16828 4 Mercury BOLT

Introduction
The special instruction provides directions on how to inspect for abrasion of stator lead cables inside the generator, how to add protective provisions to prevent cable abrasion with 416-1646 Tape and/ or new cable supports, and how to repair cables with 475-0266 Repair Kit in the event the cables have been damaged due to abrasion.This procedure is for low, medium, and high voltage generators (400V to 15,000V) of multiple lead wire configurations where stator lead cables may suffer abrasion due to repetitive movement against generator barrel window, other crossing cables, or cable supports. Testing has shown the solution to prevent abrasion is to effectively insulate cables and/ or to effectively hold the cable tightly in the cable support hole to prevent movement. This can be done by taping the leads or by using clamp style cable supports to ensure cables fit snugly in the holes. After periodic cable inspection, one or more of the following actions may be required:
If no significant abrasion is observed, taping around cable is suggested.
If significant abrasion is observed, cables will need repair prior to taping or upgrade to cable support.Important Safety Information
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not specifically recommended by Caterpillar is used, ensure that it is safe for you and for other people to use.Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.
Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Caterpillar dealer for replacement manuals. Proper care is your responsibility.
Personal injury or death can result from high voltage.When power generation equipment must be in operation to make tests and/or adjustments, high voltage and current are present.Improper test equipment can fail and present a high voltage shock hazard to its user.Make sure the testing equipment is designed for and correctly operated for high voltage and current tests being made.When servicing or repairing electric power generation equipment:
Make sure the unit is off-line (disconnected from utility and/or other generators power service), and either locked out or tagged DO NOT OPERATE.
Remove all fuses.
Make sure the generator engine is stopped.
Make sure all batteries are disconnected.
Make sure all capacitors are discharged.Failure to do so could result in personal injury or death. Make sure residual voltage in the rotor, stator and the generator is discharged.
Personal injury or death can result from a spark.An incompletely discharged capacitor can cause a spark.Do not use the insulation tester in an explosive atmosphere.
Personal injury or death can result from electrocution.The megohmmeter is applying a high voltage to the circuit.To avoid electrocution, do not touch the instrument leads without first discharging them. When finished testing also discharge the generator windings.
Personal injury or death can result from the engine starting.Regardless of the cleaning method used; to avoid serious injury or death, make sure there is no voltage applied to the windings.Make sure the engine can not be started.
Parts Required
Illustration 1 g03782038
If no lead abrasion is observed, add Scotch Electrical Splicing Tape #23 ( 416-1646 Tape ) around the cables for protection and to achieve a tight fit where the cables pass through the cable supports.
If lead abrasion is observed, 475-0266 Repair Kit is suggested to repair cable and add taping around cable. If desired, clamping cable supports are available to be ordered separately. - Silicon RTV - Insulating Tape - Heat Shrink Tubing - Sand Paper - Denatured Alcohol Wipes - 8" x 8" x 0.12" neoprene mats (2)Step 1 Inspection:
Generators are periodically inspected for cable abrasion. An action plan and parts can be ordered after determining the specific needs for each generator. The following inspection procedure must be followed:
Lock Out - Tag Out Engine - Generator from operation.
Remove Terminal Box cover.
Ground the Phase terminals to insure the winding are at ground potential. The location of the inspections is the area where the lead cables enter the terminal box though the lead board from generator and,
If necessary remove incoming Load Leads from Terminals T1, T2, T3 to allow access to generator leads.
Illustration 2 g03780719