LC5000, LC6100, and LC7000 Electric Power Generation Caterpillar

Removal Procedure

Start By:

1. Remove the terminal box.
2. Remove the generator.
3. Remove optional permanent magnet Pilot exciter (PMG) attachment if equipped.

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Illustration 1	g03342079

1. Remove air exit screen (1) .

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Illustration 2	g03342081

2. Remove outer bearing cover (2) .

Note: Failure to perform next step will result in damage to internal components of the generator.

3. Remove bolts (3) from the bearing cap.

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Illustration 3	g03341492
Typical example

Note: Mark orientation of cable assemblies (4) prior to disconnecting.

4. Disconnect cable assemblies (4). Remove terminals (5) from the terminal assembly.

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Illustration 4	g03341976

5. Install Tooling (A), a suitable lifting device, and Tooling (B) to generator (6). Refer to Table 2 for the approximate weight of generator (6).
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   Table 2

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

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Illustration 5	g03342084

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Illustration 6	g03342209

6. Use Tooling (A) and a suitable lifting device to position generator (6) on Tooling (C) .

7. Remove Tooling (A), the suitable lifting device, and Tooling (B) from generator (6) .

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Illustration 7	g03334652

8. Remove brace (7). Remove plate set (8) and the shims.

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Illustration 8	g03337287

9. Install Tooling (B) and a suitable lifting device on flange (9). Refer to Table 3 for the approximate weight of flange (9).
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   Table 3

   Approximate Weight of Flange (9)
   Model	Approximate Weight
   LC 5	41 kg (90 lb)
   LC 6	50 kg (110 lb)
   LC 7	58 kg (128 lb)

10. Remove bolts (10) from flange (9). Remove flange (9) .

11. Remove Tooling (B) and the suitable lifting device from flange (9).

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Illustration 9	g03334672

12. Install Tooling (D) and a suitable lifting device to rotor (11). Refer to Table 4 for the approximate weight of rotor (11).
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    Table 4

    Approximate Weight of Rotor (11)
    Model	Approximate Weight
    LC 5	357 kg (787 lb)
    LC 6	508 kg (1120 lb)
    LC 7	703 kg (1550 lb)

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Illustration 10	g03341790

13. Remove rotor (11) from generator (6) .

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Illustration 11	g03341798

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Illustration 12	g03334676

14. Attach Tooling (A) and a suitable lifting device to position rotor (11) on Tooling (E) .

Installation Procedure

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Illustration 13	g03334799

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Illustration 14	g03334783

1. Install Tooling (F) in bearing cap (12). Install Tooling (D) and a suitable lifting device to rotor (11). Install Tooling (A) and a suitable lifting device to rotor (11). Refer to Table 5 for the approximate weight of rotor (11).
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   Table 5

   Approximate Weight of Rotor (11)
   Model	Approximate Weight
   LC 5	357 kg (787 lb)
   LC 6	508 kg (1120 lb)
   LC 7	703 kg (1550 lb)

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Illustration 15	g03341848

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Illustration 16	g03341790

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Illustration 17	g03334787

2. Use Tooling (A), Tooling (D), and the suitable lifting devices to position rotor (11) vertically.

3. Remove Tooling (A) from rotor (11) .

4. Lower rotor (11) slowly into generator (6) .

5. Carefully guide Tooling (F) through holes (13) in the bracket assembly.

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Illustration 18	g03334672

6. Remove Tooling (D) and suitable lifting devise from rotor (11) .

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Illustration 19	g03337287

7. Attach a suitable lifting device and Tooling (B) to flange (9). Refer to Table 6 for the approximate weight of flange (9).
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   Table 6

   Approximate Weight of Flange (9)
   Model	Approximate Weight
   LC 5	41 kg (90 lb)
   LC 6	50 kg (110 lb)
   LC 7	58 kg (128 lb)

8. Install flange (9) and bolts (10) .

9. Remove the suitable lifting device and Tooling (B) from flange (9) .

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Illustration 20	g03334652

10. Install plate set (8) and the shims. Install brace (7) .

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Illustration 21	g03341838

11. Install Tooling (A), a suitable lifting device, and Tooling (B) to generator (6). Refer to Table 7 for the approximate weight of generator (6).
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    Table 7

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

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Illustration 22	g03342084

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Illustration 23	g03341976

12. Use Tooling (A), a suitable lifting device, and Tooling (B) to position generator (6) as shown in Illustration 23.

13. Remove Tooling (A), the suitable lifting device, and Tooling (B) from generator (6) .

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Illustration 24	g03341492
Typical example.

14. Connect cable assemblies (4). Install terminals (5) on the terminal assembly.

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Illustration 25	g03342087

15. Install outer bearing cover (2) .

16. Remove one Tooling (F) and install one bolt (3). Remove other Tooling (F) and install other bolt (3) .

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Illustration 26	g03342079

17. Install air exit screen (1) .

End By:

1. Install optional permanent magnet Pilot exciter (PMG) attachment if equipped.
2. Install the generator.
3. Install the terminal box.