C7.1 Marine Engine Caterpillar

Removal Procedure

Start By:

1. Remove the control system.

2. Remove the air cleaner housing.

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When servicing or repairing electric power generation equipment: Make sure the unit is off-line (disconnected from utility and/or other generators power service), and either locked out or tagged DO NOT OPERATE. Remove all fuses.

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Disconnect batteries before performance of any service work.

1. The engine can start automatically. Ensure that the power supply is isolated before any service or repairs is performed.

2. Turn the battery disconnect switch to the OFF position.

3. Turn the air supply at the air reservoir to the OFF position. Ensure that the air pressure is drained from the starting air system.
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   Illustration 1	g06114918

4. Disconnect the customer connection from the generator. Temporarily install cover (1) to terminal box (2).

   Note: Mark the position of all straps, cable assemblies, and harness assemblies for assembly purposes.

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   Illustration 2	g06114919

5. Disconnect cable assembly (3) from generator (4).
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   Illustration 3	g06114921

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   Illustration 4	g06114923
   (C) Dimension 40.0 mm (1.58 inch).

6. Remove blanking device (5) and (6) from the lifting eyes on generator (4).

7. Attach Tooling (B) onto Tooling (A) and attach Tooling (A) to a suitable lifting device.

8. Attach Tooling (A) onto generator (4). The weight of generator (4) is approximately 625 kg (1378 lb).

   Note: Ensure the correct center of gravity of the generator.

9. Remove bolts (8) from generator mountings (7). On radiator cooled engines, sufficiently loosen the engine front mounting bolts to allow generator (4) raised to dimension (C).

10. Raise the generator dimension (C) and support the weight of the engine with suitable cribbing under flywheel housing (9). Refer to Illustration 4 for dimension (C).
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    Illustration 5	g06114926

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    Illustration 6	g06114929

11. Remove bolts (11). Remove screen (10).

12. Remove locking nuts (13) and the washers from generator (4) to the fly wheel housing. Remove bolts (12) and the washers from generator (4) to the flywheel housing. Discard the locking nuts.

13. Remove locking nuts (14) and the washers from generator drive plate (15) to fly wheel (16). Discard locking nuts.

14. Slide generator (4) away from the engine flywheel housing and remove generator (4).

Installation Procedure

1. Install generator (4) in the reverse order of removal.

2. Install washers to the studs and loosely install new locking nuts (13) to the flywheel housing of generator (4). Loosely install bolts (12) and the washers to the flywheel housing of generator (4). Ensure generator (4) is mounted correctly onto the flywheel housing. Tighten bolts (12) to a torque of 44 N·m (33 lb ft). Tighten locking nuts (13) to a torque of 44 N·m (33 lb ft).

3. Install locking nuts (14). Tighten locking nuts (14) to a torque of 44 N·m (33 lb ft).

   Note: Do not rotate the generator drive plate to align the generator drive plate with the flywheel.

4. Align generator mountings (7) with mounting pads. Install bolts (8) and tighten to a torque of 190 N·m (140 lb ft). Tighten the engine front mounting hardware to a torque of 190 N·m (140 lb ft).