SERVICE BULLETIN CATEGORY: Accessories IDENT NO: 1-2507 ‘SUPERSEDES: NEW DATE: May 15, 1987 SUBJECT: Front End Belt Drive With Outboard Bearing MODELS AFFECTED: P9390G, GSI and GL Engines SUMMARY: As a product improvement to remove excessive side loading from the front of the crankshaft, a new front end belt drive with an outboard bearing has been released. This drive is now standard equipment on all 16 cylinder. G, GStand-GL engines. INFORMATION & The following is a brief index to the contents of this bulletin. INSTRUCTIONS: ——————— SSS | Topic General Description. Horsepower Limitations ...... Installation Flexible Coupling and Drive Pulley. Outboard Bearing . Preliminary Alignment Final Alignment .. Protective Guarding . Outboard Bearing Lubrication ......... Belt Changing .. ceeee Field Retrofit Installation . Alignment Outboard Bearing Lubrication . Belt Changing .. Protective Guarding . Parts List. Torque Values GENERAL There are two front drive configurations currently available, each DESCRIPTION based on model and load. A single, Part Number 199331, vibration damper is used on all P9390G and some GSI (continuous rating or less) engines. Two, Part Number 211150A, vibration dampers are used on all P9390GL and some GSI (intermittent rating) engines.No. 1-2507, Page 2 of 10 SPACER IS USEDONENGINES = j, Ash i | WITH ONLY ONE VIBRATION IL DAMPER: es | FIGURE 1 TYPICAL INSTALLATION iO FRONT FACE OF CRANKCASE GENERAL Figure 1 shows the new front drive in a typical installation utilizing two DESCRIPTION vibration dampers and a unit mounted radiator. In applications where (Continued) only one vibration damper is required, a spacer is used so that the position of the drive assembly is the same in both cases.No. 1-2507, Page 3 of 10 ee HORSEPOWER LIMITATIONS Figure 2 defines the horsepower versus rpm limitations of the drive respect to various applications. A SERVICE FACTOR is used to equate equipment rating with various loading conditions. 12 s10¢ 24 ENGINE RPM 0 30 408060 70 G0 80 100 110120 HORSEPOWER FIGURE 2 SERVICE FACTORS SERVICE TYPE OF EXAMPLES FACTOR LOADING | 10 Continuous running loads | Blowers, fans, : generators, pumps. 15 Nearly continous running, | Lobe or vane but with varying torque —_| type blowers, loads. force draft fans with fluid or slip clutches. 2.0 Frequent stop/start cycles | Compressors or | or significant variation pumps-rotary or in torque loads while vane type running. 25 Light shock loading or . severe torque variations while running. | 3.0 Heavy shock loads. : * CONSULT THE WAUKESHA ENGINE DIVISION APPLICATION ENGINEERING DEPT. BEFORE SUBJECTING A FLEXIBLE COUPL- ING TO THESE SERVICE FACTORS.No. 1-2507, Page 4 of 10 INSTALLATION FLEXIBLE COUPLING AND DRIVE PULLEY INSTALLATION OUTBOARD BEARING 90 FT-LBS (122 N-m) QD HUB’ ELASTOMER HALF DRIVE PULLEY OUTBOARD BEARING FIGURE 3 FRONT END DRIVE WITH OUTBOARD BEARING Remove protective guarding as necessary to gain access to the stub shaft mounted on the end of the crankshaft. Seat the key onto the stub shaft. Place one of the flexible coupling quick disconnect (QD) bushings (flange towards the engine) onto the stub shaft. Mount one of the QD hubs (with the large end of the taper towards the engine) onto the QD bushing. Install the three capscrews finger tight. Remove the three capscrews, separate the QD hub from the QD bushing and place the quick disconnect drive pulley (with bushing flange towards the outboard bearing) onto the key and larger outside diameter shaft portion of the ‘outboard bearing as far towards the bearing portion as possible. Reinstall the three capscrews finger tight. Mount the second QD hub (with the inside diameter large end towards the engine) onto the outboard bearing. Place the other QD bushing (flange towards the engine) onto the key and smaller outside diameter shaft portion of the outboard bearing. Install the three capscrews finger tight. The outboard bearing must be supported solidly. The positioning of the support should allow for alignment shims. Refer to Figure 4 for the correct bolt hole pattern. Six 600” Grade 5 (or better) bolts should be used. After the outboard bearing has been mounted, position both flexible coupling halves to achieve the clearances shown in Figure 5. Torque all QD bushing and hub capscrews and the drive pulley cap- screws to 75 ft-Ibs (102 N-m) dry.6.75 .562 DIAMETER HOLES - 6 PLACES 22.84 FIGURE 4 OUTBOARD BEARING oaie PROVIDE THE CLEARANCE 4.25-— FOR RE-POSITIONING APPROX. OR DISASSEMBLY 1.16 REF. FIGURE & PRELIMINARY ALIGNMENTNo. 1-2507, Page 6 of 10 PRELIMINARY ALIGNMENT FINAL ALIGNMENT Set up a dial indicator to read face runout. See Figure 5, Top. Zero the indicator and rotate the pulley half of the coupling through one revolu- tion, recording the total indicator reading (TIR). Shim or slide the outboard bearing as required to align within 0.010" (.25mm) TIR. Set up the dial indicator to read radial runout. See Figure 5, Bottom. Zero the indicator and rotate the coupling through one revolution, recording TIR. Shim or slide the outboard bearing as required to align within 0.010" (.25mm) TIR. Check that face runout remains within 0.010” (25mm) TIR. MATCH MARK HUBS AND BUSHINGS FIGURE 6 FINAL ALIGNMENT Install one of the elastomer (the flexible portion of the coupling) halves. Torque the bolts (dry) to 7 ft-Ibs (102 N-m). Mark both coupling hubs and quick disconnect bushings. Should disassembly be necessary, matching the marks during reassembly will ensure that the coupling components are in the same orientation as during alignment. Prelube the engine before barring the crankshaft. To ensure face runout accuracy, impose a force on the crankshaft to eliminate axial float. Using a dial indicator, shim or slide the outboard bearing until face and radial runout is within 0.005” (13mm) TIR. See Figure 6. Install the remaining elastomer half. With the engine at operating temperature, check that the face and radial runout remain within 0.005" (.13mm) TIR. Correct as necessary. Tighten the six outboard bearing bolts. A dry torque value of 75 ft-Ibs (102 N-m) for .500-13 UNC or 85 ft-lbs (115 N-m) for 500-20 UNF bolts is required.No. 1-2507, Page 7 of 10 esse NOTE NOTE PROTECTIVE GUARDING OUTBOARD BEARING LUBRICATION BELT CHANGING FIELD RETROFIT INSTALLATION ALIGNMENT, OUTBOARD BEARING LUBRICATION, AND BELT CHANGING PROTECTIVE GUARDING After alignment is completed, it is recommended that the outboard bearing be doweled to the support. The capscrews that hold the elastomer halves in place have self- locking patches. Because of these patches, the capscrews should not be used more than twice. If it becomes necessary to use these capscrews more often, ensure that a thread-locking adhesive is used. Figure 7 shows what front end guarding is currently being mounted at Waukesha. Note that Items 19 and 20 allow clearance for the shaft portion of the outboard bearing. Note also that Item 18 is in place when the front end belt drive assembly is not used. It is the customer's responsibility to provide adequate guarding for the drive pulley, belts, and other additional equipment. ‘The outboard bearing has been prelubricated with a high temperature, water resistant grease. A small amount of grease should be visible at the seals. When requireduse Amoco Rycon #2 or an equivalent polyurea non-EP/moly type grease. To change the drive belts, remove the guarding and both elastomer halves. The replacement belts can pass between the coupling halves. Previous configurations where the crankshaft pulley, vibration damper and assorted components were joined using 10 capscrews, must be replaced with components using 12 capscrews. See Figure 8 for a breakdown of the current configuration ‘Once the current configuration of pulley, vibration damper, etc. is assembled onto the engine, the remainder of the assembly installation follows the procedure outlined on page 4 The subjects of preliminary and final alignment, outboard bearing lubrication and belt changing are identical in nature for a field retrofit of an existing engine as they are during installation on a new engine. To ensure clearance for the vibration damper(s) and for the front end drive assembly, it is recommended that the protective guarding shown in Figure 7 be used in a retrofit program.No, 1-2507, Page 8 of 10 FIGURE 7 PROTECTIVE GUARDINGNo. 1-2507, Page 9 of 10 1 REE Seneca Ferns Guana. rsgnaarer SMS | 3 fests: "T Sitar vere ge oom 1 | S Sotere 1 Taran conanan psey 18 & toons 1 Muurkermon 5 ees? | Frm, Gea se deer 3 Semew Cop tras Grae 8, 1/27-1952.74" | 3 eentas 7 Soucek neytugu ous | fimo | Sten ale bse amo | 13 eae 12 Sepen oe nsrme- cree 2-238" 13 ome") We tee sa FIGURE 8 FRONT END BELT DRIVE, OUTBOARD BEARING ‘AND DOUBLE VIBRATION DAMPER CONFIGURATION PARTS The following chart gives a SAMPLE part number supersession using ust a TYPICAL previous pulley/damper configuration, |] pousie | sinate quantity || camper | quantity || pamper | quantity COMPONENT || PREVIOUS | PER CURRENT PER CURRENT PER NAME P/N ENGINE P/N ENGINE PN ENGINE I Cops 28576 10 28576 2 28576 12 Look washer 21054 10 21054 2 21054 12 Vibration damper | 198331 1 2111508 2 199331 1 Pulley spacer 1996228 1 199622) 1 199622) 1 Pulley taper 1s31618 1 1531618 1 1531618 1 Pulley 200596X 1 2006856 1 2006956 1 Grease fining |] NA NA 159086 1 59084 1 End plate 183162 1 1531628 1 1531628 + | Lock washer 21088, 3 21088, 3 21088. 3 Cepscrew — || 26742 3 28847 3 20887 3 Spacer || tggetes 1 1998080 1 169912) 5 Pulley 2002958 1 NA. Na NA Na Lock washer | 21054 10 21054 12 21054 12 Copserew || 2a8¢ | 0 3e738 2 39738 2No. 1-2507, Page 10 of 10 _—_—— TORQUE vee BOLT LOCATION ft-lbs N-m | WET/DRY Crankshaft End Plate 350 475 dry Vibration Damper 90 122 dry Coupling | Elastomer ] 7 102 dry Coupling Hub & Bushing 75 102 dry Drive Pulley | 75 102 dry Outboard | Bearing | 75 (.500-13UNC) 102 dry | | 85 (.500-20UNF) 115, dry It is the customer's responsibility to provide adequate guarding for the drive pulley, belts, and other additional equipment. cenvine (E)"ranrs 7ih