Service-Guide STAMFORD S1-S0-UC22-UC27-HC4-HC5-HC6-S4-S5-S6-P7-S7-P80-S9

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 It may be superseded due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

Service and maintenance procedures must only be carried out by experienced and qualified
engineers, who are familiar with the procedures and the equipment.
Risk Assessment
A risk assessment has been performed on this product by Cummins, however a separate risk
assessment must be performed by the user/operating company to establish all personnel-related
risks. All affected users must be trained on the identified risks. Access to the Power PlanUGenerator
Set during operation must be restricted to persons who have been trained on these risks.
Personal Protective Equipment (PPE)
All persons operating, servicing, maintaining or working in or with a power plant or a generator set
must wear appropriate Personal Protective Equipment (PPE) Recommended PPE includes:
• Ear and Eye Protection
• Head and face protection
• Safety footwear
• Overalls that protect the lower arms and legs
Ensure that all persons are fully aware of the emergency procedures in case of accidents.
Noise
WARNING
Noise from a running alternator can cause serious injury by permanent hearing damage.
To prevent injury, wear appropriate personal protection equipment (PPE).
Maximum A-weighted noise emissions depend on alternator type. Contact the supplier for
application-specific details.
Electrical Equipment
DANGER
Live electrical conductors can cause serious injury or death by electric shock and burns.
To prevent injury and before removing covers over electrical conductors, isolate the generator set
from all energy sources, remove stored energy and use lock out/tag out safety procedures.
All electrical equipment can be dangerous if not operated correctly. Always install, service and
maintain the alternator in accordance with this manual. Work that requires access to electrical
conductors must comply with all applicable local and national electrical safety procedures for the
voltages involved and any site specific rules. Always use genuine branded replacement parts.
Lock Out/Tag Out

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

shown in the diagram or directly in-line with any air inlet/outlet.
Make sure this consideration is captured in your risk assessment.
Hazard Warning Labels
WARNING
Safety Cover Removed
A hazard exposed when a safety cover is removed can cause serious injury or death.
To prevent injury:
• Fit the safety labels at the locations shown on the back of the label sheet supplied.
• Observe the safety labels.
• Refer to the service manual before removing covers.
The generator set manufacturer is responsible for fitting the self-adhesive hazard warning labels
supplied with the alternator.
Replace labels that are missing, damaged or painted over.
Hazard Warning Labels - continued
P0/P1
Alternator
P0/P1
Alternator
Commission Post Commission 1,000 Hour 10,000 Hours 30,000 Hours

6 Month Service 1 Year Service 2 Year Service 5 Year Service
Commission
P0/P1 Alternator Alternator Controls and Auxiliaries Windings Bearings
Inspect Inspect Inspect Inspect
■ Alternator rating ■ Synchronisation settings ■ Condition of windings ■ Condition of bearings
■ Bedplate arrangement ■ Customer settings for ■ Customer settings for
■ Coupling arrangement Test temperature sensors temperature sensors
■ Environmental conditions ■ Initial AVR set up

and cleanliness ■ AVR settings while Test Test
■ Complete machine damage, alternator is running ■ Insulation resistance of all ■ Temperature sensors while
loose parts and earth bonds ■ Customer connections of windings (P0/P1 test for LV) alternator is running
■ Guards, screens, warning auxiliaries ■ Insulation resistance of
and safety labels ■ Function of auxiliaries rotor, exciter and EBS
■ Maintenance access ■ Synchronisation while ■ Temperature sensors while
alternator is running alternator is running
Test
■ Ambient temperature (inside Cooling Rectifier Terminal Box
and outside)
■ Electrical nominal operating Inspect Inspect Inspect
conditions and excitations ■ Air flow (rate and direction ■ Diodes and varistors ■ All alternator/customer
while alternator is running while alternator is running) ■ Connections and cabling
■ Vibration while alternator is ■ Condition of fan
running
Test
■ Condition of air filter
Post Commission 250 Hours/6 Months
Inspect Test Inspect Inspect
■ Environmental conditions ■ AVR settings while ■ Condition of windings ■ Condition of bearings
and cleanliness alternator is running
■ Complete machine damage, ■ Function of auxiliaries Test
loose parts, and earth ■ Synchronisation while
bonds ■ Insulation resistance of all
alternator is running windings (P0/P1 test for LV)
■ Guards, screens, warning
and safety labels ■ Insulation resistance of
rotor, exciter and EBS
■ Temperature sensors while
Test alternator is running
■ Ambient temperature (inside
and outside)
■ Electrical nominal operating
conditions and excitations
while alternator is running Cooling Rectifier Terminal Box
■ Vibration while alternator is
running Inspect Inspect Inspect
■ Condition of fan ■ Diodes and varistors ■ All alternator/customer
connections and cabling
Test
Clean
■ Air filter
1,000 Hours/1 Year Service
■ Complete machine damage, ■ Customer connections of Test Test
loose parts, and earth auxiliaries
bonds ■ Insulation resistance of all ■ Temperature sensors while
■ Function of auxiliaries windings (P0/P1 test for LV) alternator is running
■ Guards, screens, warning ■ Synchronisation while
alternator is running rotor, exciter, and EBS
and outside)
Test
Clean
■ Air filter
■ Coupling arrangement ■ Anti condensation heater ■ Condition of windings ■ Condition of bearings
■ Environmental conditions
and cleanliness Test Test
■ Complete machine damage, ■ AVR settings while ■ Insulation resistance of all
loose parts, and earth alternator is running windings (P0/P1 test for LV)
bonds
■ Customer connections of ■ Temperature sensors while
■ Guards, screens, warning auxiliaries alternator is running
and safety labels
■ Function of auxiliaries
■ Synchronisation while
and outside)
conditions and excitations Cooling Rectifier Terminal Box
while alternator is running
■ Vibration while alternator is Inspect Inspect Inspect
running ■ Condition of fan ■ Diodes and varistors ■ All alternator/customer
Test
Clean
■ Air filter
P0/P1 Alternator 30,000 Hours/5 Year Service Kits
For the 30,000 hour service interval Kit Number Contents
we recommend replacing several
components in order to optimise the
A051C107 ■ Rectifier Service Kit
alternator’s performance.
(P0/P1 1 Bearing 30,000 Hour Service Kit) ■ NDE Bearing Kit
For the P0/P1 alternator, the kits

detailed in this table contain all parts A051C115 ■ Rectifier Service Kit
necessary to execute the maintenance P0/P1 2 Bearing 30,000 Hour Service Kit) ■ DE and NDE Bearing Kit
and repairs.
Frame Part Number Description
P0/P1 45-1161 Heater Kit UL 230V

Inspect Replace Inspect Replace
■ Coupling arrangement ■ Anti condensation heater ■ Condition of windings ■ Bearings
loose parts, and earth alternator is running windings (P0/P1 test for LV)
bonds
and safety labels
■ Function of auxiliaries ■ Insulation resistance of
■ Synchronisation while rotor, exciter and EBS
and outside)
■ Vibration while alternator is Inspect Replace Inspect
Test
■ Condition of Air filter
S0/S1
Alternator
S0/S1
Alternator

Commission
S0/S1 Alternator Alternator Controls and Auxiliaries Windings Bearings
■ Alternator rating ■ Initial AVR set up ■ Condition of windings ■ Condition of bearings
■ Bedplate arrangement ■ AVR settings while
■ Coupling arrangement alternator is running Test
■ Environmental conditions ■ Customer connections of ■ Insulation resistance of all
and cleanliness auxiliaries windings (S0/S1 test for LV)
■ Complete machine damage, ■ Function of auxiliaries ■ Insulation resistance of
loose parts and earth bonds ■ Synchronisation while rotor, exciter and auxiliary
■ Guards, screens, warning alternator is running
and safety labels
■ Maintenance access
Test
and outside)
while alternator is running while alternator is running) connections and cabling
running
loose parts, and earth
windings (S0/S1 test for LV)
rotor, exciter and auxiliary
Test
and outside)
■ Complete machine damage, ■ Customer connections of Test
■ Function of auxiliaries windings (S0/S1 test for LV)
rotor, exciter, and auxiliary
and outside)
loose parts, and earth alternator is running windings (S0/S1 test for LV)
bonds
■ Customer connections of
■ Guards, screens, warning auxiliaries
and safety labels
Test
and outside)
S0/S1 Alternator 30,000 Hours/5 Year Service Kits
(S1 Bearing 30,000 Hour Service Kit) ■ NDE Bearing Kit
For the S0/S1 alternator, the kits

detailed in this table contain all parts A054N489 ■ Rectifier Service Kit
necessary to execute the maintenance (S0 Bearing 30,000 Hour Service Kit) ■ NDE Bearing Kit
and repairs.
S0/S1 A054K278 Heater Kit UL 12V

loose parts, and earth alternator is running windings (S0/S1 test for LV)
bonds
■ Customer connections of ■ Insulation resistance of
■ Guards, screens, warning auxiliaries rotor, exciter and auxiliary
and safety labels
Test
and outside)
Test
UC22/UC27
Alternator
UC22/UC27
Alternator

Commission
UC22/UC27 Alternator Alternator Controls and Auxiliaries Windings Bearings
■ Environmental conditions ■ Initial AVR set up

and cleanliness ■ AVR settings while Test Test
■ Complete machine damage, alternator is running ■ Insulation resistance of all ■ Temperature sensors while
loose parts and earth bonds ■ Customer connections of windings (UC22/UC27 test alternator is running
■ Guards, screens, warning auxiliaries for LV/MV)
and safety labels ■ Function of auxiliaries ■ Temperature sensors while
■ Maintenance access alternator is running
alternator is running
Test
and outside)
■ Three phase rectifier
■ Vibration while alternator is ■ Condition of fan (if fitted)
running
Test
■ Complete machine damage, ■ Function of auxiliaries Test Test
loose parts, and earth ■ Synchronisation while
alternator is running windings (UC22/UC27 test alternator is running
■ Guards, screens, warning for LV/MV)
and safety labels
■ Insulation resistance of
rotor, exciter and PMG
Test ■ Temperature sensors while
■ Ambient temperature (inside alternator is running
and outside) ■ Insulation resistance of
■ Electrical nominal operating rotor, exciter and PMG
■ Three phase rectifier connections and cabling
Test (if fitted)

■ Complete machine damage, ■ Customer connections of Test Test
■ Function of auxiliaries windings (UC22/UC27 test alternator is running
■ Guards, screens, warning ■ Synchronisation while for LV/MV)
and safety labels alternator is running ■ Insulation resistance of
rotor, exciter, and PMG
and outside)
Test (if fitted)
Clean
■ Air filter
and cleanliness Test Test Test
■ Complete machine damage, ■ AVR settings while ■ Insulation resistance of all ■ Temperature sensors while
loose parts, and earth alternator is running windings (UC22/UC27 test alternator is running
bonds for LV/MV
■ Guards, screens, warning auxiliaries ■ Temperature sensors while
and safety labels alternator is running
and outside)
Test (if fitted)
Clean
■ Air filter
UC22/UC27 Alternator 30,000 Hours/5 Year Service Kits
components in order to optimise the A051C212 ■ Rectifier Service Kit
alternator’s performance. (UC22 1 Bearing 30,000 Hour Service Kit) ■ NDE Bearing Kit
For the UC22/UC27 alternator, the kits A051C216 ■ Rectifier Service Kit
detailed in this table contain all parts (UC22 2 Bearing 30,000 Hour Service Kit) ■ DE and NDE Bearing Kit
necessary to execute the maintenance
and repairs. A051C218 ■ Rectifier Service Kit
(UC27 1 Bearing 30,000 Hour Service Kit) ■ DE and NDE Bearing Kit

(UC27 2 Bearing 30,000 Hour Service Kit) ■ DE and NDE Bearing Kit
UC22/UC27 A053N107 Heater Kit UL 110-125V
UC22/UC27 A053N108 Heater Kit UL 220-260V

and cleanliness Test Test Test
■ Complete machine damage, ■ AVR settings while ■ Insulation resistance of all ■ Temperature sensors while
loose parts, and earth alternator is running windings (UC22/UC27 test alternator is running
bonds for LV/MV)
■ Synchronisation while ■ Insulation resistance of
Test alternator is running rotor, exciter and PMG
and outside)
Test
HC4/HC5/HC6
Alternator
HC4/HC5/HC6
Alternator

Commission
HC4/HC5/HC6 Alternator Alternator Controls and Auxiliaries Windings Bearings
■ Environmental conditions ■ Initial AVR and PFC set up

and cleanliness ■ AVR and PFC settings Test Test
■ Complete machine damage, while alternator is running ■ Insulation resistance of all ■ Temperature sensors while
loose parts and earth bonds ■ Customer connections of windings (HC4/HC5/HC6 alternator is running
■ Guards, screens, warning auxiliaries test for LV/MV)
and safety labels ■ Function of auxiliaries ■ Temperature sensors while
■ Maintenance access alternator is running
Test
and outside)
running
Test
■ Environmental conditions ■ AVR and PFC settings while ■ Condition of windings ■ Condition of bearings
Test
loose parts, and earth ■ Synchronisation while ■ Temperature sensors while
bonds ■ Insulation resistance of all alternator is running
alternator is running windings (HC4/HC5/HC6
■ Guards, screens, warning test for LV/MV)
and safety labels Clean
■ Insulation resistance of ■ Grease exhaust and trap
rotor, exciter and PMG (Re-greasable bearings only)
■ Ambient temperature (inside alternator is running Replace
and outside) ■ Insulation resistance of ■ Grease for re-greasable
■ Electrical nominal operating rotor, exciter and PMG bearings
Test
Clean
■ Air filter
Inspect Test Inspect Test
■ Environmental conditions ■ AVR and PFC settings while ■ Condition of windings ■ Temperature sensors while
and cleanliness alternator is running alternator is running
loose parts, and earth auxiliaries Replace
■ Function of auxiliaries windings (HC4/HC5/HC6 ■ Bearing greasee
■ Guards, screens, warning ■ Synchronisation while test for LV/MV)
and safety labels alternator is running ■ Insulation resistance of Clean
rotor, exciter, and PMG
Test ■ Grease exhaust and trap
and outside)
Test
Clean
■ Air filter
Inspect Inspect Inspect Test
■ Coupling arrangement ■ Anti condensation heater ■ Condition of windings ■ Temperature sensors while
■ Environmental conditions alternator is running
■ Complete machine damage, ■ AVR and PFC settings while ■ Insulation resistance of all Replace
loose parts, and earth alternator is running windings (HC4/HC5/HC6 ■ Bearing grease
bonds test for LV/MV)
■ Function of auxiliaries alternator is running
■ Grease exhaust and trap
and outside)
Test
Clean
■ Air filter
HC4/HC5/HC6 Alternator 30,000
Kit Number Contents
Hours/5 Year Service Kits
(HC4 1 Bearing 30,000 Hour Service Kit) ■ NDE Bearing Kit
For the 30,000 hour service interval
we recommend replacing several A051C230 ■ Rectifier Service Kit
(HC4 2 Bearing 30,000 Hour Service Kit) ■ DE and NDE Bearing Kit
alternator’s performance. A051C232 ■ Rectifier Service Kit
(HC5 1 SEALED Bearing 30,000 Hour ■ NDE Bearing Kit
For the HC4/HC5/HC6 alternator, Service Kit)
the kits detailed in this table contain A051Z125 ■ Rectifier Service Kit
all parts necessary to execute the (HC5 1 RE-GREASABLE Bearing 30,000 ■ Re-grease NDE Bearing Kit
Hour Service Kit) ■ Cartridge and Cap
maintenance and repairs.
(HC5 2 SEALED Bearing 30,000 Hour ■ DE and NDE Bearing Kit
Service Kit) ■ Cartridge and Cap
Frame Part Description A051Z131 ■ Rectifier Service Kit
Number (HC5 2 RE-GREASABLE Bearing 30,000 ■ Regrease DE and NDE Bearing Kit
HC4 A053M965 Heater Kit UL 220-260V A051C237 ■ Rectifier Service Kit
(HC6 1 SEALED Bearing 30,000 Hour ■ NDE Bearing Kit
HC4 A053M957 Heater Kit UL 110-125V
A051Z133 ■ Rectifier Service Kit
(HC6 1 RE-GREASABLE Bearing 30,000 ■ Re-grease NDE Bearing Kit
HC5/HC6 A053N002 Heater Kit UL 220-260V Hour Service Kit) ■ Cartridge and Cap
HC5/HC6 A053M968 Heater Kit Ul 110-125V (HC6 2 SEALED Bearing 30,000 Hour ■ DE and NDE Bearing Kit
(HC6 2 RE-GREASABLE Bearing 30,000 ■ Regrease DE and NDE Bearing Kit
■ Coupling arrangement ■ Anti condensation heater ■ Condition of Windings ■ Bearings (sealed &
■ Environmental conditions re-greasable
and cleanliness Test Test ■ Bearing grease
■ Complete machine damage, ■ AVR and PFC settings while ■ Insulation resistance of all
loose parts, and earth alternator is running windings (HC4/HC5/HC6 Test
bonds test for LV/MV)
■ Guards, screens, warning auxiliaries ■ Temperature sensors while alternator is running
■ Synchronisation while ■ Insulation resistance of Clean
■ Grease exhaust & trap
■ Ambient temperature (inside (re-greasable bearings only)
and outside)
Test
Clean
■ Air filter
S4/S5/S6
Alternator
S4/S5/S6
Alternator

Commission
S4/S5/S6 Alternator Alternator Controls and Auxiliaries Windings Bearings

■ Complete machine damage, while alternator is running ■ Insulation resistance of all ■ Temperature sensors while
loose parts and earth bonds ■ Customer connections of windings alternator is running
and safety labels ■ Function of auxiliaries alternator is running
■ Maintenance access ■ Synchronisation while
Test
and outside)
running
Test
Test
alternator is running windings
and safety labels ■ Insulation resistance of Clean
rotor, exciter and PMG ■ Grease exhaust and trap
■ Temperature sensors while (Re-greasable bearings only)
■ Ambient temperature (inside ■ Insulation resistance of Replace
and outside) rotor, exciter and PMG ■ Grease for re-greasable
■ Electrical nominal operating bearings
Test
Clean
■ Air filter
Inspect Test Inspect Test
■ Environmental conditions ■ AVR and PFC settings while ■ Condition of windings ■ Temperature sensors while
and cleanliness alternator is running alternator is running
loose parts, and earth auxiliaries Replace
■ Function of auxiliaries windings ■ Bearing grease
alternator is running rotor, exciter, and PMG Clean
■ Temperature sensors while ■ Grease exhaust and trap
and outside)
Test
Clean
■ Air filter
Inspect Inspect Inspect Test
■ Coupling arrangement ■ Anti condensation heater ■ Condition of windings ■ Temperature sensors while
■ Environmental conditions alternator is running
■ Complete machine damage, ■ AVR and PFC settings while ■ Insulation resistance of all Replace
loose parts, and earth alternator is running windings ■ Bearing grease
bonds
■ Function of auxiliaries ■ Grease exhaust and trap
and outside)
Test
Clean
■ Air filter
S4/S5/S6 Alternator 30,000
Kit Number Contents
Hours/5 Year Service Kits ■ Rectifier Service Kit
A051C225
(HC4/S4 1 Bearing 30,000 Hour Service Kit) ■ NDE Bearing Kit
For the 30,000 hour service interval
we recommend replacing several (HC4/S4 2 Bearing 30,000 Hour Service Kit) ■ DE and NDE Bearing Kit
components in order to optimise the A051C232 ■ Rectifier Service Kit
alternator’s performance. (HC5/ S5/S5D 1 SEALED Bearing 30,000 ■ NDE Bearing Kit
Hour Service Kit)
For the S4/S5/S6 alternator, the A051Z125 ■ Rectifier Service Kit
kits detailed in this table contain (HC5 / S5 1 RE-GREASABLE Bearing ■ Regrease NDE Bearing Kit
30,000 Hour Service Kit ■ Cartridge and Cap
all parts necessary to execute the ■ Rectifier Service Kit
A051C234
maintenance and repairs. (HC5 / S5 2 SEALED Bearing 30,000 Hour ■ Sealed DE and NDE Bearing Kit
Frame Part Description A051Z131 ■ Rectifier Service Kit
(HC5 / S5 2 RE-GREASABLE Bearing ■ Regrease DE and NDE Bearing Kit
Number 30,000 Hour Service Kit) ■ Cartridge and Cap
S4 A053M965 Heater Kit UL 220-260V A051C237 ■ Rectifier Service Kit

(HC6/S6/S6L1D G-H Core 1 SEALED ■ Sealed DE and NDE Bearing Kit
Bearing 30,000 Hour Service Kit) ■ Cartridge and Cap
S4 A053M957 Heater Kit UL 110-125V A051C243 ■ Rectifier Service Kit
(HC6/S6/S6L1D G-H Core 2 SEALED ■ Sealed DE and NDE Bearing Kit
S5/S6 A053N002 Heater Kit UL 220-260V
A059R029 ■ Rectifier Service Kit
(S6L1D C-F Core 2 SEALED Bearing ■ Sealed DE and NDE Bearing Kit
S5/S6 A053M968 Heater Kit UL 110-125V 30,000 Hour Service Kit) ■ Cartridge and Cap
(HC6/S6 1 RE-GREASABLE Bearing 30,000 ■ Regrease NDE Bearing Kit
(HC6/S6 2 RE-GREASABLE Bearing 30,000 ■ Regrease DE and NDE Bearing Kit
■ Coupling arrangement ■ Anti condensation heater ■ Condition of Windings ■ Bearings (sealed &
■ Environmental conditions re-greasable
loose parts, and earth alternator is running windings Test
bonds
■ Customer connections of ■ Temperature sensors while ■ Temperature sensors while
■ Guards, screens, warning auxiliaries alternator is running alternator is running
and safety labels
■ Synchronisation while rotor, exciter and PMG Clean
Test alternator is running ■ Grease exhaust & trap
and outside)
Test
Clean
■ Air filter
P7
Alternator
P7
Alternator

Commission
P7 Alternator Alternator Controls and Auxiliaries Windings Bearings
■ Alternator
Generator rating
Rating ■ Synchronisation
Synchronization Settngs
settings ■ Condition of windings
Windings ■ Condition of bearings
Bearings
P0/P1
■ Bedplate arrangement
Arrangement ■ Customer settings
Settngs for ■ Customer settings
settngs for
for
■ Coupling arrangement
Arrangement Test temperature sensors temperature sensors
Conditions ■ Initial AVR and
& PFC
PFC
setset
upup
and cleanliness
Cleanliness ■ AVR and
&PFCPFCsettngs
settings
while Test Test
■ Complete machine damage, generator
settings while
is running
alternator is ■ Insulation resistance of all ■ Temperature sensors
Sensors while
while
loose parts and earth bonds running connections of
■ Customer windings (P7
(PI test
testfor
forMH/VH)
LV/MV) alternator
generator is running
■ Guards, screens,
Screens, warning
Warning ■ auxiliaries
Customer connections of ■ Temperature
Insulation resistance
sensorsof
while
and safety
Safety labels
Labels ■ auxiliaries
Function of auxiliaries alternator
rotor, exciter
is running
and PMG
■ Maintenance access
Access ■ Synchronization
while ■ Temperature sensors while
■ Synchronisation
while generator is running
■ Ambient Temperature
temperature (inside
(inside Cooling Rectifier Terminal Box
and outside)
■ Electrical nominal
Nominal operating
Operating Inspect Inspect Inspect
Conditions and
Excitations ■ Air flow
Flow(rate
(rateand
anddirection
direction ■ Diodes and varistors ■ All alternator/customer
generator/customer
while alternator
generator is running while alternator
generator is running) ■ connections
connections andand cabling
cabling
■ Vibration while alternator
generator is ■ Condition of fan
is running
running
Test
■ Condition of air
Air filter
filter
Test
Conditions ■ AVR and
&PFC PFC
settings
settings
while
while ■ Condition of windings
Windings ■ Temperature
Condition of bearings
Sensors while
P0/P1
and cleanliness
Cleanliness generator is running
alternator generator is running
Test
loose parts, and
& earth
earth
bonds ■ Synchronization
Synchronisation while ■ Temperature sensors while
■ Insulation resistance of all
■ bonds
Guards, Screens, Warning generator is running
alternator windings (P7
(PI test
testfor
forMH/VH)
LV/MV)
■ and
Guards,
Safety
screens,
Labelswarning
Test ■ Temperature sensors while (Re-greasable bearings only)
Test
■ Ambient Temperature (inside generator is running
alternator
■ and
Ambient
outside)
temperature (inside Replace
and outside)
■ Electrical Nominal Operating ■ Grease for re-greasable
■ Conditions
Electrical nominal
and Excitations
operating bearings
while generator
is running
while alternator
■ Vibration is running
while generator Cooling Rectifier Terminal Box
■ is
Vibration
runningwhile alternator is
generator/customer
Test
Air filter
filter
Clean
■ Air filter
Commission
Inspect Inspect
Test Inspect Inspect
■ Generator
Environmental
Rating
conditions ■ Synchronization Settngs
AVR and PFC settings while ■ Condition of windings
Windings ■ Condition of bearings
Bearings
P0/P1
■ and cleanliness
Bedplate Arrangement alternator is running ■ Customer Settngs for ■ Customer settngs for
Testtemperature sensors
■ Complete
■ machine damage,
Coupling Arrangement ■ Customer connections of
Test Testtemperature sensors
loose parts, and earth auxiliaries ■ Temperature sensors while
■ bonds
Environmental Conditions ■ Initial AVR & PFC set up ■ Insulation resistance of all alternator is running
and Cleanliness ■ Function of auxiliaries Testwindings (P7 test for LV/MV) Test
■ Guards, screens, warning ■ AVR &PFC settngs while
■ and
Complete ■ Synchronisation while
generator is running Clean
safetymachine
labels damage, alternator is running
■ Insulation resistance of all ■ Temperature Sensors while
loose parts and earth bonds ■ Customer connections of windings
rotor, exciter,
(PI test
andfor
PMGMH/VH) generator
■ Grease is running
exhaust and trap
■ Guards, Screens, Warning auxiliaries ■ Insulation
Temperatureresistance
sensorsofwhile (Re-greasable bearings only)
Testand Safety Labels rotor, exciter
and PMG
■ Ambient
■ temperature
Maintenance Access (inside ■ Temperature sensors while Replace
and outside) ■ Synchronization while
generator is running generator is running ■ Grease for re-greasable
Testconditions and excitations
■ while alternator
Ambient is running
Temperature (inside Cooling Rectifier Terminal Box
and outside)
■ running
Electrical Nominal Operating Inspect Inspect Inspect
Conditions and Excitations ■ Air
Condition
Flow (rate
of fan
and direction ■ Diodes and varistors ■ All alternator/customer
generator/customer
while generator is running while generator is running) ■ connections
connections andand cabling
cabling
■ Vibration while generator ■ Condition of fan
is running Test
Test
Clean
■ Air filter
Post Commission
10,000 Hours/2 Year
250Service
Hours/6 Months
Inspect Test
Inspect Inspect Inspect
Test
■ Environmental Conditions
Coupling arrangement ■ AVR
Anti condensation
&PFC settingsheater
Condition of bearings
Sensors while
P0/P1
■ and Cleanlinessconditions
Environmental generator is running generator is running
■ Complete machine damage,
and cleanliness ■ Function of auxiliaries Test
Test Test
■ loose parts,
Complete & earthdamage,
machine bonds
■ Synchronization
■ while while
AVR and PFC settings ■ Insulation resistance of all
■ Guards, Screens,
loose parts, Warning
and earth generator is
is running
running alternator is running
alternator windings (P7
(PI test
testfor
forMH/VH)
LV/MV)
and Safety Labels
bonds
■ Customer connections of ■ Insulation
sensorsofwhile Clean
■ Guards, screens, warning auxiliaries rotor, exciter
and PMG ■ Grease exhaust and trap
Testand safety labels ■ Function of auxiliaries ■ Temperature sensors while (Re-greasable bearings only)
■ Ambient Temperature (inside ■ Synchronisation while generator is running
Testand outside) alternator is running Replace
■ Electrical Nominal Operating
Ambient temperature (inside ■ Grease for re-greasable
Conditions
and outside)and Excitations bearings
■ while generator
Electrical is operating
nominal running
■ Vibration
conditionswhile
and generator
excitations Cooling Rectifier Terminal Box
is running
generator/customer
Test
Air filter
filter
Clean
■ Air filter
P7 Alternator 30,000 Hours/5 Year Service Kits
(P7/S7 LV & S7 HV 1 RE-GREASABLE Bearing ■ NDE Bearing Kit
alternator’s performance. 30,000 Hour Service Kit) ■ Cartridge and Cap
For the P7 alternator, the kits detailed
in this table contain all parts necessary
(P7/S7 LV & S7 HV 1 SEALED Bearing 30,000 ■ NDE Bearing Kit
to execute the maintenance and
HourService Kit) ■ Cartridge and Cap
repairs.
(P7 A-E core/S7 LV C-F core 2 RE-GREASABLE ■ DE Bearing Kit

(P7 F-G core/S7 LV G-J core & S7 HV G-J ■ DE Bearing Kit
core 2 RE-GREASABLE Bearing 30,000 Hour
P7 A-F A053N003 Heater Kit UL 220-260V
P7 A-F A053M969 Heater Kit UL 110-125V
P7 G-H A053N109 Heater Kit UL 220-260V
P7 G-H A053M999 Heater Kit UL 110-125V

Post Commission
30,000 Hours/5 Year
250Service
Hours/6 Months
Inspect Replace
Test Inspect Replace
Test
■ Environmental
Coupling arrangement
Conditions ■ AVR
Anti &PFC
condensation
settings heater
Bearings (Sealed & while
Sensors
P0/P1
■ and Cleanlinessconditions
Environmental generator is running re-greasable)
■ Complete
and cleanliness
machine damage, ■ Function of auxiliaries
Test Test ■ Bearing grease
■ loose parts,
Complete & earthdamage,
machine bonds
■ Synchronization
■ while while
AVR and PFC settings ■ Insulation resistance of all
■ Guards,
loose parts,
Screens,
and earth
Warning generator is
running windings (P7
(PI test
testfor
forMH/VH)
LV/MV) Test
and Safety Labels
bonds
■ Customer connections of ■ Insulation
sensorsofwhile ■ Temperature sensors while
■ Guards, screens, warning auxiliaries rotor, exciter
and PMG alternator is running
Testand safety labels ■ Function of auxiliaries ■ Temperature
Insulation resistance
sensorsofwhile
■ Ambient Temperature (inside ■ Synchronisation while generator
rotor, exciter
is running
and PMG Clean
Testand outside) alternator is running ■ Grease exhaust & trap
■ Electrical
Ambient temperature
Nominal Operating
(inside (re-greasable bearings only)
Conditions
and outside)and Excitations
■ while generator
Electrical is operating
nominal running
■ Vibration
conditionswhile
and generator
excitations Cooling Rectifier Terminal Box
is running
■ Vibration while alternator is Inspect Inspect
Replace Inspect
generator/customer
Test
Air filter
filter
Clean
■ Air filter
S7
Alternator
S7
Alternator

Commission
S7 Alternator Alternator Controls and Auxiliaries Windings Bearings

■ Complete machine damage, settings while alternator is ■ Insulation resistance of all ■ Temperature sensors while
loose parts and earth bonds running windings (P7 test for LV/MV) alternator is running
■ Guards, screens, warning ■ Customer connections of ■ Temperature sensors while
and safety labels auxiliaries alternator is running
■ Maintenance access ■ Function of auxiliaries

and outside)
running
Test
Test
alternator is running windings (P7 test for LV/MV)
■ Ambient temperature (inside Replace
and outside) ■ Grease for re-greasable
Test
Clean
■ Air filter
Test
■ Function of auxiliaries windings (P7 test for LV/MV)
alternator is running rotor, exciter, and PMG ■ Grease exhaust and trap
■ Ambient temperature (inside Replace
Test
Clean
■ Air filter
and cleanliness Test
Test Test
■ Complete machine damage, ■ Temperature sensors while
■ AVR and PFC settings while ■ Insulation resistance of all alternator is running
loose parts, and earth alternator is running windings (P7 test for LV/MV)
bonds
■ Customer connections of ■ Temperature sensors while Clean
and safety labels ■ Grease exhaust and trap
■ Function of auxiliaries (Re-greasable bearings only)
Test alternator is running Replace
■ Ambient temperature (inside ■ Grease for re-greasable
and outside) bearings
Test
Clean
■ Air filter
S7 Alternator 30,000 Hours/5 Year Service Kits
(P7/S7 LV & S7 HV 1 RE-GREASABLE Bearing ■ NDE Bearing Kit
alternator’s performance. 30,000 Hour Service Kit) ■ Cartridge and Cap
For the S7 alternator, the kits detailed
in this table contain all parts necessary
(P7/S7 LV & S7 HV 1 SEALED Bearing 30,000 ■ NDE Bearing Kit
to execute the maintenance and
HourService Kit) ■ Cartridge and Cap
repairs.
(P7 A-E core/S7 LV C-F core 2 RE-GREASABLE ■ DE Bearing Kit

(P7 F-G core/S7 LV G-J core & S7 HV G-J ■ DE Bearing Kit
core 2 RE-GREASABLE Bearing 30,000 Hour
S7 C-G A053N003 Heater Kit UL 220-260V
S7 C-G A053M969 Heater Kit UL 110-125V
S7 H-J A053N109 Heater Kit UL 220-260V
S7 H-J A053M999 Heater Kit UL 110-125V
A053M999 Heater Kit UL 110V

S7 HV
A064T028 Heater Kit UL 240V
■ Coupling arrangement ■ Anti condensation heater ■ Condition of windings ■ Bearings (Sealed &
■ Environmental conditions re-greasable)
loose parts, and earth alternator is running windings (S7 test for LV) Test
bonds
■ Customer connections of ■ Temperature sensors while ■ Temperature sensors while
■ Guards, screens, warning auxiliaries alternator is running alternator is running
and safety labels
■ Synchronisation while rotor, exciter and PMG Clean
Test alternator is running ■ Grease exhaust & trap
and outside)
Test
Clean
■ Air filter
P80
Alternator
P80
Alternator

Commission

■ Complete machine damage, settings while alternator is ■ Insulation resistance of ■ Temperature sensors while
loose parts and earth bonds running all windings (P80 test for alternator is running
■ Guards, screens, warning ■ Customer connections of MV/HV)
and safety labels auxiliaries ■ Temperature sensors while
■ Maintenance access ■ Function of auxiliaries alternator is running

and outside)
conditions and excitations ■ Air flow (rate and direction ■ Diodes and surge ■ All alternator/customer
while alternator is running while alternator is running) suppressors connections and cabling
running
Test
Test
bonds ■ Insulation resistance of alternator is running
alternator is running all windings (P80 test for
■ Guards, screens, warning MV/HV)
■ Condition of fan ■ Diodes and surge ■ All alternator/customer
suppressors connections and cabling
Test
Clean
■ Air filter
Test
■ Function of auxiliaries all windings (P80 test for
■ Guards, screens, warning ■ Synchronisation while MV/HV)
alternator is running ■ Insulation resistance of ■ Grease exhaust and trap
rotor, exciter, and PMG (Re-greasable bearings only)
Test
Clean
■ Air filter
Test Test
■ AVR and PFC settings while ■ Insulation resistance of alternator is running
loose parts, and earth alternator is running all windings (P80 test for
bonds MV/HV)
■ Customer connections of Clean
■ Function of auxiliaries alternator is running (Re-greasable bearings only)
running ■ Condition of fan ■ Diodes and surge ■ All alternator/customer
Test
Clean
■ Air filter
P80 Alternator 30,000 Hours/5 Year Service Kits
(P80 1 Bearing 30,000 Hour Service Kit) ■ NDE Bearing Kit
For the P80 alternator, the kits detailed

in this table contain all parts necessary A051C285 ■ Rectifier Service Kit
to execute the maintenance and (P80 2 Bearing 30,000 Hour Service Kit) ■ Bearing Kit Frame R, S, & T
repairs.

(P80 2 Bearing 30,000 Hour Service Kit) ■ Bearing Kit Frame X, Y, & Z
P80 45-1029 Heater Kit UL

■ Coupling arrangement ■ Anti condensation heater ■ Condition of windings ■ Bearings (sealed &
■ Complete machine damage, ■ AVR and PFC settings while ■ Insulation resistance of
loose parts, and earth alternator is running all windings (P80 test for Test
bonds MV/HV)
and outside)
Test
S9
Alternator
S9
Alternator

Commission

■ Complete machine damage, settings while alternator is ■ Insulation resistance of ■ Temperature sensors while
loose parts and earth bonds running all windings (P80 test for alternator is running
■ Guards, screens, warning ■ Customer connections of MV/HV)
and safety labels auxiliaries ■ Temperature sensors while
■ Maintenance access ■ Function of auxiliaries alternator is running

and outside)
conditions and excitations ■ Air flow (rate and direction ■ Diodes and surge ■ All alternator/customer
while alternator is running while alternator is running) suppressors connections and cabling
running
Test
Test
alternator is running all windings (P80 test for
■ Guards, screens, warning MV/HV)
Test
Clean
■ Air filter
Test
■ Function of auxiliaries all windings (P80 test for
■ Guards, screens, warning ■ Synchronisation while MV/HV)
alternator is running ■ Insulation resistance of ■ Grease exhaust and trap
rotor, exciter, and PMG (Re-greasable bearings only)
Test
Clean
■ Air filter
Test Test
■ AVR and PFC settings while ■ Insulation resistance of alternator is running
loose parts, and earth alternator is running all windings (P80 test for
bonds MV/HV)
■ Customer connections of Clean
■ Function of auxiliaries alternator is running (Re-greasable bearings only)
Test
Clean
■ Air filter
S9 Alternator 30,000 Hours/5 Year Service Kits
A065P433 ■ Rectifier Service Kit
(S9 1 Bearing 30,000 Hour Service Kit) ■ NDE Bearing Kit
For the S9 alternator, the kits detailed

in this table contain all parts necessary A065P434 ■ Rectifier Service Kit
to execute the maintenance and (S9 2 Bearing 30,000 Hour Service Kit) ■ Bearing Kit Frame A - D
repairs.

(S9 2 Bearing 30,000 Hour Service Kit) ■ Bearing Kit Frame E - F

(S9 2 Bearing 30,000 Hour Service Kit) ■ Bearing Kit Frame G - H
S9 A059S757 F9 Heater Kit

■ Coupling arrangement ■ Anti condensation heater ■ Condition of windings ■ Bearings (sealed &
■ Complete machine damage, ■ AVR and PFC settings while ■ Insulation resistance of
loose parts, and earth alternator is running all windings (P80 test for Test
bonds MV/HV)
and outside)
Test
Guaranteed
We guarantee that every product we produce
matches the quality, robustness, and proven
performance you expect from the STAMFORD range.
Built to our quality assured standards, STAMFORD
products benefit from a global support network,
extensive research and development, and world-
leading expertise.
Where people need power, businesses rely on
genuine STAMFORD alternators. Proven expertise
in design, development, manufacturing, customer
support and servicing, ensures quality in every aspect
of our business.
Visit stamford-avk.com/verify to find out how we
are protecting our customers and their businesses
against the dangers of illegal, counterfeit and
imitation products and taking action.
The Power of More™
Selecting the right alternator for the right What this means to you:
application in today’s complex world is ■ 24 hour response to service emergencies,
our goal - making your life simpler. We 7 days a week
understand the performance requirements
■ Trained engineers available locally,
that each application and operating
speaking the local language
environment demands. Our knowledgeable
and experienced Customer Engineers align ■ Commissioning of alternators onsite
individual customers’ power needs with the ■ Onsite bearing maintenance and bearing
most suitable alternator specification. condition monitoring
We take pride in our global reputation for ■ Onsite insulation integrity checks
Technical Support and After Sales Service, ■ AVR and accessories set up onsite
continually adding new, trained engineers in ■ Extensive aftermarket distribution for
locations near to our customers, worldwide. genuine STAMFORD parts
Our engineers are experienced professionals
trained in electrical, electronic and
mechanical engineering and are ready to help
at any point in the STAMFORD alternator
lifecycle, minimising risk of unexpected
downtime.
For Customer Service:
Americas: Powering the world with confidence since 1904
cgta.service@cummins.com
Phone: +1-800-367-2764
EMEA:
emea.service@cummins.com
Phone: +441780484732
APAC:
apac.service@cummins.com
Phone: +8651081103212
China:
cgt.china.service@cummins.com
Phone: +86 400 88 12390
India:
CGtil.csnotify@cummins.com
Phone: +91 (0) 20 67067639 There for you ™
For general enquires:
newagestamfordavk@cummins.com
Copyright 2020, Cummins Generator Technologies Ltd. All rights reserved.
www.stamford-avk.com Cummins and the Cummins logo are registered trade marks of Cummins Inc.
NEWAGE®, STAMFORD® and AvK® are registered trade marks of Cummins
Generator Technologies Ltd.
Part No. PG_SSG_P_EN_AF Rev.06.1

Service-Guide STAMFORD S1-S0-UC22-UC27-HC4-HC5-HC6-S4-S5-S6-P7-S7-P80-S9

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Service-Guide STAMFORD S1-S0-UC22-UC27-HC4-HC5-HC6-S4-S5-S6-P7-S7-P80-S9

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Alternator Service Guide

Skill Requirements of Personnel

Lock Out/Tag Out

Always wear suitable PPE when working in the hatched areas

Commission Post Commission 1,000 Hour 10,000 Hours 30,000 Hours

■ Environmental conditions ■ Initial AVR set up

For the P0/P1 alternator, the kits

Frame Part Number Description

P0/P1 45-1161 Heater Kit UL 230V

P0/P1 45-1162 Heater Kit UL 115V

P0/P1 45-1163 Heater Kit UL 24V

P0/P1 45-1164 Heater Kit UL 12V

Commission Post Commission 1,000 Hour 10,000 Hours 30,000 Hours

For the S0/S1 alternator, the kits

Frame Part Number Description

S0/S1 A054K278 Heater Kit UL 12V

S0/S1 A054K280 Heater Kit UL 24V

S0/S1 A054K282 Heater Kit UL 115V

S0/S1 A054K284 Heater Kit UL 230V

Commission Post Commission 1,000 Hour 10,000 Hours 30,000 Hours

■ Environmental conditions ■ Initial AVR set up

Test (if fitted)

■ Condition of air filter

Test (if fitted)

■ Condition of air filter

Test (if fitted)

■ Condition of air filter

A051C222 ■ Rectifier Service Kit

Frame Part Number Description

UC22/UC27 A053N107 Heater Kit UL 110-125V

UC22/UC27 A053N108 Heater Kit UL 220-260V

Commission Post Commission 1,000 Hour 10,000 Hours 30,000 Hours

■ Environmental conditions ■ Initial AVR and PFC set up

Commission Post Commission 1,000 Hour 10,000 Hours 30,000 Hours

■ Environmental conditions ■ Initial AVR and PFC set up

S4 A053M965 Heater Kit UL 220-260V A051C237 ■ Rectifier Service Kit

Commission Post Commission 1,000 Hour 10,000 Hours 30,000 Hours

Test alternator is running

A051C257 ■ Rectifier Service Kit

Frame Part Number Description

P7 A-F A053N003 Heater Kit UL 220-260V

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

P7 G-H A053N109 Heater Kit UL 220-260V

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

Commission Post Commission 1,000 Hour 10,000 Hours 30,000 Hours

■ Environmental conditions ■ Initial AVR and PFC set up

■ Ambient temperature (inside Cooling Rectifier Terminal Box

A051C257 ■ Rectifier Service Kit

Frame Part Number Description

S7 C-G A053N003 Heater Kit UL 220-260V

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

S7 H-J A053N109 Heater Kit UL 220-260V

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

A053M999 Heater Kit UL 110V

Commission Post Commission 1,000 Hour 10,000 Hours 30,000 Hours

■ Environmental conditions ■ Initial AVR and PFC set up

■ Ambient temperature (inside Cooling Rectifier Terminal Box

For the P80 alternator, the kits detailed

A051C291 ■ Rectifier Service Kit

Frame Part Number Description

P80 45-1029 Heater Kit UL

Commission Post Commission 1,000 Hour 10,000 Hours 30,000 Hours

■ Environmental conditions ■ Initial AVR and PFC set up

■ Ambient temperature (inside Cooling Rectifier Terminal Box