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Disassembly and Assembly

SR4B Generators
Media Number -SENR5359-13 Publication Date -01/10/2014 Date Updated -10/10/2014

i06188920

Coupling - Remove
SMCS - 4456-011

Two Bearing Flexible Coupling Removal

Start By:

A. Remove the terminal box and generator if needed. Refer to Systems Operation Testing and Adjusting
Disassembly and Assembly, SENR5359, "Generator - Remove" for a generic description to remove the
terminal box and generator.

Note: The coupling may be serviced without the complete removal of the generator if desired. The generator can
be pushed rearward on the generator set base rail. After the generator is pushed away from the engine, there
should be enough clearance to service the coupling if desired.

Remove the Rubber in Shear Type of Coupling

Note: The flexible coupling does not require disassembly when removing the generator. The inner flexible
element will slide out of the outer coupling ring as the generator is pushed away from the engine.

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Illustration 1 g01578214
Rubber in Shear Type Coupling

(1) Outer Ring

(2) Rubber Flexible Element

(3) Hardness Specification

1. Remove the outer ring mounting bolts for the coupling. If necessary, remove the outer ring of the coupling
from the engine flywheel.

Note: Care must be taken in the process of removing the ring. The ring may need to be pried off.

2. Remove the mounting bolts for the inner member of the coupling. Carefully pry the rubber flexible
element flange of the coupling from the generator hub.

Note: The coupling flexible element components weigh approximately 22.7 kg (50 lb). The outer ring
weight is approximately 5 kg (11 lb).

Generator Drive Hub Removal

NOTICE
Care must be taken to avoid damage to the main rotor shaft of the
generator.

Note: The drive hub is a heavy shrink fit installation. If the hub cannot be removed by heating, then the
destructive method may be used.

The following procedure is written to provide information for the removal and installation of the drive hub (10)
for the SR4 generators. The following procedure applies to two bearing generators.

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Illustration 2 g03327768
(10) Drive hub machined face

(11) Main rotor shaft

Always wear protective gloves when handling parts that have been
heated.

The exact process and tooling for each application may vary. That is, the process that is documented in this
publication was performed on a generator that was removed from the engine. If the generator is left on the
generator base rails for servicing, the working distance will determine the puller assembly that can be used.

Even if the generator is moved away from the engine as far as possible, but left on the generator base rails, the
working distance may not provide enough working space for the puller that is written about in this publication.

Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools
in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are
not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every
possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If tools
or procedures not recommended by Caterpillar are used, ensure that all of the tools and procedures are safe to
use.

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Ensure that the product will not be damaged or become unsafe due to the use of tools or procedures not
recommended by Caterpillar.

The following warning must be heeded due the flames, gas, and heat of the process.

Personal injury or death can result from fumes, gases and ultraviolet
rays from the weld arc.

Welding can cause fumes, burn skin and produce ultraviolet rays.

Keep your head out of the fumes. Use ventilation, exhaust at the arc, or
both, to keep fumes and gases from your breathing area. Wear eye, ear
and body protection before working.

Protect yourself and others; read and understand this warning. Fumes
and gases can be dangerous to your health. Ultraviolet rays from the
weld arc can injure eyes and burn skin. Electric shock can cause death.

Read and understand the manufacturer's instructions and your

employer's safety practices. Do not touch live electrical parts.

See "American National Standard Z49.1, Safety in Welding and

Cutting" published by the American Welding Society.

American Welding Society

2501 N.W. 7th Street
Miami, Florida 33125

See "OSHA Safety and Health Standards, 29 CFR 1910", available

from U.S. Department of Labor.

U.S. Department of Labor

Washington, D.C. 20210

Specifications
The drive hub is considered to be a "heavy shrink" fit installation.

The 9S-8900 Double Acting Cylinder produces 311 N (70,930 lbs) of rod out force at rated 68.95 kPa (10,000
psi) input.

Note: Important. The hydraulic cylinder MUST have enough stroke to remove the drive hub without stopping
once the drive hub breaks free of the rotor shaft. The stroke must be 152.4 mm (6 inch) to 203.2 mm (8 inch).

Recommendation
Due to the heat that is involved with the following process, the internal diameter of the drive hub can become
warped. If the original drive hub is to be reused, the inside diameter of the drive hub must be checked. The
inside diameter must be checked to verify if the inside diameter of the drive hub is true and round. The drive hub

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ID must maintain the original shrink fit. Caterpillar suggests that a new drive hub should be installed in place of
the original.

Tooling
A fire extinguisher that is ready to be used

High heat gloves

Appropriate eye and (full) face protection

Welding jackets for arm protection

9S-8900 Double Acting Cylinder (152.4 mm (6 inch) to 203.2 mm (8 inch) of travel are necessary to
remove the drive hub from the rotor shaft completely)

5P-2180 Puller (The 5P-2180 was modified with six new holes. The new holes match the bolt hole pattern
of the SR5 drive hub.)

3S-6224 Electric Hydraulic Pump Gp (115 V)

An appropriate lifting device that can support the weight of the drive hub, the adaptor, and the hydraulic
assembly. (The drive hub weights approximately 70 lbs.)

Optional - A weld blanket or heat shield to protect the front bracket from the heat of the rose bud tips

Link assemblies (possibly used to support the drive hub during removal and installation)

251-0030 Infrared Thermometer

Oxygen and acetylene tanks and associated equipment (hoses, gages, flint spark lighter, and tips)

Note: If available, propylene gas can be used in place of acetylene. Propylene gas has the capability of being a
hotter gas than acetylene. Propylene gas can heat the drive hub to the necessary temperature in less time, which
allows less heat transfer to the rotor shaft.

Preparation
1. Two qualified people are required to perform the process, three are preferred. Two people are needed to
heat the drive hub while the third person operates the puller.

2. Prepare two torches equipped with "rose bud" tips. There must be enough oxygen and acetylene available
to operate both tips for approximately 20 minutes.

3. A 120 VAC supply will be needed to operate the power pack for the hydraulic cylinder that is used for the
puller.

Note: The 9S-8900 cylinder produces 311 N (70,930 lbs) of rod out force at rated 68.95 kPa (10,000 psi) input.

Drive Hub Position

Make note of the position of the original drive hub (10) that is on the rotor shaft. The important dimension is
measured from the face of the drive hub flange (20) to the (machined) face (21) of the adaptor. If a new drive
hub is used, ensure that dimension "A" is the same as the original drive hub.
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Illustration 3 g02163823
Typical generator example

(20) Adaptor face

(21) Drive hub face

Tables 1, 2, and 3 shows the variety of drive hub locations for different serial numbers and applications.

Note: If there is a difference between the original measured distance of the drive hub from the face of the rotor
shaft and the information that is in Table 1, use the measured distance for your application.

Table 1
SR4 Generators
Type Model Generator serial Is the drive
number prefix hub keyed? Drive hub location
SR4
683 5RA no 46.23 mm (1.82 inch) from end of shaft.
SR4
687 5VA no 46.23 mm (1.82 inch) from end of shaft.
SR4
804 8ZD no Flush with shaft end.
SR4
807 5ZA no Flush with shaft end.
SR4
807 3WF yes Flush with shaft end.

SR4 23.9 mm (0.941 inch) from hub bolt face to close

808 2ED yes coupled adapter mounting bolt face.

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SR4 808 2ED yes

23.9 mm (0.941 inch) from hub bolt face to close
coupled adapter mounting bolt face.

SR4 23.9 mm (0.941 inch) from hub bolt face to close

808 8ZL yes coupled adapter mounting bolt face.

SR4 39.37 mm (1.55 inch) from machined face to end of

809 6LA no shaft.

SR4 39.37 mm (1.55 inch) from machined face to end of

809 6LA no shaft.

SR4 23.9 mm (0.941 inch) from hub bolt face to close

809 8FD yes coupled adapter mounting bolt face.

SR4 23.9 mm (0.941 inch) from hub bolt face to close

809 2SM yes coupled adapter mounting bolt face.
SR4
809 4MD no Flush with shaft end.
SR4
812 6WR no Flush with shaft end.

SR4 39.37 mm (1.55 inch) from machined face to end of

812 3BZ no shaft.

SR4 39.37 mm (1.55 inch) from machined face to end of

812 4SZ no shaft.

SR4 39.37 mm (1.55 inch) from machined face to end of

815 8MM no shaft.
SR4
815 3RD no Flush with shaft end.

SR4 23.9 mm (0.941 inch) from hub bolt face to close

815 8MM yes coupled adapter mounting bolt face.

Table 2
SR4B Generators
Is the drive
Type Model hub
Generator serial number prefix keyed? Drive hub location

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SR4B- 690 G5L, G5M, G5K, G5B, G5N, G4X, G5C, no

GD G5R, G4S, G5D, G5S 49.784 mm (1.96 inch) from
end of shaft to hub bolt
circle.

3EN, 3FN, 3HN, ABH, 2GM, 2DN, 4WN,

SR4B 46.228 mm (1.82 inch) from
690 ABM, 3BM, 2DM, 6SN, ABY, 4DM, 2FN, no
end of shaft to hub bolt
7DN, ACA
circle.

2HN, AAY, AAD, A4A, AAR, AAJ, 1HN,

SR4B 46.228 mm (1.82 inch) from
820 2SN, 7TN, AEB, 4GN, 9CN, AEZ, 2GZ, 8XS no
end of shaft to hub bolt
circle

SR4B- G6X, G6S, G6W, G6T, G5J, G5Z, G4Z, G5J, 46.228 mm (1.82 inch) from
820 no
GD G5A, G6C, G6R, G6F end of shaft to hub bolt
circle.

SR4B 8LZ, 6ZZ, 9GZ, 8PZ, 8TZ, 9DZ, 9WZ, 9XZ, 46.228 mm (1.82 inch) from
860 no
9MZ, 9RZ end of shaft to hub bolt
circle.

Table 3
SR4BHV Generators
Is the
Model Generator serial number drive hub
Type prefix keyed? Drive hub location

AEY, AAL, AES, ABA,

SR4BHV 2400 24.64 ± 0.76 mm (0.97 ± 0.03 inch) from
ABG, AEL, AEG, ACG, yes
hub bolt face to close coupled adapter
AEA, ACN, ACZ
mounting bolt face.

SR4BHV 2600 A5A, A4Z, A4Y, A4X, PCP

G3N, G3R, G3S, G3T, G3W,
SR4BHV 2700
G3X, G3Y, KHD, G4A, G4B
yes 25.4 mm (1 inch) from hub bolt face to
close coupled adapter mounting bolt face.
yes 25.4 mm (1 inch) from hub bolt face to
close coupled adapter mounting bolt face.

SR4BHV 2800 ABE, ADJ, ABT, ACB, ADB 24.64 ± 0.76 mm (0.97 ± 0.03 inch) from
yes
hub bolt face to close coupled adapter
mounting bolt face.

Drive Hub Removal

1. Separate the generator from the engine if needed. Refer to Systems Operation Testing and Adjusting
Disassembly and Assembly, SENR5359, "Generator - Remove" for a generic description to remove the
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terminal box and generator.

2. Install the adaptor, puller assembly, and safety chains. Refer to Illustration 4.

Illustration 4 g02163830
Typical example of modified tooling used for hub removal
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3. Ensure that all of the mounting bolts for the adaptor are installed equally. The adaptor MUST be installed
parallel to the drive hub. Proper installation will ensure that the load is distributed evenly between the
mounting bolts. Proper installation will ensure that the puller assembly pulls evenly on the drive hub.

a. Ensure that the hydraulic cylinder is fully retracted.

b. Keep the puller assembly aligned with the drive hub and rotor shaft.

c. Ensure that the puller assembly is supported by an appropriate lifting device.

4. Apply pre-load pressure to the puller assembly to allow the assembly to remain in place prior to heating
the drive hub. 20.7 kPa (3,500 psi) input was used. Therefore, the puller was producing approximately
106.8 N (24,825 lbs) of rod out force.

5. Check that the puller assembly is aligned and safe.

6. If desired, install a weld blanket or heat shield to protect the front bracket, rotor shaft, shaft lip seal, and
bearing from excessive heat.

7. From opposite sides of the adaptor, simultaneously begin to heat ONLY the backside of the drive hub at
the base of the flange. Apply the heat as evenly as possible by constantly moving the rose bud tips around
the drive hub. Refer to Illustration 5.

Note: Keep heat away from the hydraulic cylinder of the puller and away from the generator rotor shaft.

Illustration 5 g02163877

8. Ensure that the pressure on the drive hub remains constant.

9. The drive hub should break free of the rotor shaft in approximately 4 to 8 minutes.

Note: The time variation depends on the ambient temperature, the shrink fit of the hub, how well the heat
is evenly applied, and the amount of heat that is applied to the drive hub.

Note: The external temperature of the drive hub will exceed 315° C (600° F) to 371° C (700° F).
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10. Once the hub breaks free of the rotor shaft, continue to heat the hub and continue to apply pressure
with the puller until the hub is removed from the rotor shaft completely.

Note: If the heat is removed prematurely or if the hub motion is stopped before the hub is removed
completely, the hub will adhere to the rotor shaft. Damage is likely to occur to both components.

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