LC5000, LC6100, and LC7000 Electric Power Generation Caterpillar

Installation Procedure

Start By:

1. Remove optional permanent magnet pilot exciter (PMG) attachment if equipped.

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Personal injury or death can result from high voltage. When power generation equipment must be in operation to make tests and/or adjustments, high voltage and current are present. Improper test equipment can fail and present a high voltage shock hazard to its user. Make sure the testing equipment is designed for and correctly operated for high voltage and current tests being made. When servicing or repairing electric power generation equipment: Make sure the unit is off-line (disconnected from any utility and/or other generators that can provide power service), and either lock out or tag as "DO NOT OPERATE". Remove all fuses. Make sure the generator engine is stopped. Make sure all batteries are disconnected. Make sure all capacitors are discharged. Failure to do so could result in personal injury or death. Make sure residual voltage in the rotor, stator and the generator is discharged.

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High voltage may be present. The power source must be disconnected before working on the equipment. Failure to disconnect the power source could result in injury or death. Verify that the equipment is not energized before performing any maintenance. This work must be performed by trained personnel with correct tools and procedures.

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Bodily contact with electrical potential can cause bodily injury or death. To avoid the possibility of injury or death, ensure that the main power supply has been disconnected before performing any maintenance or removing any modules.

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Illustration 1	g03345879

1. Use Tooling (B) and suitable cribbing to support the rear of engine (11). Refer to Table 2 for the approximate weight of engine (11).
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   Table 2

   Approximate Weight of Engine (11)
   Model	Approximate Weight
   C9	816 kg (1800 lb)
   C15	1633 kg (3600 lb)
   C18	1701 kg (3750 lb)

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Illustration 2	g03361603

2. Remove air exit screen (16) if necessary.

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Illustration 3	g03361636

3. Insert Tooling (C) between the main rotor and stator assemblies.

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Illustration 4	g03361662

4. Remove brace (15) from generator if installed.

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Illustration 5	g03361667

5. Remove outer bearing cover (17) .

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Illustration 6	g03361702

Note: If equipped with the optional PMG attachment then use the threaded rod that has been installed.

6. Install Tooling (D) to move main rotor shaft to the rear most position.

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Illustration 7	g03362156

7. Place straight edge (21) against coupling discs (18). Use ruler (20) to measure the Distance from flange (19) to outer edge of coupling disc (18) as shown in illustration 7.
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   Table 3

   Measurement of Distance from Flange (19) to Outer Edge of Coupling Discs (18)
   Model	Measurement of Distance
   LC 5	25 ± 2 mm (1.0 ± 0.08 inch)
   LC 6	25 ± 2 mm (1.0 ± 0.08 inch)
   LC 7	16 ± 2 mm (0.63 ± 0.08 inch)

8. Refer to Table 3 for measurement specifications by generator model.

9. If the measurement is not within specifications, then remove coupling discs (18) and add or remove shims. Reinstall coupling discs (18) .

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Illustration 8	g03361667

10. Install outer bearing cover (17) .

    Note: Install optional PMG attachment if equipped.

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Illustration 9	g03346018
For photographic purpose.

11. Install Tooling (E) in flywheel (22) .

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Illustration 10	g03345640

12. Attach Tooling (A) and a suitable lifting device to generator (10). Refer to Table 4 for the approximate weight of generator (10).
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    Table 4

    Approximate Weight of Generator (10)
    Model	Approximate Weight
    LC 5	895 kg (1973 lb)
    LC 6	1293 kg (2851 lb)
    LC 7	1865 kg (4112 lb)

13. Install generator (10) to the engine.

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Illustration 11	g03346018

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Illustration 12	g03345628

14. Install bolts (13) for the flange.

15. Remove Tooling (E) from flywheel (22). Install bolts (12) for the coupling discs.

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Illustration 13	g03346112

Note: Refer to Specifications, "Crankshaft" for engine crankshaft end play.

16. Install Tooling (F) to flywheel housing (23) of the engine.

17. Measure the crankshaft end play by moving the engine damper from back to front.

    Note: If crankshaft end play is not within specification, perform Steps 17.a through 17.f.

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    Illustration 14	g03346018

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    Illustration 15	g03346276

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    Illustration 16	g03346280

    1. Remove the generator from the engine.

    2. Install Tooling (E) in flywheel (22) .

    3. Remove coupling discs (18) .

    4. Add or remove shims (24) to obtain crankshaft end play specifications.

    5. Install coupling discs (18) .

    6. Perform Steps 13 through 17.

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Illustration 17	g03345760

18. Once crankshaft end play is within specification, Remove Tooling (F) and install bolts (14) to the mount.

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Illustration 18	g03345640

19. Remove Tooling (A) and the suitable lifting device from generator (10) .

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Illustration 19	g03345619

Note: Ensure that there are no foreign objects in turbo (9) inlet tube.

20. Install air filter (7) .

21. Install air exit screen (8) .

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Illustration 20	g03345614

22. Connect harness assemblies (6) .

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Illustration 21	g03345610

23. Install panel (5) .

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Illustration 22	g03345588

24. Connect cable assemblies (3), Current Transformer (CT) wiring (2) and ground strap (4). Install cable straps if necessary.

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Illustration 23	g03345556

25. Install panel (1) .

26. Connect DC battery supply.

27. Close the AC breaker.