22235061 Volvo.Penta Cylinder liner kit

Illustration 1 g03792323
Typical generator example (1) Flex coupling disc mounting bolt (2) Flex coupling discs (3) Drive hub (4) Front flange (5) Fan (6) Lifting point (7) Main stator (8) Intermediate terminal block (9) Terminal box cover (10) Terminal box (11) Bus bar and terminal block (12) Lifting block (13) Rear cover (14) Exciter stator (15) Exciter rotor (16) Diodes (17) O ring (18) Rear bearing (19) Main rotor shaft (20) Frame (main stator housing) (21) Main rotor (22) Protection screenThe following procedure assumes the following:
The generator has been properly shut down
That any necessary software, electrical, and physical data have been recorded
The generator has been isolated from other generators or power sources of any type
That all safety procedures have been followed to lock out and tag out the unit that is being worked on
That all connections and cables are appropriately labeled
That all of the necessary components have been removed to gain accessNote: If the generator has a heat exchanger installed on top of the generator, the heat exchanger must be removed first.Note: Every component must be marked to ensure the correct orientation when the component is installed after disassembly. Refer to Systems Operation, Test and Adjust, Disassembly and Assembly, KENR5284 disassembly section for illustrations and information about marking or labeling components before removal.
Open the cover (9) of the terminal box.
Disconnect the cables from the intermediate terminal block (8), bus bar (11), terminal block (11), and the rotor cables to the exciter.
Loosen the mounting bolts that secure the terminal box (10) to the anti vibration mounts. The anti vibration mounts are bolted to the frame (19). Remove the terminal box (10) .Note: The recommended torque for the mounting bolts to the AVM is 15 1.5 N m (11 1.1 lb ft).
Remove the protection screen (22) .
Loosen the bolts holding the front flange (4) to the frame. Remove the front flange (4) .
Remove the cable clamps and mounting hardware to allow the cables to be disconnected from the main stator and exciter.
Install an M20 eye bolt in the lifting block (12) .Note: The lifting block must be used only to lift and remove the rear cover. The lifting block (12) CANNOT be used to lift the alternator. To lift the alternator, use lifting point (6) .Note: The M20 eye bolt is not supplied with the generator.
Remove the mounting bolts for the rear cover (13). Remove the rear cover.
Remove the bolts that attach the exciter stator (14) to the rear bracket. If needed, use a rubber hammer to remove the exciter stator (14) .Note: Take care to avoid accidents or damage to the coils of the exciter stator and exciter rotor.
Remove the exciter rotor (15). Refer to Systems Operation, Test and Adjust, Disassembly and Assembly, UENR5951, "Exciter - Remove" for information to remove the exciter.
Ensure that the end bracket is properly supported by an appropriate lift and rigging.
Install protective strips between the main rotor and the main stator. The protective strips are to protect against any damage to the laminations of either the main rotor and the main stator. Refer to Systems Operation, Test and Adjust, Disassembly and Assembly, KENR5284 disassembly section for illustrations and information about installation of protective strips.
Remove the mounting bolts for the rear bracket. If needed, use two pry bars, one on each side and a rubber hammer.
Illustration 2 g03794292
(25) Typical example of removal tool assembly
The removal of the rotor assembly must be done from the front of the generator, using an appropriate device.Note: The removal device is not supplied with the generator. An example of a device for main rotor removal is shown in Illustration 2.Generator Assembly
Make sure that any machined surfaces on the frame, flange, rear shield, and front bracket are clean and free of any with corrosion. If the installation requires added protection, use the appropriate corrosion protection.
Insert the main rotor at the front with an appropriate device.
Check if the O ring (17) is correctly placed in the bearing seat of the rear bracket.
Install the rear bracket on the generator stator housing (20) with the bearing installed. Install the rear bracket mounting bolts.
Install the exciter rotor on the main rotor shaft. Install the mounting bolts for the exciter and torque to the appropriate value.
Illustration 3 g03794166
(30) Rotor cable to diode crescent connection (31) Diode assembly (diode wheel) (32) Mounting nuts for diode crescent assembly (33) Mounting nuts for diode assembly (diode wheel)
Connect the cables (30) from the main rotor to the diode crescents (rectifier bridge) on the exciter rotor.Note: If the diode assembly (diode wheel) (31) was removed, torque the mounting nuts (32) and (33) to 11 N m (8 lb ft) after installation of the diode assembly (diode wheel).
Install the exciter stator (14) and mounting bolts.Note: Care must be taken not to damage any windings on the exciter stator or the exciter rotor during installation procedures.
Make sure that the cables for the exciter stator are routed correctly in order to make the connection in the terminal box.
Install the rear cover (13) and mounting bolts.
Install the front flange (4) and mounting bolts.
Install the protection screen (22) .
Install the terminal box (10) in proper position and the mounting bolts.
Connect the cables and wiring for the intermediate terminal block (8), bus bar (11), terminal block (11), and exciter.
Install the terminal box cover (9) .