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Product: GAS ENGINE


Model: G3612 GAS ENGINE BKE00809
Configuration: G3612 GENERATOR AND INDUSTRIAL BKE00001-UP

Testing and Adjusting


G3600 Engines
Media Number -RENR5908-13 Publication Date -05/01/2011 Date Updated -03/01/2017

i04230952

Basic Block
SMCS - 1200

Connecting Rod Bearings


The connecting rod bearings fit tightly in the bore in the rod. If the bearing joints are fretted, check
the bore size. Fretting can be an indication of wear because of a loose fit.

Connecting rod bearings are available with 0.50 mm (.020 inch) and 1.00 mm (.040 inch) smaller
inside diameter than the original size bearing. These bearings are for crankshafts that have been
ground.

Main Bearings
Main bearings are available with a larger outside diameter than the original size bearings. These
bearings are available for the cylinder blocks with the main bearing bore that is larger than the
original size.

Main bearings are available with 0.50 mm (0.020 inch), 1.00 mm (0.040 inch), and 2.0 mm
(0.080 inch) larger outside diameter than the original bearing.

The main bearings are also available with a 0.25 mm (0.010 inch) and 1.00 mm (0.040 inch) smaller
inside diameter than the standard bearing. Main bearings are also available with smaller inside
diameter of 0.50 mm (0.020 inch).

Cylinder Block

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If the main bearing caps are installed without bearings, the bore in the block for the main bearings can
be checked. Tighten the nuts that hold the caps to the torque that is shown in the Specifications.
Alignment error in the bores must not be more than 0.040 mm (.0016 inch). Refer to the Special
Instruction, SMHS7606 for the use of the 1P-4000 Line Boring Tool Group for the alignment of the
main bearing bores. The 1P-3537 Dial Bore Gauge Group can be used to check the size of the bores.
The Special Instruction, GMGO0981 is with the group.

Illustration 1 g00285686
1P-3537 Dial Bore Gauge Group

Flywheel and Flywheel Housing


Table 1
Tools Needed Quantity
8T-5096 Dial Indicator Group 1

Face Runout (Axial Eccentricity) of the Flywheel Housing

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Illustration 2 g00285931
8T-5096 Dial Indicator Group

If you use any other method of checking the face runout, remember that the bearing clearance must be
removed. Remove the clearance in order to get the correct measurements.

1. Fasten a dial indicator to the flywheel so the anvil of the dial indicator will contact the face of
the flywheel housing.

2. Put a force on the crankshaft toward the rear before the dial indicator is read at each point.

Illustration 3 g00285932
Checking face runout of the flywheel housing

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NOTICE

The engine must be prelubed before the crankshaft is rotated. Damage


can result if the crankshaft is rotated on dry bearing surfaces.

3. Turn the flywheel while the dial indicator is set at 0.0 mm (.00 inch) at location (A). Read the
dial indicator at locations (B), (C, and) (D).

4. The difference between the lower measurements and the higher measurements that are
performed at all four points must not be more than 0.38 mm (.015 inch), which is the maximum
permissible face runout (axial eccentricity) of the flywheel housing.

Bore Runout (Radial Eccentricity) of the Flywheel Housing

Illustration 4 g00285934
8T-5096 Dial Indicator

1. Fasten a dial indicator to the flywheel so the anvil of the dial indicator will contact the bore of
the flywheel housing.

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Illustration 5 g00285936

2. While the dial indicator is in the position at location (C), adjust the dial indicator to 0.0 mm
(.00 inch). Push the crankshaft upward against the top of the bearing. Refer to the illustration 5.
Write the measurement for bearing clearance on line 1 in column (C).

Note: Write the measurements for the dial indicator with the correct notations. This notation is
necessary for making the calculations in the chart correctly.

3. Divide the measurement from Step 2 by two. Write this number on line 1 in columns (B) and
(D).

NOTICE

The engine must be prelubed before the crankshaft is rotated. Damage


can result if the crankshaft is rotated on dry bearing surfaces.

4. Turn the flywheel in order to put the dial indicator at (A). Adjust the dial indicator to 0.0 mm
(.00 inch).

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Illustration 6 g00285932
Checking bore runout of the flywheel housing

5. Turn the flywheel counterclockwise in order to put the dial indicator at (B). Write the
measurements in the chart.

6. Turn the flywheel counterclockwise in order to put the dial indicator at (C). Write the
measurement in the chart.

7. Turn the flywheel counterclockwise in order to put the dial indicator at (D). Write the
measurement in the chart.

8. Add the lines together in each column.

9. Subtract the smaller number from the larger number in column B and column D. Place this
number on line III. The result is the horizontal eccentricity (out of round). Line III in column C
is the vertical eccentricity.

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Illustration 7 g00286046
Graph for total eccentricity
(1) Total vertical eccentricity
(2) Total horizontal eccentricity
(3) Acceptable value
(4) Unacceptable value

10. On the graph for total eccentricity, find the point of intersection of the lines for vertical
eccentricity and horizontal eccentricity.

11. If the point of intersection is in the range marked “Acceptable”, the bore is in alignment. If the
point of intersection is in the range marked “Not acceptable”, the flywheel housing must be
changed.

Face Runout (Axial Eccentricity) of the Flywheel

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Illustration 8 g00286049
Checking face runout of the flywheel

1. Refer to illustration 8 and install the dial indicator. Always put a force on the crankshaft in the
same direction before the dial indicator is read. The force will remove any crankshaft end
clearance.

2. Set the dial indicator to read 0.0 mm (.00 inch).

NOTICE

The engine must be prelubed before the crankshaft is rotated. Damage


can result if the crankshaft is rotated on dry bearing surfaces.

3. Turn the flywheel at intervals of 90 degrees and read the dial indicator.

4. Take the measurements at all four points. Find the difference between the lower measurements
and the higher measurements. This value must not exceed the maximum permissible face
runout (axial eccentricity) of the flywheel.

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Bore Runout (Radial Eccentricity) of the Flywheel

Illustration 9 g00286054
Checking bore runout of the flywheel
(1) 7H-1945 Holding Rod
(2) 7H-1645 Holding Rod
(3) 7H-1942 Dial Indicator
(4) 7H-1940 Universal Attachment

1. Install the 7H-1942 Dial Indicator (3). Make an adjustment of the 7H-1940 Universal
Attachment (4) so that the dial indicator makes contact on the flywheel.

2. Set the dial indicator to read 0.0 mm (.00 inch).

NOTICE

The engine must be prelubed before the crankshaft is rotated. Damage


can result if the crankshaft is rotated on dry bearing surfaces.

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3. Turn the flywheel at intervals of 90 degrees and read the dial indicator.

4. Take the measurements at all four points. Find the difference between the lower measurements
and the higher measurements. This value must not exceed the maximum permissible bore
runout (radial eccentricity) of the flywheel.

Illustration 10 g00286058
Flywheel clutch pilot bearing bore

5. Take the measurements at all four points. Find the difference between the lower measurements
and the higher measurements. This value must not exceed the maximum permissible pilot bore
runout of the flywheel.

Checking Crankshaft Deflection (Bend)


The crankshaft can be deflected if the engine was not installed correctly. If the engine mounting rail is
not fastened correctly to the foundation mounting rail, the cylinder block can twist or the cylinder
block can bend. The deformation will cause the crankshaft to deflect. This deflection can cause
crankshaft failure and bearing failure.

The crankshaft deflection must be checked after the final installation of the engine. The following
procedure can be used to check the crankshaft deflection.

1. Remove an inspection cover from the cylinder block that will give access to the connecting rod
journal. This inspection cover should be nearest to the center of the engine. This check must be
made at the center connecting rod journals.

NOTICE

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The engine must be prelubed before the crankshaft is rotated. Damage


can result if the crankshaft is rotated on dry bearing surfaces.

2. Turn the crankshaft in the direction of normal rotation until the center of the counterweights
barely go beyond the connecting rod.

3. When the counterweight is not available on both sides, install a 2B-7218 Bolt with a 1B-4333
Nut or 2J-3507 Full Nut in the crankshaft. Tighten the nut against the crankshaft. The bolt and
the nut are used to provide a locating face.

4. Install a Starrett Crankshaft Distortion Dial Gauge No. 696 with a Starrett No. 696B between
the bolt and the counterweight. Put the dial indicator within 10 mm (.39 inch) of the end of the
counterweight. Turn the dial of the dial indicator in order to align the zero with the pointer.
Turn the dial indicator on the end points until the pointer of the dial indicator will not move
from zero.

5. Turn the crankshaft in the direction of the normal rotation until the dial indicator almost
contacts the connecting rod. This connecting rod is on the other side of the crankshaft.

Note: Do not allow the dial indicator to contact the connecting rod.

6. The dial indicator reading must not change more than 0.080 mm (.0032 inch) for the
approximate 300 degrees of crankshaft rotation. Now turn the crankshaft in the opposite
direction to the starting position. The dial indicator must now read zero. If the dial indicator
does not read zero, do the procedure again.

If the dial indicator read more than 0.080 mm (.0032 inch), the cylinder block is distorted. Loosen the
bolts that hold the engine mounting rails to the foundation mounting rails. Adjust the shims in order to
make the engine straight again. Ensure sufficient clearance for the engine mounting bolts in order to
allow the engine to expand as the engine gets hot.

Engine Alignment
Engine alignment with the driven equipment should be checked at scheduled maintenance intervals.
Refer to the engine Operation and Maintenance Manual .

Refer to the following alignment specifications:

Crankshaft end play ... 0.40 ± 0.20 mm (0.016 ± 0.008 inch)

Maximum allowable softfoot ... 0.08 mm (0.0031 inch)

Maximum allowable parallel offset or bore offset ... 0.127 mm (0.0050 inch)

Maximum allowable axial offset or face offset ... 0.178 mm (0.0070 inch)

Maintain proper tension on the engine mounting feet to base bolts at all times. The torque must be
checked every 1000 hours. Refer to following service manuals for more information: Special

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Instruction, REHS0423, "Alignment Of Two-Bearing Generators", Application & Installation Guide ,


LEBW4975, "Alignment" and Application & Installation Guide , LEBW4974, "Mounting".

Vibration Damper
Damage to the damper or failure of the damper will increase vibrations. The vibration will result in
damage to the crankshaft.

Replace the damper if the damper is bent or damaged. Replace the damper if the bolt holes are
oversize. Replacement of the damper is also needed at the time of a crankshaft failure due to torsional
forces.

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