3512 Generator Set Engine 67Z00772-UP(SEBP2640 - 43) - Product Structure

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Product: GEN SET ENGINE Model: 3512 GEN SET ENGINE 67Z Configuration: 3512 Generator Set Engine 67Z00772-UP

Special Instruction
Alignment Of The Close Coupled Two-Bearing Generators{4450}
Media Number -REHS0177-02 Publication Date -01/03/1999 Date Updated -16/11/2001

i01102607

Alignment Of The Close Coupled Two-Bearing Generators {4450}

SMCS - 4450-024 Engines: 3508 (S/N: 1ZF; 23Z; 70Z) G3508 (S/N: 4WD; 2JF; 9TG) 3508B (S/N: 3DM; 4GM; 6PN) 3512 (S/N: 3YF; 24Z; 67Z) G3512 (S/N: 4KC; 5JD; 7NJ) 3512B (S/N: 8EM; 8RM; 6WN) 3516 (S/N: 4XF; 5SJ; 25Z; 73Z) G3516 (S/N: 3RC; 8LD; 4EK) 3516B (S/N: 6HN; 7RN; 9AN)

Introduction
This special instruction explains the installation procedure for 3500 engines with the close coupled type of two-bearing generators. This special instruction will also explain the alignment procedure. 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 that are needed. Alignment between the generator and the engine must be correct to get the maximum performance and the longest life from the generator set.

Close Coupled Two-Bearing Generators

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Illustration 1 g00294234 This is an Illustration of a close coupled two-bearing generator. (1) Engine. (2) Two-Bearing Generator. (3) Adapter Housing. (4) Crankshaft End Play. (5) Shims. (6) Generator Mounts. (7) Engine Mounts.

Close coupled two-bearing generators use a piloted adapter housing between the generator housing and the flywheel housing to determine alignment. The alignment is controlled by the bolting together of these housings. Take care not to introduce stresses that are caused by the incorrect installation of the generator on the engine. Stresses can be introduced in the following ways: Incorrect End Clearance Incorrect Mounting Of The Generator To The Base When you are mounting the generator to the base, the surfaces of the generator's mount on the base must be flat. The surfaces must also lie in the same plane. Use shims between the generator's mounts and the base to put the generator and the adapter housing in correct vertical alignment with the flywheel housing. All of the generator's mounts must be in solid contact with the base before the installation of the anchor bolts. If the mounts are not in solid contact, distortion of the generator housing, the adapter housing and/or flywheel housing can result.

Alignment Of The Close Coupled Two-Bearing Generator

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Illustration 2 g00463540 (A) The flywheel housing and the driven equipment's housing must be parallel within 0.025 mm (0.001 inch) to 0.127 mm (0.005 inch).

If you are installing a new flexible coupling or a generator, bolt the flexible coupling assembly to the flywheel. Support the generator with a crane. Bring the close coupled adapter's mounting surface completely up to the flywheel housing's mounting surface. Tighten the bolts that fasten the hub to the flexible coupling. Tighten the sixteen close coupled adapter bolts to the half of the torque. While the generator is supported by the crane, install the shims underneath the mounts. Loosen the generator from the crane. Tighten the bolts on the mounts to half of the standard torque. Loosen the sixteen close coupled adapter's bolts. Ensure that the bolts are visually centered in the clearance holes. Check the gap between the mounting faces of the close coupled adapter and the flywheel housing. The gap should be checked at the three o'clock position, the six o'clock position, the nine o'clock position, and the twelve o'clock position. This gap should be between 0.03 mm (0.001 inch) and 0.13 mm (0.005 inch). Adjust the number of shims that are under the generator's mount if the gap is not correct. Ensure that the sixteen close coupled adapter's bolts are visually centered in the clearance holes. Repeat the procedure. This outlines the actions that are necessary for a realignment in the field. It is possible that the alignment could have been altered from the original alignment due to the handling during shipment and different mounting conditions. It is necessary to check the alignment after the set has been placed in the permanent position in order to minimize any possible stresses from installation. 1. Loosen the sixteen close coupled adapter bolts (5). Visually ensure that these bolts are centered in the clearance holes. 2. Check the gaps at the three o'clock, the six o'clock, the nine o'clock, and the twelve o'clock positions. Note: The two o'clock, four o'clock, eight o'clock, and ten o'clock positions will be adequate if the twelve o'clock, and six o'clock positions are inaccessible. 3. If the gaps are between 0.03 mm (0.001 inch) and 0.13 mm (0.005 inch), tighten all of the bolts. The alignment check is complete. If any of the gaps are not within the correct range, loosen the bolts that fasten the generator to the base frame. If necessary, adjust the amount of shims under each mount. It may be necessary to move the rear of the generator to the right or

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left. The direction will depend on the gaps at the three o'clock and nine o'clock positions. 4. After any adjustment of the generator's position, tighten the generator mounting bolts to one half of the standard torque 450 Nm (332 lb ft). Repeat the procedure starting with Step 1.

Illustration 3 g00463543 This is an Illustration of the 104-6203 Generator Installation . (1) The Generator Mounting Bolts should be tightened to a torque of 900 Nm (660 lb ft). (2) Generator Housing. (3) Jacking Screws. (4) The bolt should be tightened to a torque of 200 Nm (150 lb ft). (5) The bolt should be tightened to a torque of 100 Nm (75 lb ft). (6) Rear Face Of The Flywheel Housing. (7) Rail For Support. (8) The bolt should be tightened to a torque of 620 Nm (460 lb ft). (9) Flywheel Housing.

Once the gaps are within the acceptable values, the bolts should be torqued to the specifications in Illustration 3. After all of the bolts have been torqued, check the end play in the crank. Ensure that the end play in the crank is equal to the amount of end play before the generator's installation. If necessary, adjust the position of the hub on the generator shaft to the correct crankshaft end play.

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