C18 Generator Set Caterpillar

Removal Procedure

Illustration 1	g00619076
(1) Stationary pilot exciter armature (2) Rotating pilot exciter field

Note: This procedure describes removing the generator terminal box from the generator. Some service operations do not require the removal of the generator terminal box. The removal of the generator terminal box may not be necessary.

Illustration 2	g02174575

1. Remove the side and rear panels of the generator terminal box in order to access the wiring.

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Illustration 3	g00619117
Terminal Strips (DIN)

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Illustration 4	g00619124
Terminal Strips

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Illustration 5	g00619154
Terminal Strips (Control Panel interior)

2. To remove the generator terminal box, disconnect all the wiring that extends from the generator terminal box to the generator or to the engine. Disconnect the following wires:
   • engine harness wires

   • generator leads

   • current transformer wires

   • temperature sensing wires

   • space heater wires

   • ground wires

   Remove the engine harness from the generator terminal box.

   Most of the wiring can be disconnected at the terminal strips. The exact location of the terminal strips and the type of terminal strips varies with the different generator set packages. The preceding illustrations show some of the various terminal strips.

3. To remove the generator terminal box, remove the lower rear panel and the screen beneath the rear of the generator.

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Illustration 6	g00619180
Generator Terminal Box (Typical 600 Frame)

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Illustration 7	g00619185
Generator Terminal Box (Typical 400 Frame)

4. Attach a hoist to the four corners of the generator terminal box.

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Illustration 8	g00619192
Top View (3) Bolt

5. Remove bolts (3) which fasten the generator terminal box to the mounting brackets. Use the hoist to lift the generator terminal box and remove the generator terminal box.

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Illustration 9	g00619203
Generator support (4) Support Beam

6. If there are no supports between the base of the generator set and the flywheel end of the engine, perform this Step. For supporting the engine during removal of the generator, use one of the following devices:
   • hoist

   • jack

   • support beam (4)

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Illustration 10	g00621148
Generator ground strap (5) Ground strap (6) Bolt

7. Remove bolt (6) that attaches ground strap (5) to the generator.

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Illustration 11	g00619206
(7) Screen (8) Shield (9) Bolts

8. Attach a hoist to the generator. The point of attachment varies with the size of the generator. A strap must be used on smaller generators when no shackle is provided.

9. Remove bolts (9) which fasten the generator to the base.

10. Remove shield (8) and screen (7) .

11. Remove bolts (11) which fasten the fan and the coupling plate to the engine flywheel.

12. Remove bolts (10) which fasten the generator housing to the flywheel housing.

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Illustration 12	g00619267
(12) Bolts (13) Coupling Plate

13. Separate the generator from the engine. Remove the generator. Place the generator on solid blocking material which will not allow the generator to roll.

14. Remove bolts (12) which fasten coupling plate (13) to the rotor. Remove coupling plate (13) .

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Illustration 13	g00619275
(14) Shims (15) Fan

15. Remove shims (14) from the rotor shaft. If the fan (15) is not attached to the rotor, remove the fan from the generator housing.