25/5/2019 Media Search - REHS7485 - Alignment of Diesel Generator Sets with the Two-Bearing Generator {1000, 4450, 7002}

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Special Instruction
Alignment of Diesel Generator Sets with the Two-Bearing Generator {1000, 4450, 7002}
Media Number -REHS7485-02 Publication Date -12/03/2014 Date Updated -25/05/2016

i06702442

Alignment of Diesel Generator Sets with the Two-Bearing Generator

{1000, 4450, 7002}
SMCS - 1000; 4450; 7002

Gen Set-Military
3512B (S/N: NSC1-UP)
3516B (S/N: TAK1-UP)

Introduction
Note: Before starting the alignment procedure. Make a copy of the Generator Set Alignment Data Sheet that is
located at the end of this Special Instruction.

This Special Instruction is the recommended procedure for alignment of the two-bearing generators listed above.

This procedure must be performed with all components at ambient temperature. Do not start the final alignment
of the generator until the base is in the permanent position.

Complete the initial and final alignment of the generator per this procedure. The generator must be resting on the
resilient mounts for a minimum of 48 hours after ship is placed in the water, prior to checking alignment.

Required Tools
Refer to Table 1 for the tools needed to perform the alignment check when using dial indicators.

Table 1
Required Tools
Qty Part Number
1 4C-5647 Pry Bar
2 8T-5096 Dial Indicator Gp
1 6V-2042 Yoke

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1 6V-2043 Bar

Procedure For Alignment

Note: The engine jacket water heaters must be switched off to allow the engine to reach the ambient room
temperature. The generator space heaters must also be switched off. Run the prelube just prior to performing the
alignment to provide an oil film on the bearings.

To achieve correct operating alignment, the factors listed below have been considered in determining alignment
specifications.

Illustration 1 g03003997

During the alignment procedure, the crankshaft lies at the bottom of each main bearing bore. Under
running conditions, firing pressures, centrifugal forces, and engine oil pressure all tend to lift the
crankshaft. Lifting of the crankshaft cause rotation around the center of the main bearing bores.

The weight of the flywheel and coupling cause a small deflection of the crankshaft during the alignment
procedure.

During operation, the engine heat causes expansion of the metal in the engine and generator. The result of
the expansion is a change in the locations of the centerlines of the crankshaft and generator shaft. The
thermal expansion is greater in the crankshaft than the generator shaft. The centerline of the crankshaft
will change more than the generator. Due to the change in the relationship of the centerline of the engine
and the generator. The alignment procedure positions the centerline of the generator shaft above the
centerline of the engine crankshaft.

In the past, a hot alignment check may have been used to check the accuracy of the cold alignment
procedure. However, factory tests have shown that the results of the hot alignment check are inconsistent.
Therefore, hot alignment is not recommended.

Crankshaft End play

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Measure the engine and generator end play. The end play readings should be within the specifications listed
below:

S/N: S/N:TAK
The split ring must be removed to take end play measurements. Reinstall the split ring prior to performing
alignment.

Crankshaft end play is 0.178 mm (0.007 inch) to 0.640 mm (0.025 inch).

Generator end play is 0.348 mm (0.0137 inch) to 0.950 mm (0.0374 inch).

S/N: S/N:NSC

This application does not utilize a split ring and there is sufficient clearance in the coupling to not interfere when
taking end play measurements.

Crankshaft end play is 0.178 mm (0.007 inch) to 0.640 mm (0.025 inch).

Generator end play is 0.406 mm (0.016 inch) to 1.016 mm (0.040 inch).

Note: Never pry on the crankshaft damper.

1. To measure the crankshaft end play, use a pry bar between the cylinder block and the crankshaft
counterweight . Move the crankshaft all the way to the front of the engine. Move the crankshaft until a
definite “clunk” is heard when the crankshaft bearing hits the outer stop.

a. Install a dial indicator on the face of the engine flywheel and preload the indicator a minimum of
one turn. Zero the indicator. If a digital indicator is used, preload the indicator to 2 mm and then
zero the indicator.

b. Move the crankshaft all the way toward the rear of the engine. Record the indicator reading. The
reading on the indicator is the crankshaft end play.

c. Repeat the measurement 3 times to ensure consistent measurements.

d. Record the measurements on the Generator Set Alignment Data Sheet.

2. To measure the generator shaft end play, use the following steps.

Note: All prying must take place against the generator hub.

a. The end play of the generator shaft is measured in a similar way, except the indicator is positioned
on the coupling flange.

b. Repeat the measurements of the generator shaft end play three times to ensure consistent
measurements.

c. Record the measurements on the Generator Set Alignment Data Sheet.

3. When initially coupling the generator to the engine, pull the generator shaft to the maximum forward
position and hold the generator shaft in place. Move the engine crankshaft to the maximum forward
position to remove all end play.

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4. Position the generator such that the rotor hub can be bolted to the flexible coupling hub. Move the
crankshaft forward to remove end play. Move the generator shaft towards the engine to remove the end
play in the generator. Position the generator so that dimension (X) in figure 2 equals 17 ± 0.02 mm
(0.67 ± 0.0008 inch) for the coupling. Ensure that all components are free from interference and the
elements are centered. Dimension (X) as shown in illustration 2 is the location of the split ring spacer. The
figure shows the split ring spacer removed.

Illustration 2 g03004760
Coupling Dimension (X) is needed to install the split ring spacer.

Split Ring Installation (S/N: TAK Only)

1. Check the positions of the crankshaft and the generator shaft. This verification will help center the shafts
during operation in the middle of end play of the shafts. Position the crankshaft all the way forward
toward the front of the base. Position the generator shaft toward the rear of the base against the thrust
bearing. Install the split ring spacer and check the gap that is left between the split ring and either the
generator or the coupling. Take the previously recorded values for the end play of the crankshaft and the
end play of the generator. Adjust the generator to set the gap. Set the gap to one half (50 percent) of the
total end play of the generator and of the engine.

Note: To reduce the effect of coupling sag, measure with the feeler gauge at the 90 degree side and the
180 degree side of the coupling.

2. After the alignment of the generator meets the specifications of the preliminary alignment, record the
dimensions. Install the split ring spacer and torque the bolts to the specifications of the flexible coupling
assembly.

Dial Indicator Alignment Procedure

Note: Before taking any measurements, make sure that all surfaces are free from grease, paint, rust, and dirt.
These agents will affect the alignment measurements. When checking the alignment, measure the face and bore
alignments simultaneously.

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Note: Use the dial indicator carefully. Improper mounting, positioning, and reading of the indicators can result
in the following problems.

Improper support of the indicator

Incorrect interpretation of measurements

Incorrect compensation of the movement of the axial shaft

Illustration 3 g06086789
(7) Generator
(8) Rigid Bracket
(9) Crankshaft
(A) Dial Indicator
(B) Dial Indicator

1. Attach a rigid bracket (yoke and bar in tools list) to the hub for the generator to support both the
indicators. Attach indicator (A) to read the angular misalignment of the flywheel at the 12 o'clock
position. Attach the second indicator (B) to read the parallel alignment at the 12 o'clock position.

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Illustration 4 g06086820

2. S/N: NSC Only

Prior to performing alignment, insert two wedges at (C) approximately 3/8 inch thick in the coupling
between rubber element and outer ring to remove all excess movement.

Note: The coupling must be assembled to perform alignment measurements.

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Illustration 5 g06086843
(A) Twelve o'clock
(B) Three o'clock
(C) Six o'clock
(D) Nine o'clock

3. Rotate the flywheel clockwise until the rotor starts to turn. This action will determine if the rotation will
have a detrimental effect on the measurements. Then set indicator (A) and indicator (B) to zero. Rotate the
flywheel counterclockwise until the rotor starts to turn. If either indicator records more than 0.051 mm
(0.0020 inch) change in this short radial distance that was traveled, place a chalk mark on the flywheel
close to the location of the indicator (A). Always move the flywheel until the flywheel lines up with the
chalk mark. Perform this rotation before indicators are zeroed. Rotate the flywheel before measuring at the
3 o'clock, 6 o'clock, and the 9 o'clock positions. Before taking the indicator readings during the alignment
check, always move the engine crankshaft and generator rotor towards the front of the engine to remove
the end play. Do not use force against either the crankshaft or the generator shaft while taking the indicator
readings.

4. At the 12 o'clock position, set the dial indicators to zero. Rotate the engine and the generator in the
direction of operation. Record the readings at the 3 o'clock, 6 o'clock, and 9 o'clock positions. Continue to
rotate the engine to the 12 o'clock position to verify the indicators return to zero.

For the dial indicator mounted vertically, the sum of (A) and (C) represents the vertical offset, and the sum
of (B) and (D) represents the horizontal offset. For the dial indicator mounted horizontally, the sum of (A)
and (C) represents the vertical angularity, and the sum of (B) and (D) represents the horizontal angularity.

5. Adjust the alignment until all the measurements are within the specifications that are called out on the
"Generator Set Alignment Data Sheet". Record the final measurements on the data sheet.

6. Once the alignment is within the specifications, torque the generator mounting bolts to the proper
specifications.

7. Recheck the crankshaft end play. After generator install and alignment. The crankshaft end play must not
be less than the end play prior to the installation of the generator.

8. Perform a soft foot check. Refer to "Soft Foot Check Procedure".

Indicator Readings
If, the indicator reading a positive (+), the tip of the indicator moved into the indicator and minus (-) means that
the tip of the indicator moved out of the dial indicator.

When comparing two positive (+) indicator readings, the larger numerical reading is more than the smaller
numerical reading. However, when comparing two minus (-) indicator readings, the larger numerical reading is
less than the smaller numerical reading. In both cases, the indicator reading becomes less as the tip of the
indicator moves out of the dial indicator.

The Total Indicator Reading (TIR) is the total amount of movement of the indicator needle. The TIR is always a
positive value even though one or both of the readings are negative. For example: If the indicator reading varied
from -10 to +5, the TIR was 15. If the indicator reading is varied from -5 to - 15, the TIR was 10.

Laser Tool Alignment Procedure

Note: Refer to the laser alignment tool user manual instructions for additional information regarding operation
of the tool.
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To do laser tool alignment, perform the following steps:

1. Mount the transducer to the outer coupling element.

2. Attach the reflector to the generator hub.

3. Enter the required dimensions into the laser alignment tool. Examples of possible dimensions required
include the following:

Transducer to reflector

Transducer to coupling centerline

Coupling diameter

Rotations Per Minute (RPM)

Transducer to front feet

Front feet to rear feet

4. Turn the laser ON, adjust the laser beam to the center of the reflector dust cap. Once the laser beam is
centered, remove the dust cap.

5. Rotate the drive line one complete revolution.

6. Record the results displayed on the laser alignment tool. Compare the readings to the acceptable values
listed in the "Generator Set Alignment Data Sheet".

7. Adjust the generator as needed to obtain the correct alignment. Shims may be installed or removed to
achieve the correct vertical alignment. Use the horizontal adjustment screws to make horizontal
adjustments.

8. Once the alignment is within the specifications, torque the generator mounting bolts to the proper
specifications.

9. Perform a soft foot check. Refer to "Soft Foot Check Procedure".

Soft Foot Check Procedure

Note: The soft foot check can be completed with the laser alignment tool if the tool has this function.

1. Ensure that all jacking screws are loose

2. Mount a dial indicator from the base assembly to the top of the generator mounting foot to be measured.

3. Preload the dial indicator to a minimum of one revolution or 2 mm (0.08 inch). Once the correct preload is
set, zero the dial indicator.

4. Loosen the mounting bolt at the location that is being measured. Measure and record the vertical
deflection of the generator mounting foot at this location as close to the mounting bolt as possible. Only
loosen one bolt at a time.

5. The maximum deflection of the mounting foot is 0.076 mm (0.003 inch). If the indicator reading is greater
than this amount, add shims to eliminate the soft foot condition. Torque the mounting bolt before moving

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to the next mounting foot to be measured for soft foot.

6. Repeat the procedure on the remaining generator mounting feet.

7. Perform the final torque of the generator mounting bolts.

Dowel or Pinning Generator

1. Mount the genset in its final location on the vessel.

2. After the vessel has been sitting in the water for at least 48 hours, verify that the resilient mount height is
correct before performing the alignment check. Make any adjustments as needed.

3. Dowel/pin the generator at the following locations:

S/N: S/N:NSC - Two front (drive end) corners

S/N: S/N:TAK - All four corners

4. Perform the alignment readings again and document the readings in the "Final Readings" column in the
"Generator Set Alignment Data Sheet" of this document. Submit the completed "Generator Set Alignment
Data Sheet" to Caterpillar Defense and Federal Products engineering.

Table 2
Generator Set Alignment Data Sheet

Alignment Specification and Data Sheet for two-bearing generator. Refer to Note A
Ship Hull Number _____________________________________________________
Engine Serial Number __________________________________________________
Engine Hours __________________________________________________
Dial Indicator Alignment Final
Laser Alignment Tolerance
Tolerance Readings

Engine End 0.17 mm (0.007 inch) to 0.63 mm 0.17 mm (0.007 inch) to 0.63 mm
Play (0.025 inch) (0.025 inch)

Generator End 0.348 mm (0.0137 inch) to 0.348 mm (0.0137 inch) to

Play 0.950 mm (0.0374 inch) 0.950 mm (0.0374 inch)

Vertical Offset
+0.38 ± 0.05 mm +0.19 ± 0.025 mm
See Note B and
(+0.015 ± 0.002 inch) TIR (+0.0075 ± 0.001 inch)
C
Horizontal
Offset 0.20 mm (0.008 inch) MAX TIR 0.10 mm (0.004 inch) MAX
See Note B
Vertical
Angularity 0.20 mm (0.008 inch) MAX TIR 0.10 mm (0.004 inch) MAX
See Note B
Horizontal 0.20 mm (0.008 inch) MAX TIR 0.10 mm (0.004 inch) MAX
Angularity
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See Note B
Date Inspected ___________________________________________________________
Method Used: Dial Indicator or Laser

Inspection Company ______________________________________________________

Inspector Name and Company ______________________________________________
Note A: Final alignment check using laser alignment equipment and/or dial indicators. Perform the
alignment cold and without the jacket water heaters operating. If equipped, the generator space heaters must
be switched off before performing the alignment.
Operate the generator prelube pump while the alignment is performed.

Note B: Dial indicator values are in Total Indicator Reading (TIR). Laser values represent the actual offset.
Note C: For vertical offset, the positive value represents that the generator is set high to allow for thermal
growth of the engine. Depending on the measurement set up, this may be reported as positive or negative.
Always confirm that the result is that the generator is higher than the engine.
Return a completed copy of this form to:
Caterpillar Defense and Federal Products
Tech Center, Building A
PO Box 470
Mossville, IL 61552

Attn: Marine Lead Engineer

Copyright 1993 - 2019 Caterpillar Inc. Sat May 25 2019 [Link] GMT-0400 (hora de Venezuela)
All Rights Reserved.
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