Alignment of Two-Bearing

Generators{4471} Caterpillar

Alignment of Two-Bearing Generators{4471}

Usage:
3616 1FN 3616 1PD 3616 1PD 3616 1PD 3616 1PD G3612 1YG
3608 1ZD 3618 2MW G3606 3XF G3616 4CG G3608 4WF G3606
B 4ZS 3608 5PG 3608 6MC 3608 6MC 3608 6MC 3608 6MC 3
608 7WR 3608 8LL 3606 8RB 3606 8RB 3606 8RB 3606 8RB
3612 9FR 3612 9RC 3612 9RC
Information for equipment:

GENERATORS

A New Service Support Center Is Available For The Products That Are
Assembled At The Large Engine Center {1000, 4490, 7002, 7274} 2001/09/01
Caterpillar Factory Commissioning Services {1000, 4450, 7000,
7002} 2006/08/14

Alignment of Two-Bearing Generators{4471} Alignment of Two-Bearing

Generators{4471}

Engine: All 3600 All C280 All G3600

Introduction
This Special Instruction explains the alignment procedure for 3600 engines
with two-bearing generators. Do not start the alignment procedure until the
electric set is permanently installed. If the generator set is moved to a
different location, check the alignment and make any corrections
necessary. Alignment between the generator and the engine must be
correct to get the maximum performance and the longest life from the
generator set. Refer to Illustration 1 in order to view the different
parameters for alignment.
Procedure For Alignment
1. Review the components of the complete installation. When the weight
of any attachment or fluid compartment exceeds 225 kg (500 lb), fill
the compartment or simulate the weight of the fluid before you
proceed with the alignment.

2. Attach the isolators to the base. The clearance between the floor and
the bottom of the base should be at least 25.4 mm (1.00 inch).

Level the isolators. Refer to Special Instruction, SEHS9162 for details

on the procedure.

3. The end play of the crankshaft should be 0.4 ± 0.2 mm (0.016 ± 0.008
inch). The inspection of the end play of both the crankshaft and the
generator shaft must be performed. This inspection will ensure that
the thrust bearings for the generator and the engine bearings are not
damaged during operation.

Note: In order to protect the bearings against damage, prelube the

engine and the generator before rotation.

In order to protect the generator bearings from damage, lubricate the

generator bearings before any axial movement. Also lubricate the
shafts before the shafts are turned. If the generator is not equipped
with a pump for prelube, drain the oil from the bearing into a clean
container. Replace the drain plug. Refill the bearing with the oil from
the top. This procedure will provide the prelube that is needed to turn
the shaft.

Check the end play of the crankshaft by attaching a dial indicator to

the engine block or a stationary surface. Clean the surface of the
following materials: grease, dirt and protectant. The reading can be
taken in one of two areas. In order to gain access to the first area,
remove a side cover from the engine block. Install the indicator rod
against the crankshaft at the counterweight or some other suitable
location on the crank. For the second area, install the indicator rod
against the flywheel at the rear of the engine. Avoid the flexible part
of the coupling.

Use a clean pry bar against the crankshaft in order to move the
crankshaft back and forth. The crankshaft may be difficult to move. If
necessary, prelube the crankshaft in order to reduce the force that is
required to move the crankshaft. Repeat the measurements several
times in order to verify the results.
 Note: Never pry on the damper in order to check the end play of the
crankshaft.

4. The split flange will not be installed for rough alignment. Install two
alignment bolts at an angle of 180 degrees between the drive flange
for the generator and the adapter. (Do not install the nuts.)

The two alignment bolts will allow the generator shaft and the
crankshaft to rotate. Therefore, only the misalignment will be
measured.

Different alignment methods:

Illustration 1 g00565566
(1) Face gap (top)

(2) Diameter gap (top)

(3) Face or angular misalignment

(4) Bore or parallel misalignment

(5) Face gap (bottom)

(6) Diameter gap (bottom)

(A) Face Alignment

 (B) Bore Misalignment

1. Laser alignment:

Note: The laser alignment tools typically measure the actual offsets.
The dial indicators measure a total indicator reading (TIR).

Follow the instructions provided by the manufacturer in order to

ensure that the parallel misalignment and the angular misalignment
are within the specifications.

Typically, the laser alignment tools compensate for any axial

movement of the rotor shaft for the generator or the crankshaft. If the
axial shaft moves during the angular measurements, consult the
literature on the laser alignment tool for information.

2. Dial indicators:

If laser alignment tools are not available, the use of dial indicators is
acceptable for alignment. Use the dial indicator with caution because
the following problems will result: the interpretation of
measurements, the compensation of the movement of the axial shaft
and the proper support.

Use the following procedure to operate the dial indicator:

a. Attach a rigid bracket to the hub for the generator in order to

support both of the indicators. Attach one indicator and read
the angular misalignment of the flywheel at the 12 o'clock
position. The indicator "A" is shown in illustration 2. Attach the
second indicator "B" and read the parallel misalignment at the
12 o'clock position.
 Illustration 2 g00565584
(7) Rigid Bracket

(8) Generator

(9) Crankshaft

(10) Indicator (7H1942 or equivalent)

(A) Indicator

(B) Indicator

(C) Indicator

b. During crankshaft rotation, the rotor will extend beyond the

flywheel due to the clearance between the two loose alignment
bolts and the holes. 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. Now, rotate the flywheel
counterclockwise until the rotor starts to turn. If either
indicator records more than a 0.051 mm (0.0020 inch) change in
this short radial distance that was traveled, then 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 you set the indicators
to zero. Rotate the flywheel before you measure at the 3
o'clock, the 6 o'clock, and the 9 o'clock positions.
 Note: The equipment should be at ambient temperature for the
initial cold alignment procedure. The engine will have a larger
thermal expansion than the thermal expansion of the generator.
The thermal expansion is accounted for in the specifications
listed in the ""Alignment Data Sheets" ".

At the 12 o'clock position, set the dial indicators to zero. Rotate

the engine and rotate the generator in the direction of
operation. Record the readings at the 3 o'clock, the 6 o'clock,
and the 9 o'clock positions. Continue to rotate the engine to the
12 o'clock position in order to verify the repeatability.

Whenever the generator is repositioned, the bezel on all four

dial indicators must be reset to zero at the 12 o'clock position.
Always zero the dial indicators at the 12 o'clock position before
repeating the measurements. Repeat the measurements at the
3 o'clock, the 6 o'clock, and the 9 o'clock positions.

The engine or the generator shaft may move axially during the
rotation of the crankshaft. Since this movement is unavoidable,
compensate for the movement in the angular measurements. In
order to record a valid angular measurement, add the axial
travel of the indicator "C" to the reading of the other indicator
"A". Refer to illustration 2. The final result is the true value of
the angular alignment.

Softfoot check:

1. Soft foot is measured with a dial indicator. Mount a dial indicator from
the base assembly to the top of the foot next to the engine block. Be
sure that all the jacking screws are loose. While one foot at a time is
loosened, the deflection of the foot must not change more than 0.076
mm (0.0030 inch). If necessary, add shims in order to eliminate the
soft foot. Repeat the procedure for the soft foot until all the feet are
measured for compliance with specifications. If necessary, add shims
under the feet in order to eliminate gaps. When possible, avoid using
shims under the foot with the slider block. Do not trim the shims. The
addition of shims is required in order to provide equal loading on each
foot. This equalization prevents unnecessary stresses in the welds
and the components.

2. Loosen the mounting bolts for the generator from one foot at a time.
Check for gaps with a feeler gauge. If necessary, add shims under the
feet in order to eliminate gaps. Shims must be added in order to
provide equal loading on each foot. This equal loading prevents
unnecessary stresses in the welds and in the components (soft foot).
 Torque the alignment bolts again. Refer to the generator mounting
group for values of torque.

Split ring installation:

1. Check the positions of the crankshaft and the generator shaft. This
verification will help to center the shafts during operation in the
middle of the 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. For generators
without thrust bearings, the generator must be positioned in the
magnetic center. 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 in order 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 coupling sag, measure with the feeler
gauge at the 90 degree side and the 180 degree side of the coupling.

For generators with an end play of less than 0.102 mm (0.0040 inch),
the end play of the generator may be omitted from the above
procedure. In this case, only centering of the crankshaft is necessary.

During the operation of the engine, monitor the temperatures of the

generator bearings. Compare the temperature to the limits specified
by the generator manufacturer. If the temperatures are higher than
the limits, repeat the procedure for centering the generator and the
crankshaft.

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.

Final alignment check:

1. A final check of the alignment must be performed in order to meet the

specifications for the final alignment.

For the specifications of the final alignment, the parallel misalignment

for the vertical offset (12 o'clock to 6 o'clock) must be within 0.076 ±
0.076 mm (0.0029 ± 0.0029 inch). The parallel misalignment is
measured as the bore with the indicator "B". The parallel
misalignment for the horizontal offset (3 o'clock to 9 o'clock) must be
within 0.000 ± 0.127 mm (0.0000 ± 0.0050 inch).

Note: The equipment must be up to full operating temperature before

you complete the final alignment. The alignment must be completed
before the equipment cools off. Any cooling of the equipment will
possibly give false alignment readings due to thermal contraction.

For the specifications of the final alignment, the angular misalignment

must be within 0.000 ± 0.102 mm (0.0000 ± 0.0040 inch) at the 6
o'clock position. Apply this tolerance to the values that are measured
between the 3 o'clock position and the 9 o'clock position.

Illustration 3 g00565623
(11) Edge of housing

(12) Feeler Gauge

(13) Housing

(14) Generator

(15) Notch

(16) Rotor

(A) Detail A
2. Assemble all the following assemblies: screens, the covers and the
guards.

3. After the engine has reached operating temperatures, check the

levels of vibration in the following locations:
o the front of the engine (vertical and horizontal)
o the rear end of the engine (vertical, horizontal, and axial)
o the front of the generator (vertical and horizontal)
o the rear of the generator (vertical, horizontal, and axial)

The following limits of vibration are for the 3600 generator set
applications:

o Peak to peak displacement limit at 1/2 order frequency = 0.13

mm (5.0 mils)
o Peak to peak displacement limit at the first order frequency =
0.13 mm (5.0 mils)
o Overall displacement = 0.22 mm (8.5 mils)
o Overall velocity = 34.3 mm/s (1.35 in/s)

Levels of vibration in excess of these limits are an indication of

possible misalignment or of an imbalance in the package. These
issues must be addressed immediately.

If the levels of vibration exceed the limits, consult the Caterpillar

dealer, or consult the factory.

Refer to the Caterpillar Engine Data Sheet, LEKQ4023 for additional

information on the following items: linear measurements of vibration,
limits and corrective actions.

4. After the generator set has run for 200 hours to 500 hours, check the
alignment. If the alignment is not within the final specifications,
realign the engine. Run the engine for 200 hours to 500 hours, and
check the alignment again. Continue this procedure until the
alignment is within the final specification. If the alignment is within
the final specification, dowel the generator in accordance with the
generator mounting group:
o Drill the holes to a diameter of 25.37 ± 0.02 mm (0.9908 ±
0.0007 inch) and to a depth of 80 mm (3.15 inch).
o Ream the holes to a diameter of 25.405 mm (1.0002 inch).
o Assemble the dowels. The standard size 2W-2988 Dowel
measures 25.405 mm (1.0002 inch). The oversize 4W-
5222 Dowel measures 28.626 mm (1.1270 inch). The other
oversize 4W-5223 Dowel measures 31.801 mm (1.2520 inch).
 Note: The engine and the generator must be doweled on the identical
side in order to fix a single direction for thermal growth of the
equipment.

Alignment Data Sheets

Table 1
Generator Set Alignment Data Sheet
Generator
Project: Engine Shipping Order
Manufacturer

Alignment tolerances are measured with cold equipment. At operating temperature, the
offset is zero.
Rough Specifications Without Split Flange
Dial Indicator
Laser Tool Finished
Measurement (Total Indicator
(Actual) Uncoupled
Reading)

Vertical Offset 0.457 ± 0.127

0.914 ± 0.254 mm
(1)
mm (0.0179 ± 0.0050
(0.0359 ± 0.0100 inch)
inch)

0.000 ± 0.254 mm
Horizontal Offset 0.000 ± 0.508 mm
(0.00000 ± 0.0100
(0.0000 ± 0.0200 inch)
inch)

Vertical Angularity 0.000 ± 0.127 mm

0.000 ± 0.254 mm
(2)
(0.00000 ± 0.0050
(0.0000 ± 0.0100 inch)
inch)

Horizontal 0.000 ± 0.127 mm

0.000 ± 0.254 mm
Angularity (0.00000 ± 0.0050
(0.0000 ± 0.0100 inch)
inch)
Final Specifications With Split Flange
Dial Indicator
Laser Tool
Measurement (Total Indicator Final (Coupled)
(Actual)
Reading)
Vertical Offset
0.076 ± 0.076 mm 0.152 ± 0.152 mm
 (0.0029 ± 0.0029
(0.0059 ± 0.0059 inch)
inch)

0.000 ± 0.127 mm
Horizontal Offset 0.000 ± 0.254 mm
(0.00000 ± 0.0050
(0.0000 ± 0.0100 inch)
inch)

0.000 ± 0.102 mm
Vertical Angularity 0.000 ± 0.204 mm
(0.00000 ± 0.00402
(0.0000 ± 0.0080 inch)
inch)

Horizontal 0.000 ± 0.102 mm

0.000 ± 0.204 mm
Angularity (0.00000 ± 0.00402
(0.0000 ± 0.0080 inch)
inch)
Front Right Foot

Generator Shim Rear Right Foot

Thickness Front Left Soot
Rear Left Foot

Engine and Engine (mm)

Generator End Play Generator (mm)
Engine and Generator Mid-position Verified By
Engine and Generator Soft Foot Check Verified By
Date Operator
Transducer to prism distance
Transducer to front foot distance
Lesser Alignment
Front to rear mounting foot dimension
Only
Center of coupling to prism distance
Coupling Diameter
(1)
Due to a coupling stiffness difference use the following targets for vertical offset: Inline Engines 0.457 mm
(0.018 inch) and Vee Engines 0.584 mm (0.023 inch). If these specifications are not used, the final
alignment specification may not be met.
(2)
The angularity values are provided for a measurement of offset of a 254 mm (10 inch) diameter, If
measurements are taken of a radius other than 254 mm (10 inch), correct the measurements to a diameter
of 254 mm (10 inch).
Crankshaft Deflection Data Sheet

Table 2
 Crankshaft Deflection Data Sheet
Generator
Project Engine Shipping Order
Manufacturer

Crankshaft Deflection Front Middle Rear

Specifications for first 300 degrees of

0.18 mm 0.08 mm 0.18 mm (0.007
rotation (Total Indicator Reading)
(0.007 inch) (0.003 inch) inch)

Specifications after returning to start 0.00 mm

0.00 mm 0.00 mm
(Total Indicator Reading) (0.00000
(0.00000 inch) (0.00000 inch)
inch)
Connecting Rod
Sales Model Rear Driven
Journal
3
3606
6
4
3608
8
5
6
3612
11
12
7
8
3616
15
16
Connecting Rod
Sales Model Front Driven
Journal
4
3606
1
5
3608
1
3612 5
 6
1
2
7
8
3616
1
2
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