Usage:
D330C (2B, 4B),
3304 (2B4364, 4B6032),
D333 (58B, 79B, 87B, 34F),
D333C (66D),
G333C (68D),
3306 (66D8891, 68D),
D334 (92B),
D336 (55B),
D342 (31B, 49B),
G342 (71B),
D343 (62B),
G343 (97N),
3406 (90U),
3408 (67U),
3412 (38S),
D346 (39J),
D348 (36J),
G348 (92R),
D349 (61P),
G349 (93R),
D353 (46B, 77B),
G353 (64B),
D379 (68B, 76B),
G379 (72B),
D398 (66B, 75B),
G398 (73B),
D399 (35B),
G399 (49C)
This instruction shows the installation and alignment procedure for electric sets with single-bearing generators. Do not start the alignment procedure until the electric set is permanently installed. If the electric set is moved to a different location, check the alignment and make any corrections necessary. The alignment between the generator and the engine must be correct to get maximum performance and long life from the electric set.
Installation Of The Generator
(1) Remove all dirt, burrs and paint from the contact surfaces of the generator supports and the base. Remove the protection material (compound) from the flywheel pilot bore (A) and from the surface (B) that makes contact with the coupling. All contact surfaces of the engine, coupling and generator must be completely clean.
(2) Remove the timing pointer cover from the flywheel housing. Install indicator group (1) as shown on the front of the engine with the tip of the indicator on the face of crankshaft pulley (2). Use a bar between the flywheel and flywheel housing to push the crankshaft toward the flywheel to remove all end play. Put the dial indicator in the "zero" position. Move the crankshaft to its most forward position, and make a record of the Total Indicator Reading (TIR). The TIR is the end play of the crankshaft.
(3) Put plate assembly (3) in position in the bore of the flywheel to check for clearance. There must be clearance between the outside diameter of plate assembly (3) and the inside diameter of the bore in the flywheel. CAUTION: Damage to the engine and/or generator can be the result if the electric set is run with a plate assembly that does not have this clearance.
(4) Install a full shim pack (4) and plate assembly (3) on the generator with bolts (5). On D379, G379, D398, G398, D399 and G399 engines, tighten bolts (5) to a torque of 370 ± 35 lb.ft. (505 ± 45 N·m). On all other engines, tighten bolts (5) to the standard torque.
NOTE: The total thickness of shims (4) must be enough to cause a reduction in the crankshaft end play (as measured in step 2) but not enough to bend plate assembly (3) when the generator is installed.
(5) Install guide bolt (6) in the flywheel. Put the generator in position on the engine, and install bolts (7) and (8). Tighten bolts (7) and (8) but do not bend the locks under bolts (8) at this time.
(6) Use dial indicator (1) to check crankshaft end play (do not use force to hold the crankshaft in position). Remove the generator. Remove only enough shims (4) to get the original amount of end play as shown in step 2.
(7) Install the generator and again check the crankshaft end play. After the correct amount of shims has been installed, bend the locks under bolts (8).
(8) Install but do not tighten all bolts (9) that fasten generator supports (10) to the base. Align the generator to the engine as shown on page 6 for electric sets without supports at the flywheel housing or page 8 for electric sets with supports at the flywheel housing.
Alignment Of Electric Sets Without Supports At The Flywheel Housing
(1) If base (1) of the electric set is fastened to a foundation, loosen all base-to-foundation bolts. Loosen all bolts (2) and (3) that fasten the generator supports and engine supports to base (1).
Check to be sure there is clearance between the bolts and the bolt holes in the base, engine supports and generator supports at all locations.
(3) Check the clearance between the base and its foundation at all mounting locations. Use shims as necessary to prevent deflection of the base as the base-to-foundation bolts are tightened. When there is no deflection in the base, tighten all base-to-foundation bolts to their final torque.
(4) Check the clearance between the base and the engine and generator supports at all four locations (A). Be sure to check the clearance over the entire length of the support. This is especially important on generators with long supports (4), since some surfaces may not be square or parallel. Use shims as necessary to prevent deflection of the supports as the bolts are tightened. After all the necessary shims have been installed, tighten all mounting bolts to their final torque.
Alignment Of Electric Sets With Supports At The Flywheel Housing
(1) If base (1) of the electric set is fastened to a foundation, loosen all base-to-foundation bolts. Loosen all bolts that fasten the engine and generator supports to the base.
(2) Check to be sure there is clearance between the bolts and the bolt holes in the base, engine supports and generator supports at all locations.
(3) Check the clearance between the base and its foundation at all mounting locations. Use shims as necessary to prevent deflection of the base as the base-to-foundation bolts are tightened. When there is no deflection in the base, tighten all base-to-foundation bolts to their final torque.
(4) Loosen all bolts (2) that fasten the generator to the flywheel housing. Tighten every other bolt to its final torque. Check the clearance between the base and the engine and generator supports at all six locations. Be sure to check the clearance over the entire length of the supports. This is especially important on generators with long supports (3). Install shims as necessary until all of the mounting surfaces are flat and parallel.
(5) Tighten all bolts that fasten the engine and generator supports to the base to one-half of their final torque. Loosen all bolts (2), and check the gap between the generator and the flywheel housing at locations (E), (F), (G) and (H). Location (E) must always be at the top. Make a record of each measurement.
(6) If the gap at location (E) is larger than the gap at location (G) by more than .005" (0.13), install an equal amount of shims under each generator support as necessary. If the gap at location (G) is larger than the gap at location (E) by more than .005" (0.13), remove an equal amount of shims from under each generator support as necessary. After a correction has been made to shim thickness, tighten the generator support as necessary. After a correction has been made to shim thickness, tighten the generator support bolts to one-half of their final torque and again check the gap at locations (E) and (G). Use this procedure again and again until the difference in gap measurements is .005" (0.13) or less.
(7) If the gap at location (F) is larger than the gap at location (H) by more than .005" (0.13), loosen the bolts in the generator supports and move the rear of the generator to the right. If the gap at location (H) is larger than the gap at location (F) by more than .005" (0.13), loosen the bolts in the generator supports and move the rear of the generator to the left. Do this procedure again and again until the difference in gap measurements is .005" (0.13) or less. Tighten bolts (2) to their final torque.
(8) Install a dial indicator on base (4) with the indicator tip next to a support mounting bolt. Tighten this bolt to its final torque, and at the same time check the indicator. If there is more than .005" (0.13) of indicator movement, the shim thickness is incorrect under that bolt. Install shims as necessary. Do this procedure again and again until all engine and generator support mounting bolts have been tightened to their final torque and support deflection is within specification.