- Place the trailer package on stable, level ground. Secure the trailer package by chocking the wheels and setting the parking brake.
- Disconnect the trailer clearance lights. The connection for the trailer clearance lights is located in the battery compartment.
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Illustration 1 g00793661 Bolt that attaches the frame to the running gear - Remove eight bolts from the frame. There are four bolts on each side of the trailer frame and four bolts on the crossmember at the front of the trailer.
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Do not approach the package while the package is being lifted. The package is extremely heavy. If the package is dropped or collided with, serious injury or death may occur.
- Remove the generator enclosure assembly from the trailer. Use the lifting eye to lift the package.
Transportation of the Enclosure Assembly
- Keep all non-essential personnel clear of the area.
- Load the package and unload the package on a level surface.
- Block the transport vehicle so the vehicle cannot move.
- Keep both the trailer bed and the trailer ramps clean. Remove any clay, oil or other slippery materials.
- If ramps are used, ensure that the ramps are of adequate size and strength. The ramps should be installed at the proper height and the angle of the ramps should be low.
- Use the lifting eye of the enclosure. Ensure that all lifting devices have adequate capacity.
- Chain the package or block the package securely before you transport the package.
- Check the height and width of the package for travel clearances. Check the weight of the package for load limitations.
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| Illustration 2 | g00103219 |
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Never bend the eyebolts and the brackets. Only load the eyebolts and the brackets under tension. Remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes less than 90 degrees. When it is necessary to remove a component at an angle, only use a link bracket that is properly rated for the weight. |
Use a hoist to remove heavy components. Use an adjustable lifting beam to lift the engine. All supporting members (chains and cables) should be parallel to each other. The chains and cables should be perpendicular to the top of the object that is being lifted.
Some removals require lifting fixtures in order to obtain proper balance. Lifting fixtures also help to provide safety.
To remove the engine ONLY, use the lifting eyes that are on the engine.
Lifting eyes are designed and installed for the specific engine arrangement. Alterations to the lifting eyes and/or the engine make the lifting eyes and the lifting fixtures obsolete. If alterations are made, ensure that proper lifting devices are provided. Consult your Caterpillar dealer for information regarding fixtures for proper engine lifting.
Engine Lifting with a Generator
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Do not use the engine lifting eyes to remove the engine and generator together. |
Place the unit on stable, level ground. Chock the wheels.
Remove the enclosure assembly from the trailer. Refer to Operation and Maintenance Manual, "Enclosure Lifting" for further information.
Remove the cover from the front battery compartment. Disconnect the enclosure lighting wiring harness from the trailer frame wiring harness.
Disconnect the battery cables. Be sure to pull the cables out of the battery compartment through the electrical cable bushing and through the wall. This will avoid damage to the wall of the enclosure and damage to the cables.
Remove the mounting nuts around the edge of the enclosure. Lift the foam liner as required in order to gain access to the mounting nuts. Be careful not to damage the bottom seal of the enclosure during removal.
Remove the mounting bolts from the exhaust elbow of the turbocharger. The flexible exhaust piping and the exhaust silencer remain with the enclosure.
Remove the rear bulkhead.
Disconnect the generator leads.
Disconnect the voltage regulator.
Disconnect the battery charger DC wiring.
Disconnect the jacket water heater, the battery charger, and the generator heater from the receptacles.
Disconnect the engine wiring harness from the control panel.
Disconnect the oil drain line and water drain line after the ball valve which attaches to the enclosure inside the discharge air plenum.
Remove the fumes disposal tube which is routed to the discharge air plenum.
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Be sure that the enclosure is completely disconnected and ready to remove from the base before loosening the lifting arch attachment bolts. |
Loosen, but do not remove the bolts for the lifting arch attachment. The lifting arch should remain loosely attached to the base assembly during the removal of the enclosure. The lifting arch should have some play so that the enclosure does not bind on the lifting eye during the removal of the enclosure.
When you remove the enclosure, be careful not to catch the enclosure on miscellaneous engine components.
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Doors should be secured prior to lifting process. |
Use the door openings as lifting points. Place nylon straps through the door openings and then lift the enclosure. Spread the straps to each end of the door openings in order to distribute the weight and avoid damaging the enclosure.
Place the enclosure aside for a later reinstallation. Remove the lifting arch attachment bolts. Place the lifting arch aside for a later reinstallation.
Remove the following items:
- engine mounting bolts
- generator mounting bolts
- fan guard
- upper radiator supports
Disconnect the ground strap for the generator.
Disconnect the fuel lines.
Drain the radiator. Remove the upper water line and the lower water line for the radiator.
Remove the engine and the generator. Lifting the engine and the generator together requires special equipment and procedures. Consult your Caterpillar dealer for information regarding fixtures for proper lifting of your complete package.
Lifting package generator sets will not be level if you lift the unit with a single point lift. A counterweight can be added between the package frame rails whenever the application requires frequent relocation of the unit. For complete information about adding the counterweight, consult your Caterpillar dealer.
The single point lifting eye is secured from the factory before the enclosure is shipped. The correct orientation of the single point lifting eye will allow you to look through the eye when you stand at the end of the enclosure. The lifting eye may stretch when the package is lifted. This may cause the locking nuts to loosen. This could cause the lifting eye to swivel. Ensure that the lifting eye is correctly oriented on the package generator set. Ensure that the lifting eye is tightened to the correct torque before you lift the package generator set.
Reverse the process in order to install the engine, the generator and the enclosure assembly.
Tighten all fasteners to specifications.
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Engine mounting bolts for resilient mounts must be torqued to |
Engine Lifting with a Fuel Tank
Lifting the engine with a fuel tank that is mounted to the engine requires special equipment and procedures. Do not lift the unit with fuel in the fuel tank. Consult your Caterpillar dealer for information regarding fixtures for proper lifting of your complete package.
Installing the Generator Enclosure Assembly onto the Trailer
When you install the generator enclosure assembly on the trailer, reverse the removal procedure.
Reconnect the trailer clearance lights. Inspect the lights and brakes before towing.