3000 Frame SR5 Electric Power Generation Caterpillar

Removal Procedure

Start By:

1. Remove the end bracket. Refer to Disassembly and Assembly, "End Bracket (Opposite Drive End) - Remove and Install".

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Illustration 1	g01651282
(A) 329-1968 Adapter

Note: All of the cable assemblies should be fed through the center of the adapter.

1. Install Tooling (A) onto the opposite drive end of the rotor. Install the retaining bolts and washers in order to secure Tooling (A).
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   Illustration 2	g01651284
   (A) 329-1968 Adapter (B) 328-1720 Tube As

2. Install a suitable lifting device onto Tooling (B). The weight of Tooling (B) and the main rotor assembly is approximately 2858 kg (6300 lb).

3. Position Tooling (B) onto Tooling (A), as shown.

4. Install the retaining bolts in order to secure Tooling (B).
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   Illustration 3	g01651275
   (B) 328-1720 Tube As (C) 8S-7640 Stand, 8S-7611 Tube, 8S-8048 Saddle (D) Polyethylene strips Thickness of 5 mm (0.200 inch)

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   Illustration 4	g01651281
   (1) Main Rotor (2) Main Stator (D) Polyethylene strips Thickness of 5 mm (0.200 inch)

   Note: The Polyethylene strips must remain between the rotor poles and the stator during the rotor removal process.

   Note: The main rotor (1) and the main stator (2) should not contact each other.

5. Use the suitable lifting device in order to lift Tooling (B) until the main rotor assembly is centered within the main stator. Verify that the main rotor is centered within the main stator by checking the air gap between the main rotor and the main stator. The air gap can be verified by installing Tooling (D) between the main rotor and the main stator at four points around the main rotor.

6. Position Tooling (C). Lower Tooling (B) and the main rotor onto Tooling (C). Verify that the main rotor is centered within the main stator by checking the air gap between the main rotor and the main stator. The air gap can be verified by installing Tooling (D) between the main rotor and the main stator at four points around the main rotor.

7. Position suitable blocking between Tooling (C) and the generator housing.
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   Illustration 5	g01651280
   (3) Harness Assembly (4) Mounting Bolts for the Adapter (5) Adapter

   Note: Put identification marks on adapter (5) in order to aid in the installation process.

8. Attach a suitable lifting device to adapter (5). The weight of adapter (5) is approximately 117 kg (258 lb).

9. Disconnect harness assembly (3) (not shown).

10. Remove bolts (4) and remove adapter (5).
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    Illustration 6	g01651287
    (6) Mounting Bolts for the End Bracket (7) End Bracket (E) 128-5049 Guide Studs (F) 3E-3881 Eyebolt (G) 1U-9200 Lever Puller Hoist (H) (Not Shown) 154-6184 Forcing Bolt

11. Attach a suitable lifting device to end bracket (7). The combined weight of end bracket (7) and the main rotor is approximately 2994 kg (6600 lb).

12. Install Tooling (E) and Tooling (H) (not shown).

13. Apply lifting pressure to the suitable lifting device and remove bolts (6) that secure end bracket (7). Tighten Tooling (H) (not shown) on both sides equally until the pilot shoulder on end bracket (7) is no longer contacting the generator housing.

14. Apply lifting pressure on the suitable lifting device until the weight is off of Tooling (E). Remove Tooling (E) by hand and remove Tooling (H) (not shown).

15. Install Tooling (F) and Tooling (G) to the end of the main rotor. The other end of Tooling (G) must be attached to a suitable anchor.
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    Illustration 7	g01651279

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    Illustration 8	g01651273

16. Use Tooling (G) and the suitable lifting device in order to remove end bracket (7) and the main rotor out of the generator housing.

17. Position end bracket (7) and main rotor (1) onto Tooling (C). Position Tooling (C) on the other side of main rotor (1).

Installation Procedure

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Illustration 9	g01651276

1. Position Tooling (D) onto main stator (2).
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   Illustration 10	g01651285

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   Illustration 11	g01651277

2. Attach a suitable lifting device to both the main rotor (1) and end bracket (7). The weight of main rotor (1) is approximately 2994 kg (6600 lb).
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   Illustration 12	g01651286

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   Illustration 13	g01651274

3. Position the main rotor partially into the generator, as shown. Position Tooling (C) on both sides of the generator. Center the main rotor in relation to the main stator and support both ends of the main rotor with Tooling (C).
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   Illustration 14	g01651278

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   Illustration 15	g01651281

   Note: The main rotor (1) and the main stator (2) should not contact each other.

4. Reposition the suitable lifting device on Tooling (B).

5. By using a suitable lifting device, insert the main stator (1) into position on the generator. Center the main rotor within the main stator during this process. Constantly check the air gap between the main rotor (1) and the main stator (2) during this process. The air gap can be verified by installing Tooling (D) between the main rotor and the main stator at four points around the main rotor.
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   Illustration 16	g01651283

6. Install Tooling (E) into the generator housing.

7. Position the main rotor and end bracket (7) onto Tooling (E).

8. Install bolts (6).

9. Remove the suitable lifting device from end bracket (7).
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   Illustration 17	g01651284

10. Install a suitable lifting device onto Tooling (B). The weight of Tooling (B) and the main rotor assembly is approximately 136 kg (300 lb).

11. Remove Tooling (B) and remove Tooling (A).

End By:

1. Install the end bracket. Refer to Disassembly and Assembly, "End Bracket (Opposite Drive End) - Remove and Install".