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Disassembly and Assembly

SR4 GENERATOR
Alignment Of Single-Bearing Generators
(Typical)
SMCS - 4450-11
Installation Of The Generator
NOTE: For information or alignment of two bearing generators make reference to Form
No. SEHS7073.
Typical installation and alignment procedure for electric sets with single-bearing
generators. Do not start the alignment procedure until the electric set is permanently
installed. If the electric set is moved to a different location, check the alignment and
make any corrections necessary. The alignment between the generator and the engine
must be correct to get maximum performance and long life from the electric set.
Shutdown SIS

Previous Screen
Product: GEN SET ENGINE
Model: 3516 GEN SET ENGINE 25Z
Configuration: 3516 GENERATOR SET ENGINE
25Z00001-00683
Media Number -SENR7968-03 Publication Date -01/03/1983 Date Updated -15/01/2009

SENR79680007
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REAR OF ENGINE
A. Pilot bore. B. Surface.
1. Remove all dirt, burrs and paint from the contact surfaces of the generator supports and
the base.


FRONT OF ENGINE
1. Indicator group. 2. Crankshaft pulley.
Remove the protection material (compound) from the flywheel pilot bore (A) and from
the surface (B) that makes contact with the coupling. All contact surfaces of the engine,
coupling and generator must be completely clean.
2. Remove the timing pointer cover from the flywheel housing. Install indicator group (1)
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as shown on the front of the engine with the tip of the indicator on the face of crankshaft
pulley (2). Use a bar between the flywheel and flywheel housing to push the crankshaft
toward the flywheel to remove all end play. Put the dial indicator in the "zero" position.
Move the crankshaft to its most forward position, and make a record of the Total
Indicator Reading (TIR). The TIR is the end play of the crankshaft.


FRONT OF GENERATOR
3. Plate assembly. 4. Shim pack.
3. Put plate assembly (3) in position in the bore of the flywheel to check for clearance.
There must be clearance between the outside diameter of the plate assembly (3) and the
inside diameter of the bore in the flywheel.
4. Install a full shim pack (4) and plate assembly (3) on the generator with bolts (5). On
D379, G379, D398, G398, D399 and G399 engines, tighten bolts (5) to a torque of 370
35 lb. ft. (505 45 Nm). On all other engines, tighten bolts (5) to the standard torque.


INSTALL PLATE ASSEMBLY
NOTICE
Damage to the engine and/or generator can be the result if
the electric set is run with a plate assembly that does not
have this clearance.
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5. Bolt.


ENGINE FLYWHEEL
6. Guide bolt.


PUT GENERATOR IN POSITION


INSTALL BOLTS
7. Bolt. 8. Bolt.
5. Install guide bolt (6) in the flywheel. Put the generator in position on the engine, and
install bolts (7) and (8). Tighten bolts (7) and (8) but do not bend the locks under bolts (8)
at this time.
6. Use a dial indicator (1) to check crankshaft end play (do not use force to hold the
crankshaft in position). Remove the generator. Remove only enough shims to get the
original amount of end play as shown in Step 2.
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PUT BOLTS IN POSITION
9. Bolt. 10. Generator support.
7. Install the generator and again check the crankshaft end play. After the correct amount
of shims has been installed, bend the locks under bolts (8).
8. Install but do not tighten all bolts (9) that fasten generator supports (10) to the base. To
align the generator to the engine, do the steps that follow:
Electric Sets Without Supports at the Flywheel Housing


GENERATOR SET
11. Bolts. 12. Base.
a. If base (12) of the electric set is fastened to a foundation, loosen all base-to-foundation
bolts. Loosen all bolts (11) that fasten the engine supports to base (12).
b. Check to be sure there is clearance between the bolts and the bolt holes in the base,
engine supports and generator supports at all locations.
c. Check the clearance between the base and its foundation at all mounting locations. Use
shims as necessary to prevent deflection of the base as the base-to-foundation bolts are
tightened. When there is no deflection in the base, tighten all base-to-foundation bolts to
their final torque.
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CHECK CLEARANCE
10. Support.
d. Check the clearance between the base and the engine and generator supports at all four
locations (11). Be sure to check the clearance over the entire length of the support. This is
especially important on generators with long supports (10), since some surfaces may not
be square or parallel. Use shims as necessary to prevent deflection of the supports as the
bolts are tightened. After all the necessary shims have been installed, tighten all mounting
bolts to their final torque.
Electric Sets With Supports at the Flywheel Housing


GENERATOR SUPPORT
10. Support. 12. Base.
a. If base (12) of the electric set is fastened to a foundation, loosen all base-to-foundation
bolts. Loosen all bolts that fasten the engine and generator supports to the base.
b. Check to be sure there is clearance between the bolts and the bolt holes in the base,
engine supports and generator supports at all locations.
c. Check the clearance between the base and its foundation at all mounting locations. Use
shims as necessary to prevent deflection of the base as the base-to-foundation bolts are
tightened. When there is no deflection in the base, tighten all base-to-foundation bolts to
their final torque.
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d. Loosen all bolts (7) that fasten the generator to the flywheel housing. Tighten every
other bolt to its final torque. Check the clearance between the base and the engine and
generator supports at all six locations. Be sure to check the clearance over the entire
length of the supports. This is especially important on generators with long supports (10).
Install shims as necessary until all of the mounting surfaces are flat and parallel.


CHECK CLEARANCE
7. Bolt.


CHECK GAP
D. Gap.
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VIEW A-A
e. Tighten all bolts that fasten the engine and generator supports to the base to one-half of
their final torque. Loosen all bolts (7), and check the gap (D) between the generator and
the flywheel housing at locations (E), (F), (G) and (H). Location (E) must always be at
the top. Make a record of each measurement.
f. If the gap at location (E) is larger than the gap at location (G) by more than .005 in.
(0.13 mm), install an equal amount of shims under each generator support as necessary. If
the gap at location (G) is larger than the gap at location (E) by more than .005 in. (0.13
mm), remove an equal amount of shims from under each generator support as necessary.
After a correction has been made to shim thickness, tighten the generator support as
necessary. After a correction has been made to shim thickness, tighten the generator
support bolts to one-half of their final torque and again check the gap at locations (E) and
(G). Use this procedure again and again until the difference in gap measurements is .005
in. (0.13 mm) or less.
g. If the gap at location (F) is larger than the gap at location (H) by more than .005 in.
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(0.13 mm), loosen the bolts in the generator supports and move the rear of the generator
to the right. If the gap at location (H) is larger than the gap at location (F) by more
than .005 in. (0.13 mm), loosen the bolts in the generator supports and move the rear of
the generator to the left. Do this procedure again and again until the difference in gap
measurements is .005 in. (0.13 mm) or less. Tighten bolts (2) to their final torque.
h. Install a dial indicator on base (12) with the indicator tip next to a support mounting
bolt. Tighten this bolt to its final torque, and at the same time check the indicator. If there
is more than .005 in. (0.13 mm) of indicator movement, the shim thickness is incorrect
under that bolt. Install shims as necessary. Do this procedure again and again until all
engine and generator support mounting bolts have been tightened to their final torque and
support deflection is within specification.

Copyright 1993 - 2010 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Wed Mar 10 19:46:11 UTC+0800 2010
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