in the coil circuit.
When measuring total impedance of an assembled rotor and the voltage drop measured is out of tolerance, find the
coil or coils causing the problem by measuring voltage drops across the individual coils. Usually, bad coils will have
significantly lower voltage drops than good coils.
To check rotor impedance:
or death.
1. Apply 60 Hz 15 amp AC power to F1 and F2 (collector ring connections).
2. The rotor field coil impedance value is listed in section 6.1.2., ELECTRICAL TESTING ALTERNATOR DATA in this
publication.
3. If the impedance is not within the allowable range, individual coils (disconnected from the tie rings) may be
tested. Coils with lower impedance indicate coil failure.
5.3.2.3. Resistance Tests
Resistance test results are directly affected by the ambient temperature of the surroundings of the alternator com-
ponents. As temperature increases, resistance values increase. All resistance values are in ohms at ambient temper-
ature of 77° F (25° C). Contact the GE Representative if resistance readings cannot be taken at the listed ambient
temperature.
Due to low resistance (less 0.2 ohms) of windings or coils, a low ohm precision ohmmeter is required for this test.
To test the resistance of the fields:
1. Check the resistance of the main stator fields (T1 to T2, T2 to T3, and T3 to T1). To check resistance:
a. Ensure that the main stator field leads (T1, T2, and T3) are clear of surrounding metal and clear for test per-
sonnel to check resistance without touching other leads.
NOTE: Resistance allowable limits are based on ambient temperature of 77° F (25° C).
b. Connect the low ohm precision ohmmeter leads sequentially across T1 to T2, T2 to T3, and T3 to T1 stator
leads or connections. Do not touch the copper field leads or the metal of the meter leads when connecting

GEK-91723A
the meter. Initial application of the ohmmeter power onto the coil leads may generate voltage high enough
to feel a shock if contact is made with any part of the field circuit.
c. The stator field allowable resistance limits are listed in section 6.1.2., ELECTRICAL TESTING ALTERNATOR
DATA in this publication.
2. Check the resistance of the tertiary field (T15 and T16). To check resistance:
a. Connect a low ohm precision ohmmeter leads across T15 and T16 tertiary field leads or connections. Do not
touch the copper field leads or the metal of the meter leads when connecting the meter. Initial application
of the ohmmeter power onto the coil leads may generate voltage high enough to feel a shock if contact is
made with any part of the field circuit.
b. The tertiary field allowable resistance limits are listed in section 6.1.2., ELECTRICAL TESTING ALTERNATOR
3. Check the resistance of a rotor coil. The resistance checks for rotor coils are done on a single coil, not in circuit
with all rotor coils. To check the resistance of a rotor coil:
a. Connect a low ohm precision ohmmeter leads across a rotor coil connections. Do not touch the copper coil
bus or theme tal of the meter leads when connecting the meter. Initial application of the ohmmeter power
onto the coil leads may generate voltage high enough to feel a shock if contact is made with any part of the
field circuit.
b. The rotor coil allowable resistance limits are listed in section 6.1.2., ELECTRICAL TESTING ALTERNATOR DATA
in this publication.
or death.
Always test with a megohmmeter first. High Potential test only after megohmmeter
CAUTION tests show two megohms resistance or higher. High Potential test only after the wind-
ings have been cleaned, baked dry and tested with a megohmmeter. If an insulation
failure occurs as a result of a High Potential test, the alternator will be permanently
damaged.
High potential (hi-pot) tests evaluate the insulation dielectric strength (ability to insulate) of alternator components. A
high potential test set applies high voltage between the windings and ground or between windings.
For values of coils (new and in service) during Hi pot test, refer to section 6.1.2., ELECTRICAL TESTING ALTERNATOR
NOTE: DC leakage test voltage is 1.4 times AC voltage. Leakage limit is 1 ma.
To hi-pot test the alternator fields:

GEK-91723A
Hi-pot testing involves high voltage. Ensure personnel are clear of the test area and
WARNING follow safety procedures for high voltage. Failure to do so may result in injury or
death.
1. To hi-pot the main stator field:
a. Connect a main stator field lead (T1, T2, or T3) to one of the hi-pot test leads. Connect the other hi-pot test
lead to a clean ground on the stator frame.
b. Apply high voltage AC for the time interval to themain stator field as specified in section 6.1.2., ELECTRICAL
c. The current leakage will be below the leakage level as specified in section 6.1.2., ELECTRICAL TESTING
ALTERNATOR DATA in this publication. If the leakage current level is exceeded, the main stator field insula-
tion is not sufficient for alternator operation.
2. To hi-pot the tertiary field:
a. Connect the tertiary field leads T15 and T16 together with one of the hi-pot test leads. Connect the other hi-
pot test lead to a clean ground on the stator frame.
b. Apply high voltage AC for the time interval to the tertiary field as specified in section 6.1.2., ELECTRICAL
ALTERNATOR DATA in this publication. If the leakage current level is exceeded, the tertiary field insulation is
not sufficient for alternator operation.
3. To hi-pot the rotor coils:
a. Connect the rotor coil leads F1 and F2 together with one of the hi-pot test leads. Connect the other hi-pot
test lead to a clean ground on the rotor yoke frame.
b. Apply high voltage AC for the time interval to the rotor coil leads as specified in section 6.1.2., ELECTRICAL
ALTERNATOR DATA in this publication. If the leakage current level is exceeded, the rotor coil insulation is not
sufficient for alternator operation.
5.3.2.4. Hi-Pot Test the Collector Ring Assembly After Installation
After installation of the collector ring assembly onto the rotor shaft, the collector ring assembly must be tested to
ensure proper function. To hi-pot test the collector ring assembly:
Hi-pot testing involves high voltage. Ensure personnel are clear of the test area and
WARNING follow safety procedures for high voltage. Failure to do so may result in injury or
death.
1. Connect the hi-pot leads to the steel collector rings or the copper bar leads to the steel collector rings.

GEK-91723A
2. Apply high voltage AC for the time interval to the rotor coil leads as specified in section 6.1.2., ELECTRICAL TEST-
ING ALTERNATOR DATA in this publication. Current leakage should be lower than specified in section
6.1.2., ELECTRICAL TESTING ALTERNATOR DATA in this publication.
3. Repeat the hi-pot test between each steel collector ring or collector ring lead and ground.
5.3.3. Dimensional Inspection
The components listed in this section should be checked dimensionally for reuse. Any components that have visual
damage or wear must be checked dimensionally to determine reusability. Refer to the local GE Representative for
dimensional information not listed in this publication. Some damaged or worn components can be repaired as listed
in section 5.4., ALTERNATOR COMPONENT RECONDITIONING OR REPAIR in this publication.
5.3.3.1. Rotor Shaft Dimensional Inspection
Check the rotor shaft dimensions as shown in Figure 27 found in section 6.4.1., ROTOR SHAFT DIMENSIONAL INSPEC-
TION in this publication. Replace the component if the dimensional inspection criteria are out of the allowable limits.
Visually inspect the rotor shaft for impact or wear damage. Any impact or wear damage in the critical fit areas,
including the taper fit for the impeller drive hub, requires repair or replacement of the shaft. Refer to the local GE
Representative for any questions.
5.3.3.2. Bearing Housing Dimensional Inspection
Check the bearing housing dimensions as shown in Figure 28 found in section 6.4.2., BEARING HOUSING DIMEN-
SIONAL INSPECTION in this publication. Replace the component if the dimensional inspection criteria are out of the
allowable limits.
Visually inspect the bearing housing for impact or wear damage. Any impact or wear damage in the critical fit areas
requires repair or replacement of the housing. Refer to the local GE Representative for any questions.
5.3.3.3. Bearing Cap Dimensional Inspection
Check the bearing cap dimensions as shown in Figure 29 found in section 6.4.3., BEARING CAP DIMENSIONAL
INSPECTIONin this publication. Replace the component if the dimensional inspection criteria are out of the allowable
limits.
Visually inspect the bearing cap for impact or wear damage. Any impact or wear damage in the critical fit areas
requires repair or replacement of the bearing cap. Refer to the local GE Representative for any questions.
5.3.3.4. Flinger Dimensional Inspection
Check the rotor shaft collar dimensions as shown in Figure 31 found in section 6.4.5., FLINGER DIMENSIONAL INSPEC-
TION in this publication. Replace the component if the dimensional inspection criteria are out of the allowable limits.
Visually inspect the flinger for impact or wear damage. Any impact or wear damage in the critical fit areas requires
repair or replacement of the flinger. Refer to the local GE Representative for any questions.

GEK-91723A
5.4. ALTERNATOR COMPONENT RECONDITIONING OR REPAIR
Alternator components can be repaired or reconditioned during overhaul interval. Alternator components not listed
in this section should be replaced when repair is required.
5.4.1. Rotor Assembly Reconditioning
The rotor assembly requires reconditioning at the overhaul interval. Close inspection, varnish application, collector
ring machining, and balancing are typical of procedures during the overhaul process. If a rotor coil does not pass the
electrical test procedure as described in section 5.3.2., STATOR AND ROTOR ELECTRICAL TESTS in this publication,
proceed to the rotor coil replacement process described in section 5.4.1.2., SINGLE ROTOR COIL REPLACEMENT.
When replacing all rotor coils, refer to section 5.4.1.3., REPLACING ALL ROTOR COILS. After replacing one or more
rotor coils, balance the rotor as described in section 5.4.1.5., ROOTR ASSEMBLY BALANCING and return to this section
to recondition the rotor assembly.
5.4.1.1. Rotor Assembly Reconditioning Procedure
Follow this procedure only after the rotor has passed visual and electrical testing. To recondition a rotor assembly:
1. Inspect the rotor assembly for defects. Inspect for the following:
a. Inspect for damaged rotor coils (8) for flaking, cracking, cut, or burnt insulation.
b. Inspect for rotor end electrical connections (to the tie rings) for burnt, discolored, cut, or loose glass banding
tape over the tie rings/rotor connections (73).
c. If the collector ring assembly (69) did not require removal during disassembly, inspect the collector ring
assembly for loose rings, loose or broken glass banding, and rough or etched brush surface of the metal
rings. Inspect the jumper straps (71) and jumper clamps (72) to the tie rings. Measure the collector rings
diameter and groove depth for minimum dimensions as described in section 6.1.2., ELECTRICAL TESTING
ALTERNATOR DATA in this publication. Hi pot test the collector rings as described in section 5.3.2.4., HI-POT
TEST THE COLLECTOR RING ASSEMBLY AFTER INSTALLATION in this publication. Collector rings can be
repaired as described in section 5.4.1.4., COLLECTOR RING ASSEMBLY REPAIR in this publication.
d. If the alternator Impeller hub (68) did not require removal during disassembly, inspect the alternator impel-
ler hub for elongated drive pin bore, damaged threads in the tapped holes, impact or damage on the impel-
ler mounting surface.
e. If the flinger (56) and the speed sensor hub (55) did not require removal during disassembly, inspect the
components for wear from rubbing, impact damage, and a smooth seal riding surface on the flinger.
The rotor assembly weighs approximately 3100 lbs. (1406 kg). Use appropriate lifting
The engine adapter weighs approximately 175 lbs. (80 kg). Use appropriate lifting
2. If not yet removed, remove the engine adapter (6) from the rotor assembly.

GEK-91723A
3. To protect threaded holes, run bolts into all open tapped holes of the alternator assembly.
4. Heat the rotor assembly in an oven at 140° C to 150° C (284° F to 302° F) for eight hours to drive out moisture.
5. Remove the rotor from the oven and let cool to 40° C to 60° C (104° F to 140° F).
6. Lower the rotor assembly, with the collector rings up, into the approved varnish until the rotor coils and connec-
tions at the rotor coils are immersed in the varnish. Do not immerse the alternator impeller hub or components
higher than the hub into the varnish. Due to occasional changes in varnish material, contact the local GE Repre-
sentative for the current approved varnish.
7. Lift the rotor assembly out of the varnish and suspend the rotor assembly over the varnish tank until excess var-
nish has left the rotor assembly.
8. Heat the rotor assembly in an oven at 140° C to 150° C (284° F to 302° F) for six to eight hours to dry the varnish.
9. Remove the rotor assembly from the oven, let cool, remove bolts in open holes, and remove excess varnish from
the assembly.
10. Balance the rotor as described in section 5.4.1.5., ROOTR ASSEMBLY BALANCING in this publication.
5.4.1.2. Single Rotor Coil Replacement
NOTE: When replacing all rotor coil assemblies, refer to the section following this section.
NOTE: Refer to ALTPSB001 for additional instructions.
Replace a single rotor coil assembly as follows:
1. Position the rotor in the shaft vertical position.
2. Remove the rotor shaft from the rotor yoke as described in section 5.1.13., ROTOR SHAFT AND ROTOR YOKE SEP-
ARATION in this publication.
3. Cut any glass banding insulation or tape on the coil connection tabs (Figure 9).
4. Using brazing tongs, heat the connections to the rotor coil and connection straps (Figure 9) and release the rotor
coil connections.
5. Attach the coil lifting fixture as shown in publication GEK-91747, OHV ROTATING EQUIPMENT OVERHAUL TOOL
GUIDE listed in section 1.2., RELATED PUBLICATIONS in this publication.
A rotor coil assembly weighs approximately 135 lbs. (61 kg). Use appropriate lifting
6. Remove the ten pole bolts, washers, and washer blocks (located on the inner diameter of the rotor yoke) secur-
ing the coil/pole assembly to the rotor yoke (Figure 9).

GEK-91723A
7. Lift the rotor coil assembly from the rotor yoke. Previous varnish treatments may prevent the coil assembly from
lifting from the toke. Use heat on the varnish and tap the steel pole portion of the coil assembly with a hammer
to free the coil assembly from the yoke.
8. Before installing the replacement rotor coil assembly, thoroughly clean the coil mounting position on the rotor
yoke. Remove any burrs and smooth any surface imperfections that would prevent the replacement rotor coil
from seating flush on the yoke. Remove any varnish on the yoke’s coil assembly mounting surface.
9. Oil the bolt washer face on all ten pole bolts with a high-pressure oil (such as automotive motor oil). Do not lubri-
cate the bolt threads.
10. Lift the replacement rotor coil assembly into position on the rotor yoke. Ensure the coil connection tabs align
with the connection straps tie ring connections (out and inner tie rings). Do not bend or twist the coil connection
tabs, tie rings, or bus bar to the collector rings to align the electrical connection. The short copper bus bars (con-
nection straps and jumper straps) allow for adjustment (Figure 9).
11. Assemble the ten pole bolts, hardened washers, and washer blocks and thread the bolts through the yoke into
the rotor coil assembly (Figure 9).
12. Torque all ten bolts to 80% of the torque value shown in section 6.3., TORQUE VALUES in this publication.
13. Torque all the bolts to the full torque value shown in section 6.3., TORQUE VALUES in this publication.
14. Assemble the connection straps (Figure 9) between the coil connection tabs and the tie ring connections with
brazing strip material (refer to the Parts Catalog for brazing strip part numbers) between the all copper bar con-
nections. Two of the rotor coil assemblies will share a tie ring connection point with collector ring jumper strap
as shown in Figure 9. The rest of the eight rotor coil assembly connections will be with only inter-coil connections
routed with the tie rings.
15. Torque the tie ring support bolts to the value shown in section 6.3., TORQUE VALUES in this publication.
16. Wrap a wet, nonflammable 1 x 5 in. (25 x 127 mm) material (ceramic cloth) around each coil terminal to protect
the terminal insulation from heat damage.
17. Using brazing tongs (refer to publication GEK-91747, OHV ROTATING EQUIPMENT OVERHAUL TOOL GUIDE) and
brazing material, braze the connections per P9B-EP1. Refer to the GE Representative for brazing process ques-
tions.
18. After cooling, wrap the electrical connections with glass banding insulation (Figure 9) or tape (refer to the Parts
Catalog for banding or tape part numbers). Ensure the tape overlaps at least 0.5 inches (12.7mm) with the last
wrap of tape applied.
19. Test the rotor coil as described in section 5.3.2., STATOR AND ROTOR ELECTRICAL TESTS in this publication.
20. Follow the reconditioning process described in section 5.4.1.1., ROTOR ASSEMBLY RECONDITIONING PROCEDURE
21. The rotor will require balancing as described in section 5.4.1.5., ROOTR ASSEMBLY BALANCING in this publication.
5.4.1.3. Replacing All Rotor Coils
NOTE: Refer to ALTPSB001 for additional instructions.

GEK-91723A
If it is necessary to replace all ten rotor coils, the processes are similar to the single rotor coil replacement. To replace
all ten rotor coils:
NOTE: The rotor should be in the shaft vertical position for rotor coil replacement.
1. If the engine adapter (Figure 9) is not mounted to the rotor yoke, attach the engine adapter to the rotor yoke.
Torque the bolts to the value shown in section 6.3., TORQUE VALUES in this publication.
2. Remove all banding insulating tape from the electrical connections at each rotor coil. Note the connections of
the jumper straps to the collector rings (Figure 9).
3. Using brazing tongs, heat and break all brazed connections to all the rotor coils.
4. Attach the rotor coil lifting fixture as shown in publication GEK-91747, OHV ROTATING EQUIPMENT OVERHAUL
TOOL GUIDE.
A rotor coil assembly weighs approximately 135 lbs. (61 kg). Use appropriate lifting
5. Remove the pole bolts, hardened washers, and washer blocks (Figure 9) for the rotor coil being removed.
Remove one rotor coil assembly at a time; do not remove the pole bolts for other rotor coils until attached to a
lifting device.
6. Lift the rotor coil assembly from the rotor yoke. Previous varnish treatments may prevent the coil assembly from
lifting from the toke. Use heat on the varnish and tap the steel pole portion of the coil assembly with a hammer
to free the coil assembly from the yoke.
7. Repeat Step 4 through Step 6 for each rotor coil.
8. Before installing the replacement rotor coil assemblies, thoroughly clean the coil mounting positions on the rotor
yoke. Remove any burrs and smooth any surface imperfections that would prevent the replacement rotor coil
from seating flush on the yoke. Remove any varnish on the yoke’s coil assembly mounting surface.
9. The ten replacement rotor coils must be installed based on weight; from the heaviest rotor coil assembly to the
lightest rotor coil assembly. Figure 9 (lower left item) depicts the sequence of coil mounting starting from 1 (the
heaviest rotor coil assembly) to 10 (the lightest rotor coil assembly). The first (heaviest rotor coil assembly) may
be installed in any yoke position, the rest of the rotor coils must be installed in sequence from the first coil posi-
tion.
10. Oil the bolt washer face on all pole bolts with a high-pressure oil (such as automotive motor oil). Do not lubricate
the bolt threads.
11. Lift the first rotor coil assembly (the heaviest) into a position on the rotor yoke. Ensure connection tabs align with
the tie ring connections.
12. Assemble ten pole bolts, hardened washers, and washer blocks and thread the bolts through the yoke into the
first (heaviest) rotor coil assembly (Figure 9). Snug the pole bolts into the rotor coil assembly but do not torque
the pole bolts until all rotor coil assemblies are mounted on the rotor yoke.

GEK-91723A
Figure 9. Rotor Coil Components and Mounting Order
13. Continue mounting each rotor coil assembly in sequence, from the heaviest assembly to the lightest assembly,
as shown in Figure 9.

GEK-91723A
14. When all rotor coil assemblies are mounted on the rotor yoke, torque the pole bolts to 80% of the torque value
shown in section 6.3., TORQUE VALUES in this publication. Ensure all 100 pole bolts have 80% torque value
applied.
15. Torque all the bolts to the full torque value shown in section 6.3., TORQUE VALUES in this publication. To ensure
all pole bolts (ten bolts on each of the ten coil assemblies is one hundred bolts) have the proper torque, mark
each bolt when complete by using an indelible marker, paint stick, or other marker type.
16. Hi-pot and impedance test the coils as described in section 5.3.2., STATOR AND ROTOR ELECTRICAL TESTS in this
publication.
17. Assemble the connection straps, Figure 9, between the coil connection tabs and the tie ring connections with
brazing strip material (refer to the Parts Catalog for brazing strip part numbers) between the all copper bar con-
nections. Two of the rotor coil assemblies will share a tie ring connection point with collector ring jumper strap
as shown in Figure 9. The rest of the eight rotor coil assembly connections will be with only inter-coil connections
routed with the tie rings
19. Torque the tie ring support bolts to the value shown section 6.3., TORQUE VALUES in this publication.
brazing material, braze the connections per P9B-EP1. Refer to the local GE Representative for brazing process
questions.
21. Repeat Step 15 through Step 17 for each rotor coil assembly electrical connections.
22. After cooling, wrap the electrical connections of all rotor coil assemblies with glass banding insulation (Figure 9)
or tape (refer to the Parts Catalog for banding or tape part numbers). Ensure the tape overlaps at least 0.5
inches (12.7 mm) with the last wrap of tape applied.
23. Test the rotor coils as described in section 5.3.2., STATOR AND ROTOR ELECTRICAL TESTS in this publication.
24. Follow the reconditioning process described in section 5.4.1.1., ROTOR ASSEMBLY RECONDITIONING PROCEDURE
25. The rotor will require balancing as described in section 5.4.1.5., ROOTR ASSEMBLY BALANCING in this publication.
5.4.1.4. Collector Ring Assembly Repair
The collector ring assembly steel rings can be machined to repair surface damage such as grooving, surface corro-
sion, or electrical etching or pitting. The collector ring assembly must be mounted in position on the alternator rotor
shaft assembly to machine. To machine the collector ring assembly:
1. Determine if enough material remains on the steel collector rings to machine without decreasing the diameter
below the minimum diameter list in section 6.1.2., ELECTRICAL TESTING ALTERNATOR DATA in this publication.
2. The rotor balance arbor must be installed on the rotor assembly to mount in a lathe. Install the rotor balance
arbor as described in publication GEK-91747, OHV ROTATING EQUIPMENT OVERHAUL TOOL GUIDE. The alter-
nator rotor assembly must be in the shaft horizontal position to install the rotor balance arbor.

GEK-91723A
3. Before attempting to lift the rotor assembly with the rotor balance arbor, wrap a heavy felt pad around the bear-
ing fit located on the collector ring end of the shaft.
The alternator rotor assembly with the rotor balance arbor weighs approximately
WARNING 3500 lbs. (1588 kg). Use appropriate lifting devices for this weight. Failure to do so may
result in injury or death.
4. Wrap a lifting cable around the rotor shaft and wrap another cable around the shaft of the adapter tool. The
rotor can now be lifted horizontally and set in a lathe.
5. Use a carboloy cutting tool and machine the surface of the collector rings to remove pits and grooves. Use No.
00 sandpaper and polish the machined surface of the collector rings. Ensure the grooves do not have burrs or
sharp edges in the grooves.
6. Check collector ring runout. Refer to section 6.1.1., GENERAL ALTERNATOR DATA in this publication for runout
specifications.
7. Remove the rotor assembly/rotor balance arbor from the lathe. The rotor balance arbor may remain of the rotor
assembly to perform the alternator rotor assembly balance procedure described in section 5.4.1.5., ROOTR
ASSEMBLY BALANCING in this publication.
5.4.1.5. Rotor Assembly Balancing
Rotor assembly dynamic balancing is the last rotor reconditioning procedure performed prior to alternator assem-
bly. To balance the rotor assembly:
1. Mount the rotor assembly balance arbor onto the rotor assembly as described in GEK-91747, OHV ROTATING
EQUIPMENT OVERHAUL TOOL GUIDE publication. The rotor assembly must be in the shaft horizontal position to
mount the balance arbor.
The alternator rotor assembly with the rotor balance arbor weighs approximately
WARNING 3500 lbs. (1588 kg). Use appropriate lifting devices for this weight. Failure to do so may
result in injury or death.
2. Place the rotor assembly/balance arbor into a dynamic balance machine.
NOTE: The rotor assembly balancing should be done utilizing the rotor shaft bearing fit and the shaft of the
arbor shaft. Do not use center holes drilled into the shaft ends.
3. If a rotor coil or all the rotor coils have been replaced, remove the old balance weights.
4. Balance the rotor assembly within specifications listed in section 6.1.2., ELECTRICAL TESTING ALTERNATOR DATA
5. Attach balance weights to the rotor yoke as shown in Figure 10.
6. Remove the rotor assembly/balance arbor from the dynamic balance machine.
7. Remove the balance arbor from the rotor assembly.

GEK-91723A
5.4.2. Stator Reconditioning
After visually inspecting the stator windings for insulation damage, the stator can be cycled through a Vacuum Pres-
sure Impregnation (VPI) as described in P5D-EP25 with the approved varnish. Refer to the GE Representative for pro-
cess information and approved varnish. Ensure to thread bolts into tapped holes of the stator prior to the VPI
procedure. Process P5D-EP25 describes stator preheat, VPI parameters, and post heat.
After VPI procedure, remove the bolts threaded into open stator frame holes, clean excess varnish from the stator
electrical connections and mating surfaces.
If any additional work is required on the stator, contact the GE Representative for information.
5.5. ALTERNATOR ASSEMBLY
NOTE: Ensure all required Field Modifications Instructions (FMI) updates and product improvements are installed
prior to final assembly of the alternator. Refer to the GE Representative for information or questions.
The hardware (nuts, bolts, washers, etc.) is specifically selected for this application. Do
CAUTION not substitute hardware with standard hardware. Use only hardware from the Parts
Catalogue for this alternator. Failure to do so may result in premature alternator fail-
ure.
There are component subassemblies within the alternator assembly procedure. The following sections describe
alternator assembly with subassemblies as required.
Figure 10. Rotor Balance Weight Attachment Points

GEK-91723A
5.5.1. Rotor Shaft Impeller Hub and Collector Ring Assembly Installation
NOTE: If the impeller hub and collector ring were not removed during disassembly, proceed to the next major
section of the assembly process.
The alternator impeller hub and collector ring assembly must be installed prior to proceeding in the assembly proce-
dure. The rotor shaft and rotor yoke must be separated for this procedure to allow the shaft to be mounted in a ten-
sioning machine or lathe with a tensioning attachment.
5.5.1.1. Alternator Impeller Hub Installation
NOTE: If the alternator impeller hub was not removed during disassembly, proceed to the next section.
The alternator shaft (1) should be in the vertical position for the alternator impeller hub (68) installation. To install the
alternator impeller hub:
1. Heat the alternator impeller hub (68) in an oven to 100º C (180º F) rise above alternator shaft (1) or room ambient
temperature. For example, if the ambient shaft (room) temperature is 22º C (71.6º F), heat the impeller hub to
122º C (251.6º F) which is ambient temperature of 22º C (71.6º F) plus (+) temperature rise of 100º C (180º F).
NOTE: For rise or change in temperature from ambient (room or part), only compare the ratio of change between
Celsius and Fahrenheit. Every 5 degrees of change in Celsius, Fahrenheit change will be 9 degrees. The opposite
would be true for Fahrenheit to Celsius change comparison, every 9º F change represents 5º C change. Do not
add or subtract the offset (32 degrees).
The heated component may be hot enough to cause burns. Follow procedures and use
WARNING safety equipment for handling heated components. Failure to do so may result in
injury.
2. Remove the alternator impeller hub (68) from the oven and align the impeller hub on the alternator rotor shaft
(1). To align the hub, ensure the impeller hub tapped hole (next to the hub slot) and the rotor shaft base drilled
hole share the same center line as shown in Figure 11.
3. Firmly press the impeller hub (68) against the rotor shaft (1) should until the hub is seated against the shoulder.
5.5.1.2. Collector Ring Assembly Installation
Contact the local GE Representative for collector ring assembly procedures.
5.5.2. Rotor Shaft Mounting to the Rotor Yoke
If the rotor shaft (1) and rotor yoke (2) were not separated during disassembly, proceed to the next section of the
assembly procedure.
To mount the rotor shaft to the rotor yoke:

GEK-91723A
The rotor shaft weighs approximately 450 lbs. (204 kg) and the rotor yoke weighs
WARNING approximately 2430 lbs. (1102 kg). Use appropriate lifting devices for these weights.
1. Ensure the mating surfaces and fits of the yoke (2) and shaft (1) are clean, free of varnish, burrs, and other sur-
face damage.
2. Assemble the adapter plate and swivel hoist ring on the end of the rotor shaft as shown in publication GEK-
this publication.
3. Heat the yoke assembly in an oven to 40° C (72° F) rise above shaft (room) ambient temperature. For example, if
the shaft (room) ambient temperature is 22° C (71.6° F), heat the yoke to 62° C (143.6° F), which is ambient tem-
perature of 22° C (71.6° F) plus the heat rise of 40° C (72° F).
The heated component may be hot enough to cause burns. Follow procedures and use
injury.
4. Remove the rotor yoke from the oven and position vertically on the floor.
5. Lift the rotor shaft (1) and position it over the rotor yoke (2). Align the holes marked with an X.
6. Lower the rotor shaft onto the rotor yoke. To aid aligning the shaft and yoke, three 0.625-11 x 3 in. minimum
guide rods may be threaded into equally spaced yoke tapped holes. The guide rods can be made from all thread
rod or bolts with the heads cut off.
7. Remove guide rods and thread the fifteen bolts and washers (70) through the rotor shaft base into the rotor
yoke tapped holes.
8. Evenly tighten the bolts and draw the shaft into the yoke fit.
9. Torque the bolts to the torque value shown in section 6.3., TORQUE VALUES in this publication.
5.5.2.1. Connecting the Rotor Coils to the Collector Rings
If the rotor coils were not disconnected during disassembly, proceed to Step 11 in this section.
The rotor coil (8) connections with the collector rings (69) can be completed after mating the rotor shaft (1) and rotor
yoke (2) together. To connect the rotor coils:

GEK-91723A
Figure 11. Alternator Impeller Hub Alignment and Installation
1. Assemble the connection straps connecting the coils together. Refer to Figure 9 (lower center view) for the rotor
coil interconnection representation.

GEK-91723A
brazing material, braze the connections per P9B-EP1. Connect and braze only the coil connections at this time.
Two coils will have connection straps for the jumper straps to the collector rings as shown in Figure 9. The col-
lector ring jumper straps will be brazed in a later operation. Refer to the GE Representative for brazing process
questions.
4. Assemble the tie ring support blocks and supports brackets (73) and install the supports brackets onto the rotor
yoke using the bolts and washers (75). Install both the five inner tie ring support brackets and the five outer tie
ring support brackets. The support brackets must be arranged to avoid contacting the connection straps to the
rotor coils. Refer to Figure 9, top view, for detailed representation of the coil connections and support attach-
ment. Torque the bolts to the value shown in section 6.3., TORQUE VALUES in this publication.
5. Insert the inner tie ring into position between the coil connection straps and the tie ring supports (75) as shown
in Figure 9, upper center view. Center the inner tie ring axially beneath the notched flange of the five support
brackets.
6. Place strips of insulation between the inner tie ring and the support brackets as required to provide a tight
assembly.
7. Secure the inner tie ring to the five support brackets using tie wrap 41A252287ACP4 at the support bracket
location.
8. Assemble the outer tie ring between the coil connection straps and the outer tie ring support brackets. Center
the outer tie ring axially beneath the notched flange of the five support brackets.
9. Place strips of insulation between the support brackets and the outer tie ring as required to provide a tight
assembly.
10. Wrap tape around the tie ring, connection straps, and the support brackets using A2L14B tape. The tape wrap
should be continuous. Overlap the tape by half the width of the tape.
11. Align the two jumper straps for the collector rings with the coil connection straps. Braze the collector ring
jumper straps and the coil connection straps using the brazing tongs and brazing material. Refer to publication
GEK-91747, OHV ROTATING EQUIPMENT OVERHAUL TOOL GUIDE for brazing tongs information.
12. Once cooled, wrap tape around the brazed connection of the collector ring jumper straps and the coil connec-
tion straps using A2L14B tape. Overlap the tape by half the width of the tape from the coil connection point
around the 90° bend to the collector rings.
13. Assemble the cleat base (with the slots for the collector ring jumper straps) behind the collector ring jumper
straps. Align the cleat cap (72) with the cleat base and thread the two bolts and washers (74) through the cleat
cap and cleat base into the tapped holes in the shaft. Torque the bolts to the value shown in section
6.3., TORQUE VALUES in this publication.
14. Wrap lock wire through the holes in the cleat mounting bolts and twist 3 to 5 times every inch (25.4 mm).
15. Varnish and balance the rotor assembly as described in subsections of section 5.4.1., ROTOR ASSEMBLY RECON-
DITIONING in this publication. Rough balance weights can be bolted and wire locked into the tapped holes on
the flat of the rotor shaft.
5.5.3. Rotor Shaft Component Installation
NOTE: The rotor assembly should be in the shaft up vertical position for the following procedures.

GEK-91723A
The rotor shaft components (shown in Figure 7) are installed in the following section. Procedures for installing all
components are provided but may not be required if the components were not removed during disassembly.
5.5.3.1. Alternator Impeller Installation
The alternator impeller (66) is mounted to the impeller hub (68) with a locating or dowel pin and bolts and washers
(67). To install the impeller:
1. Ensure the impeller (66) and impeller hub (68) mounting surfaces are clean and free of surface damage.
2. Assemble the locating pin and the fifteen bolts and washers (67) used for impeller mounting to the impeller hub.
If the locating pin is not new, inspect the pin to ensure it is not damaged.
3. Insert the locating pin into the impeller hub (68) pin hole. The pin will only fit into one untapped hole of the impel-
ler hub.
4. Align the impeller (66) onto the locating pin in the impeller hub (68).
5. Thread the fifteen bolts and washers (67) through the impeller (66) into the impeller hub (68). Snug the bolts and
ensure the impeller is seated firmly against the impeller hub mating surface.
6. Torque the bolt to the torque value shown in section 6.3., TORQUE VALUES in this publication.
5.5.3.2. Rotor Shaft Flinger and Speed Sensor Hub Installation
NOTE: If the flinger and speed sensor hub were not removed during disassembly, proceed to the next section.
The flinger (56) and speed sensor hub (55) are installed on the rotor shaft (1) with this procedure. To install the flinger
and speed sensor hub:
1. Ensure the flinger (56) and the speed sensor hub (55) are clean and free of surface damage.
2. Heat the flinger (56) and the speed sensor hub (55) in an oven to 40° C (72° F) rise above the rotor shaft (room).
For example, if the rotor shaft (room) ambient temperature is 22° C (71.6° F), heat the flinger and the speed sen-
sor hub to 62° C (143.6° F) which is the rotor shaft (room) ambient temperature plus (+) the temperature rise of
40° C (72° F).
3. Remove the flinger (56) from the oven and align on the rotor shaft with the outside diameter shoulder of the
flinger toward the speed sensor hub (55) fit of the rotor shaft. Press the flinger onto the rotor shaft fit until firmly
seated against rotor shaft shoulder.

GEK-91723A
4. Remove the speed sensor hub (55) from the oven and align the hub on the rotor shaft with the larger diameter
hub end toward the flinger (56). Press the speed sensor hub until firmly seated against the flinger (56).
5.5.3.3. Bearing Housing Installation
The bearing housing (52), with the bearing (51), is assembled onto the rotor shaft (1) in this section. Prior to installing
the bearing housing, the bearing must be pressed into the bearing housing. To press the bearing into the bearing
housing and install the bearing housing onto the rotor shaft:
The bearing housing with the bearing weighs approximately 81 lbs. (37 kg). Use appro-
WARNING priate lifting devices for this weight. Failure to do so may result in injury.
Heated components may be hot enough to cause burns. Follow procedures and use
injury.
1. Pack at least 1 oz. (28.35 g) into the inboard cavity of the bearing housing (520 as shown in Figure 12.
2. Heat the bearing housing (52) to 100° C (212° F) in an oven. Do not exceed 110° C (230° F) due to oil bleeding
from the grease.
3. Pack grease into the bearing (51). Fill all the air gaps within the bearing with grease as shown in Figure 12.
4. Remove the bearing housing (52) from the oven and position with the bearing cavity up.
5. Press the bearing (51) into the bearing housing until firmly seated against the should of the bearing housing. A
soft drift (copper, bronze, wood, etc.) with a small mallet may be used to tap the outer race of the bearing to
ensure seating against the bearing housing shoulder.
6. Heat the bearing housing/bearing assembly to 100° C (212° F) in an oven. Do not exceed 110° C (230° F) due to
oil bleeding from the grease.
7. On the rotor shaft (1), cover the exposed flinger (56) surfaces, the collector ring (69) inside diameter (ID) at the
flinger, and the inboard diameter surface of the speed sensor hub (55) (inboard of the teeth of the hub) with
grease as shown in Figure 12.
8. Remove the bearing housing (52) from the oven and align the lip seal into the slot on the inboard side (toward
the speed sensor hub and flinger) of the bearing housing as shown in Figure 12. Tap the seal into the bearing
housing slot. Cover the inboard diameters of the bearing housing with grease as shown in Figure 12.
9. Position the bearing housing (52) onto the shaft. Evenly press the assembly onto the bearing fit of the rotor shaft
(1) until the inner race of the bearing (51) is firmly seated against the speed sensor hub (55). A soft drift (copper,
bronze, wood, etc.) with a small mallet may be used to tap the inner race of the bearing to ensure seating
against the speed sensor hub.

GEK-91723A
Figure 12. Bearing Assembly Installation Information
5.5.3.4. Rotor Shaft Sleeve Installation

injury.

GEK-91723A
The rotor shaft sleeve (50) or collar is installed in this procedure. To install the rotor shaft sleeve:
1. Ensure the sleeve (50) is clean and free of surface damage.
2. Heat the sleeve in an oven to 50° C (90° F) rise above the ambient temperature of the rotor shaft (room). For
example, if the rotor shaft (room) ambient temperature is 22° C (71.6° F), heat the flinger and the speed sensor
hub to 72° C (161.6° F) which is the rotor shaft (room) ambient temperature plus (+) the temperature rise of 50° C
(90° F).
3. Remove the sleeve (50) from the oven and position onto the rotor shaft (1).
4. Press the sleeve firmly onto the rotor shaft fit until seated against the inner race of the bearing (51). A soft drift
(copper, bronze, wood, etc.) with a small mallet may be used to tap the sleeve to ensure seating against the inner
race of the bearing.
A product improvement has changed the design of this sleeve to a uniform outside
CAUTION diameter. If the original sleeve is reused, ensure the sleeve is installed with the larger
outside diameter toward the bearing cap as shown in Figure 14. Failure to do so may
result in premature failure.
5. Cover the outside diameter of the sleeve (50) with grease as shown in Figure 12.
5.5.3.5. Bearing Cap Installation
The bearing cap (46) will be installed and bolted to the bearing housing in this procedure. To install the bearing cap:
1. Align and tap the outboard lip seal (47) into location in the bearing cap as shown in Figure 12.
2. Fill the bearing cap inboard cavity with grease as shown in Figure 12.
The bearing cap weighs approximately 40 lbs. (18 kg). Use appropriate lifting devices
WARNING for this weight. Failure to do so may result in injury.
3. Cover the lip seal (47) and the inside diameters (ID) on the outboard side of the bearing cap with grease as
shown in Figure 12.
4. Position the bearing cap (46) onto the rotor shaft (1) against the bearing housing (52).
5. Thread the six bearing cap bolts (48) and washers through the bearing cap into the bearing housing (52).
6. Torque the bolts (48) to the value shown in section 6.3., TORQUE VALUES in this publication.

GEK-91723A
5.5.4. Frame Head Installation
The frame head (37) will be installed onto the rotor assembly in this procedure. To install the frame head (37):
1. Install two frame head eyebolt lifting assemblies into the open brush holder mounting holes (Figure 6) of the
frame head as shown in the GEK-91747, OHV ROTATING EQUIPMENT OVERHAUL TOOL GUIDE listed in section
1.2., RELATED PUBLICATIONS in this publication.
2. Attach the two lifting lugs on the frame head (37) to the first hoist (Figure 6). Attach the second hoist to the two
eyebolts.
The frame head weigh approximately 1470 lbs (670 kg). Use appropriate lifting devices
WARNING for this weight. Failure to do so may result in injury or death.
3. Lift the frame head (37) with the two hoists and align over the rotor assembly. To aid aligning the frame head
with the bearing housing (52), thread two 0.625-11 X 2.5 in studs (or all thread) into equally spaced bearing hous-
ing outer tapped holes.
4. Lower the two hoists evenly until the frame head (37) is on the bearing housing with alignment studs through
the frame head holes. Do not detach the hoists until the frame head is secured to the bearing housing.
5. Thread four frame head mounting bolts and washers (53) through the frame head into the bearing housing (52).
6. Remove the alignment studs and thread the last two frame head mounting bolts and washers (53) through the
frame head into the bearing housing (52).
7. Torque the bolts to the value shown in section 6.3., TORQUE VALUES in this publication.
5.5.5. Rotor Assembly Installation into the Stator Assembly
this publication.
2. Attach a hoist to the swivel hoist ring on the end of the rotor shaft (Figure 5).
The rotor assembly and frame head weigh approximately 3460 lbs (1570 kg). Use
WARNING appropriate lifting devices for this weight. Failure to do so may result in injury or
death.
3. Lift the rotor assembly and position over the stator assembly. To aid aligning the frame head with the stator
assembly mounting holes, thread two 0.625-11 X 2.5 in studs (or all thread) into equally spaced frame head
tapped holes (outer tapped holes on the inboard side of the frame head).
4. Lower the rotor assembly onto the stator assembly while aligning the center of frame head outer flat with the
stator center lifting lug (Figure 3).

GEK-91723A
5. Thread the frame head mounting bolts and washers (14) through the stator (24) holes into the frame head (52).
6. Remove the alignment studs from the frame head.
7. Thread the remaining two frame head mounting bolts and washers (14) through the stator (24) holes into the
frame head (52).
5.5.6. Speed Sensor and Brush Holder Installation
The speed sensor (54) and brush holder assemblies (59) are installed in this procedure. to install the brush holders
and speed sensor:
1. Thread the speed sensor (54) into the bearing housing (52) speed sensor tapped hole. Thread the speed sensor
into the tapped hole until the speed sensor contacts the speed sensor hub (55). Turn the speed senor 120° (0.33
turn) back from the speed sensor hub. Tighten the lock nut on the speed sensor.
2. Install the six brush holder studs (58) into the frame head (37). Thread the brush holder stud bolts and washers
(63) through the frame head into the studs. Torque the bolts to the torque value shown in section 6.3., TORQUE
VALUES in this publication.
3. Adjust the brush holder clearance to the collector ring to the limits listed in section 6.1.1., GENERAL ALTERNATOR
4. Route the speed sensor cable to the speed sensor and lock the cable connector into the speed sensor (54).
5. Route the brush holder cables and speed sensor cable through the frame head (37) and tie the cables to the
metal staples on the frame head (37) as shown in Figure 13.
5.5.7. Rotate the Alternator Assembly to Horizontal
The alternator assembly will be rotated to the shaft horizontal position to continue the assembly process. To rotated
the alternator assembly to the shaft horizontal position:
this publication.
2. Prepare blocking or cradle to lower the alternator assembly onto after rotation to the shaft horizontal position of
the alternator assembly.
3. Attach the center lifting lug to one hoist. Attach the second hoist the swivel hoist ring.
The alternator assembly weighs approximately 9500 lbs (4310 kg). Use appropriate lift-
WARNING ing devices for this weight. Failure to do so may result in injury or death.
4. Lift the alternator assembly off the floor.

GEK-91723A
Figure 13. Routing and Securing Brush Holder Cables and Speed Sensor Cable
5. When the alternator assembly is approximately 3 feet (1 meter) off the floor, lower the hoist attached to the
swivel hoist ring and lift with the hoist attached to the center lifting lug. The alternator assembly should rotate to
the shaft horizontal position as depicted by Figure 3.
6. Lower the alternator evenly until secure in blocking or cradle (to prevent alternator roll).
5.5.8. Traction Motor/Control Cooling Impeller Drive Hub Installation
The traction motor/control cooling impeller hub (44) will be installed in this procedure. To install the impeller hub (44):
1. Clean, inspect, and prepare the rotor shaft taper and hub taper per SI-10011 section 11. For detailed informa-
tion on the SI-10011 section 11 process, contact the GE Representative.
2. Fit the hub onto the rotor shaft taper cold several times. Note the location of the hub on the rotor shaft. When
heated, the hub should fit 0.030 - 0.040 inches (0.732 - 1.016 mm) further (advance) on the rotor shaft.

GEK-91723A
3. Heat the impeller hub (44) in an oven to 100º C (180º F) rise above the rotor shaft (room) temperature. For exam-
ple, if the rotor shaft (room) ambient temperature is 22º C (71.6º F), heat the rotor shaft to 122º C (251.6ºF), which
is rotor shaft (room) temperature 22º C (71.6º F) plus the temperature rise of 100º C (180º F).
injury.
4. Remove the impeller hub (44) from the oven and snap it onto the rotor shaft. Ensure the advance of 0.030 - 0.040
inches (0.732 - 1.016 mm) is achieved.
5. Let the rotor shaft and impeller hub cool to room temperature prior to proceeding with the assembly process.
5.5.9. Air Inlet Housing Installation
The air inlet housing (38) will be installed on the frame head (37) in this procedure. To install the air inlet housing (38):
1. Cover outside the outer bolt circle of the frame head (37) air inlet housing mating surface with Lubriplate™ 630-
A* before attaching the air inlet housing (38).
2. Run a 0.12 inch (3.05 mm) bead of sealant (Silmate-RTV-1473) around the inside of the outer bolt circle of the
frame head (37) air inlet housing mating surface.
The blower air inlet housing weighs approximately 295 lbs (135 kg). Use appropriate
3. Lift the air inlet housing (38) over the alternator assembly and align the center of the inlet with the center of the
frame head flat and the center lifting lug.
4. Lower the air inlet housing into place on the frame head.
5. Thread the air inlet mounting bolts and washers (39) through the frame head into the air inlet housing. A portion
of the bolts on the bolt circle are inside the frame head.
5.5.10. Traction Motor/Control Cooling Impeller Installation
The impeller (43) will be installed on the impeller hub (44) in this procedure. To install the impeller (43):
1. Insert the impeller pin into the impeller hub (44) to the dimension shown in Figure 12.
The impeller blade weighs approximately 170 lbs (77 kg). Use appropriate lifting

GEK-91723A
2. Lift the impeller (43) and align over the impeller hub (44).
3. Thread the impeller mounting bolts and washers (45) through the impeller (43) into the impeller hub (44).
5.5.11. Air Outlet Housing Installation
The air outlet housing (42) will be installed in this procedure. To install the air outlet housing:
1. Run a 0.12 inch (3.05 mm) bead of sealant (Silmate-RTV1473) around the inside of the outer bolt circle of the air
outlet housing (42) air inlet mating surface.
The blower air outlet housing weighs approximately 125 lbs (56.7 kg). Use appropriate
WARNING lifting devices for this weight. Failure to do so may result in injury.
2. Lift the air outlet housing (42) and position over the air inlet housing.
3. Align the outlet of the air outlet housing (42) 180° opposite of the inlet for the air inlet housing (38).
4. Lower the air outlet housing (42) into position on the air inlet housing (38).
5. Thread the air outlet mounting bolts and washers (40) through the air outlet housing (42) into the air inlet hous-
ing (38).
5.5.12. Alternator Frame Adapter Installation
The alternator frame adapter (13) is mounted to the alternator stator frame in this procedure. To install the frame
adapter:
1. Lace a lifting cable or sling through a window of the frame adapter (13) as shown in Figure 2.
The frame adapter weighs approximately 330 lbs (150 kg). Use appropriate lifting
WARNING devices for this weight. Failure to do so may result in injury.
2. Lift the frame adapter with a hoist and position at the alternator assembly end near the mounting position.
3. Thread a 0.625-11 eyebolt into the upper tapped hole of the engine adapter (6) outer bolt circle (Figure 2). This
will allow the rotor to be lifted slightly. Lace a lifting sling or cable through the eyebolt. Attach the sling or cable
to a second hoist (not the hoist lifting the frame adapter). Lift the rotor assembly slightly so the frame adapter
can be moved into position on the stator frame. Do not lift the alternator with the eyebolt

GEK-91723A
4. Move the frame adapter (13) into mounting position on the stator frame (24) when the rotor assembly is sus-
pended by the hoist attached to engine adapter (6).
5. Thread the frame adapter mounting bolts and washers (14) through the stator frame (24) into the frame adapter
(13).
5.5.13. Power Cables and Cover Installation
The power cables (27) and cover (25) are installed in this procedure. To install the power cables and cover:
1. Each power cable (27) passes through a cable connector (26) on the cable cover (25). Ensure the connectors are
loose and the cables can be moved through the connector.
2. Pull the power cables though the connector to allow slack to connect the cables. Align each cable to the con-
nection bus and thread the terminal bolts and washers (29) in the tap blocks. Torque the bolts to the value
shown in section 6.3., TORQUE VALUES in this publication.
3. Move the cover (25) down over the connected power cables (27) until the cover is aligned with the mounting
holes. Thread the cover mounting bolts through the cover and tighten.
4. Tighten the cable connectors (26) around the power cables.
5.6. ALTERNATOR ROTATIONAL TESTING
To test the alternator while rotating:
1. Secure the alternator to the rotational test fixture on the test stand.
2. Spin the alternator up to 1875 RPM.
3. Apply the DC amperage to the collector ring cables (F1 and F2) for the line-to-line voltage test described in sec-
tion 6.1.2., ELECTRICAL TESTING ALTERNATOR DATA in this publication.
4. The alternator output will be at the value described in section 6.1.2., ELECTRICAL TESTING ALTERNATOR DATA in
this publication.

GEK-91723A
6. SUMMARY DATA
6.1. ALTERNATOR DATA
6.1.1. General Alternator Data

Table 3. Gernal Alternator Data
Model 5GTA39
Classification 8 Pole, 3 Phrase, Y-connected, AC Generator
Rotation CCW
Brush Type GE-320
Brush Quality (total, 3 per collector ring) 6
Brush Minimum Length (at Maintenance Interval), in 1.5 (38.1)
(mm)
Brush Spring Arm Pressure (new brush) lbs, (kg) 4.25 - 4.75 (1.93 - 2.15)
Brush Holder Collector Ring Clearance, in (mm) 0.10 - 0.125 (2.54 - 3.175)
Collector Ring Diameter (new), in (mm) 11.00 (279.4)
Collector Ring Minimum Diameter, in (mm) 10.84 (275.3)
Collector Ring Maximum Runout, in (mm) 0.003 (0.076)
Collector RIng Groove 2.75 Right Hand Grooves Per Inch (25.4 mm)
Collector Ring Groove Depth (new), in (mm) 0.110 (2.794)
Collector Ring Minimum Groove Depth, in (mm) 0.030 (0.762)
Collector Ring Minimum Groove Depth, in (mm) 0.030 (0.762)
Collector Ring Groove Width, in (mm) 0.06 - 0.10 (1.52 - 2.54)
Rotor Dynamic Balance, maximum per end of rotor 126
(gram-inch)
Rotor Bearing Lubrication GE Spec D6A2C10
Rotor Diameter (over rotor coils), in (mm) 29.68 - 29.72 (753.8 - 754.8)
Stator Bore Diameter, in (mm) 29.96 - 30.00 (761.5 - 762.0)
Rotor-to-Stator Air Gap, in (mm) 0.26 - 0.32 (6.6 - 8.1)
Ventilation Requirements, @ 2.9 in (73.66 mm) H20 Differ- 3500 (99.12)
ential Pressure, ft3/min (m3/min)

GEK-91723A
6.1.2. Electrical Testing Alternator Data

Table 4. Electrical Testing Alternator Data
Rotor Field Coil Impedance (voltage drop @ 15 amps at 14.8 - 16.1 volts
60 Hz AC power)
Rotor Coil Resistance @ 77°F (25°C) in Ohms (Ω) 0.183 - 0.194
Stator Field Resistance, each winding, @ 77°F (25°C) in 0.00356 - 0.00340
Ohms (Ω)
Tertiary Field Resistance (T15-T16) @ 77°F (25°C) in Ohms 0.0139 - 0.0113
(Ω)
Electrical Testing, Line-to-Line Voltage Test (alternator At alternator RPM of 1875, apply approximately 100
rotating test) amps DC to Collector Ring Rotor Field (F1 and F2), AC
voltage output on T1 to T2, T2 to T3, and T3 to T1 should
be equal within 1% deviation between highest and low-
est voltage reading. Tertiary AC output under same test
conditions will be 338 - 353 voltage (AC).
Megohmmeter Minimum 2 Megohms
Hi-Pot, Main stator field leads (T1, T2, and T3) to stator New - 5000v, Reconditioned - 4000v
frame (test voltage @ 60 Hz AC for one minute with less
than 1 ma leakage current)
Hi-Pot, Rotor coil leads (F1 and F2) to rotor yoke frame New - 2000v, Reconditioned - 1600v
(test voltage @ 60 Hz AC for one minute with less than 1
ma leakage current)
Hi-Pot, Tertiary field leads (T15 and T16) to stator frame New - 2900v, Reconditioned - 2320v
(test voltage @ 60 Hz AC for one minute with less than 1
ma leakage current)
Hi-Pot, Collector Ring Assembly Installation (test voltage 2500v
@ 60 Hz AC for one minute with less than 1 ma leakage
current)
6.1.3. Alternator and Component Approximate Weights

Table 5. Alternator and Component Approximate Weights
Rotor (shaft, components, and yoke with coils), lbs. (kg) 3092 (1403)
Rotor Assembly (complete assembly), lbs. (kg) 3461 (1570)
Stator (frame with windings), lbs. (kg) 5557 (2521)
Stator Assembly (complete assembly), lbs. (kg) 7286 (3305)
Alternator (complete assembly), lbs. (kg) 10747 (4875)

GEK-91723A
6.2. ALTERNATOR COMPONENT IDENTIFICATION BY MODEL
Figure 14. 5GTA39A1, 5GTA39A2, and 5GTA39B1 Component Identification (Part 1 of 2)

GEK-91723A
Figure 15. 5GTA39A1, 5GTA39A2, and 5GTA39B1 Component Identification (Part 2 of 2)

GEK-91723A
Figure 16. 5GTA39B2 Component Identification (Part 1 of 2)

GEK-91723A
Figure 17. 5GTA39B2 Component Identification (Part 2 of 2)

GEK-91723A
Figure 18. 5GTA39C1 Component Identification (Part 1 of 2)

GEK-91723A
Figure 19. 5GTA39C1 Component Identification (Part 2 of 2)

GEK-91723A
Figure 20. 5GTA39C2 and 5GTA39C3 Component Identification (Part 1 of 2)

GEK-91723A
Figure 21. 5GTA39C2 and 5GTA39C3 Component Identification (Part 2 of 2)

GEK-91723A
Figure 22. 5GTA39D1 and 5GTA39D2 Component Identification (Part 1 of 2)

GEK-91723A
Figure 23. 5GTA39D1 and 5GTA39D2 Component Identification (Part 2 of 2)

GEK-91723A
6.3. TORQUE VALUES
Figure 24. Torque Values, Part 1 of 3

GEK-91723A

GEK-91723A

GEK-91723A
6.4. DIMENSIONAL INSPECTIONS
6.4.1. Rotor Shaft Dimensional Inspection
Figure 27. Alternator Rotor Shaft Dimensional Inspection Criteria

GEK-91723A
6.4.2. Bearing Housing Dimensional Inspection
Figure 28. Bearing Housing Dimensional Inspection Criteria
6.4.3. Bearing Cap Dimensional Inspection
Figure 29. Bearing Cap Dimensional Inspection Criteria

GEK-91723A
6.4.4. Rotor Shaft Collar Dimensional Inspection
Figure 30. Rotor Shaft Collar Dimensional Inspection Criteria
6.4.5. Flinger Dimensional Inspection
Figure 31. Flinger Critical Dimensions

Mantenimiento 5GTA39

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Mantenimiento 5GTA39

Uploaded by

Copyright:

Available Formats

GE Transportation

Rev Date By Description

NEW Jun-2008 PAB Initial release of publication.

ii GE Proprietary and Confidential Information

GE Proprietary and Confidential Information iii

iv GE Proprietary and Confidential Information

Figure 1. 5GTA39 Alternator

Revisions are indicated by margin bars.

GE Proprietary and Confidential Information 1

1.2. RELATED PUBLICATIONS

Table 1. Related Publications

Publication Title Publication Number

1.3. SAFETY INFORMATION

1.4. MODEL DIFFERENCES

2. CONTROLS AND INDICATORS

5. REMOVAL AND REPLACEMENT

2 GE Proprietary and Confidential Information

5.1. ALTERNATOR DISASSEMBLY

5.1.1. Blower Housings and Traction Motor/Control Impeller Removal

1. To remove the air outlet housing (42):

2. To remove the impeller blade (43):

GE Proprietary and Confidential Information 3

h. Remove the guide pins from the impeller drive hub.

3. To remove the air inlet housing (38):

5.1.2. Traction Motor/Control Impeller Drive Hub Removal

To remove the impeller drive hub (44):

4 GE Proprietary and Confidential Information

5.1.3. Frame Adapter Removal

5. Remove the sling from the frame adapter.

5.1.4. Install the Stator Support Posts

GE Proprietary and Confidential Information 5

Figure 2. Alternator Engine Connection End Frame Adapter Sling Positioning

6 GE Proprietary and Confidential Information

3. Lift the alternator evenly with both hoists.

Figure 3. Alternator in the Shaft Horizontal Position

GE Proprietary and Confidential Information 7

Figure 4. Alternator in the Shaft Vertical Position

5.1.6. Separate the Rotor and Stator Assemblies

8 GE Proprietary and Confidential Information

GE Proprietary and Confidential Information 9

5.1.7. Frame Head Removal

9. Remove the hoist cables or slings.

10 GE Proprietary and Confidential Information

5.1.8. Rotor Bearing Housing Assembly Removal

1. Remove the bearing cap (46). To remove the bearing cap:

a. Remove the six bearing cap bolts and washers (48).

GE Proprietary and Confidential Information 11

Figure 7. Rotor Bearing Assembly

12 GE Proprietary and Confidential Information

5.1.9. Rotor Shaft Speed Sensor Hub Removal

5.1.10. Alternator Impeller Removal

GE Proprietary and Confidential Information 13

5.1.11. Collector Ring Assembly Removal

14 GE Proprietary and Confidential Information

Figure 8. Preparation for Collector Ring Assembly Removal

5.1.12. Alternator Impeller Drive Hub Removal

GE Proprietary and Confidential Information 15

4. Remove the tool assembly from the drive hub.

5.1.13. Rotor Shaft and Rotor Yoke Separation

1. Position the rotor yoke/shaft assembly in the shaft vertical orientation.

7. Lift the rotor shaft from the rotor yoke.

5.2. CLEANING ALTERNATOR COMPONENTS

16 GE Proprietary and Confidential Information

• Do not inhale fumes.