The Installation And The Alignment Of The Two-Bearing Locomotive Generators{4471} Caterpillar

Engine:

3508 (S/N: 6TJ)

3512 (S/N: 2WK)

3516 (S/N: 9KF)

Introduction

This Special Instruction describes the procedure for the installation and cold alignment of two-bearing generators to locomotive engines. These units are permanently mounted on a Caterpillar base. This procedure for alignment relates to traction generators which are driven from the flywheel (rear driven). This procedure also relates to auxiliary generators that are driven from the front power take-off.

Do not check the final alignment of the generators until the base is in the permanent position. In addition, the engine and generators must be permanently installed on the base. When the initial alignment of the generators is performed at the factory, the alignment is within the tolerance of the "new" category. Refer to the ""Specifications" " Section for details.

Do not perform any procedure in this Special Instruction until you have read this information and you have understood this information.

General Information

Cold Alignment

This section describes the recommended procedure for the cold alignment of two-bearing generators to Caterpillar diesel engines. This procedure must be performed with all of the components at ambient temperature.

The following steps have taken into consideration several factors in order to achieve the correct operating alignment.

Illustration 1	g00588910
(1) Static clearance (2) Crankshaft (3) Running clearance (4) Bearing bore (A) Position of crankshaft during cold alignment (B) Position of crankshaft during operation

1. During the procedure for cold alignment, the crankshaft lies at the bottom of the bores of the main bearing. The following conditions tend to lift the crankshaft and these running conditions cause the crankshaft to rotate approximately around the center of the bores of the main bearing: firing pressures, centrifugal forces and engine oil pressure.

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Illustration 2	g00588938
(5) Engine (6) Vertical Change In The Location Of The Crankshaft (7) Generator (8) Crankshaft (9) Vertical Change In The Location Of Generator Shaft (10) Rear (11) Front (C) The Location Of The Centerlines Of The Shaft For Cold Alignment (D) The Location Of The Centerlines Of The Shaft During Operation

2. The weight of the flywheel and the coupling causes a small deflection of the shafts during the procedure for the cold alignment.

3. Heat from the engine causes the expansion of metal in the engine and in the generator during operation. The result of this expansion is a change in the locations of the centerlines of the crankshaft and generator shaft. The thermal expansion of the engine is greater than the thermal expansion of the generator. This difference will cause the change in the horizontal centerline of the engine crankshaft to be greater than the change in the horizontal centerline of the generator shaft.

4. Due to these factors, the procedure for the cold alignment positions the horizontal centerline of the generator shaft above the horizontal centerline of the crankshaft. Refer to the specifications for cold alignment in the ""Specifications" " Section in order to correctly align the unit during operation.

Hot Alignment

In the past, a check of the hot alignment may have been used to check the accuracy of the procedure for the cold alignment. However, tests have shown that the results of the check of the hot alignment are inconsistent. Therefore, this procedure is not recommended.

Indicator Readings

When you take indicator readings, always remember that a plus reading means that the tip of the indicator has moved into the dial indicator. A minus reading means that the tip of the indicator has moved out of the dial indicator.

When you compare two plus indicator readings, the larger numerical reading is more than the smaller numerical reading. However, when you compare two minus indicator readings, the larger numerical reading is less than the smaller numerical reading. In both cases, the indicator reading will decrease as the tip of the indicator moves out of the dial indicator.

The total indicator reading (TIR) is the total amount of movement of the indicator needle. The TIR is always a positive value even though one or both of the readings are negative. The TIR is equal to fifteen when the indicator reading varies from a value of minus ten to a value of five. The TIR is equal to ten when the indicator reading varies from a value of minus five to a value of minus fifteen.

Illustration 3	g00589131
(1) Bore (2) Face (A) Dial Indicator Position (B) Dial Indicator Position (C) Dial Indicator Position (D) Dial Indicator Position

Indicator readings are taken at the following four locations: "A", "B", "C" and "D". Refer to Illustration 3. The dial indicator is always zeroed at location "A" before any readings are taken. When readings are taken, the indicator must be returned to location "A" in order to be sure that the indicator reading returns to zero. The reading at "C" should equal the sum of the readings at "B" and "D". This formula is valid when the driving shaft and the driven shaft are rotated together. Check the alignment of these components as these components are rotated.

Illustration 4	g00589173
(3) Traction Generator Shaft (4) Engine (5) Auxiliary Generator Shaft (6) Crankshaft (7) PTO Shaft (8) 0.28 mm (0.011 inch) reading (9) 0.13 mm (0.005 inch) reading (E) Rear (F) Front

When you check the alignment of both generators, the indicator reading of the bore will be a positive value. Refer to Illustration 4. This reading occurs because of the following reasons: the mounting of the indicator on the generator, the placement of the tip on the engine side of the coupling and the location of the generator centerlines above the engine centerline.

Crankshaft End Play

The crankshaft end play must be checked during the procedure for the cold alignment. Check this end play both before the installation and after the installation of the driven unit. The end play must not be less than the original end play before the installation of this equipment. In order to check the crankshaft end play, mount a dial indicator on the flywheel housing or on the front housing. The tip of the indicator must be on the face of the flywheel or on the face of the torsional damper. Use a pry bar in order to push the crankshaft toward the rear of the engine as far as possible. Zero the dial indicator. Use a pry bar to push the crankshaft toward the front of the engine as far as possible. The total movement of the indicator needle (TIR) is the crankshaft end play. When you check the crankshaft end play, do not use the bar in order to keep the load against the crankshaft or the generator shaft. Erroneous readings will result from this process. After the installation and the alignment of the generator, the crankshaft end play must not be less than the original end play before the installation of the generator. The end play should be checked after the engine is at operating temperature. The end play must not be less than the end play during cold alignment.

Note: Do not pry against the crankshaft torsional damper. Damage to the damper may result.

Before you take any indicator readings during the alignment, always move the crankshaft toward the front of the engine to the end of the end play. Move the generator shaft toward the engine to the end of the end play.

Types Of Misalignment

Illustration 5	g00589810
This is an Illustration of two shafts that experience parallel misalignment. (1) Face Gap (Top) (2) Diameter Gap (Top) (3) Coupling Output Flange (4) Companion Flange Driven Equipment (5) Bore Or Parallel Misalignment (6) Diameter Gap (Bottom) (7) Face Gap (Bottom)

Parallel misalignment occurs when the centerlines of the driven equipment and the centerlines of the engine are parallel, but these centerlines are not in the same plane. Refer to Illustration 5.

Illustration 6	g00589825
This is an Illustration of two shafts that experience angular misalignment. (8) Face Gap (Top) (9) Coupling Output Flange (10) Companion Flange Driven Equipment (11) Face Or Angular Misalignment (12) Face Gap (Bottom)

Angular misalignment occurs when the centerlines of the driven equipment and the engine are not parallel. Refer to Illustration 6.

Illustration 7	g00589833
This is an Illustration of bore runout. (13) Hub Centerline (14) Hub (15) Shaft Centerline (16) Shaft

The bore runout refers to the offset distance between the centerline of the hub and the centerline of the shaft. Refer to Illustration 7.

Illustration 8	g00589853
This is an Illustration of face runout. (17) Runout (18) Hub (19) Shaft

The face runout is the distance between the hub face and a line which is perpendicular to the shaft centerline. Refer to Illustration 8.

Installation And Alignment Procedure

Tooling Needed

Illustration 9	g00591493
This is an Illustration of the two dowel pins which measure 15.875 mm (0.625 inch) by 90 mm (3.5 inch) long. Make this dowel pin from a 0L-1169 Bolt . (A) 90 ± 2 mm (3.5 ± 0.1 inch) (B) 13 ± 1 mm (0.52 ± 0.04 inch) (C) 6 ± 1 mm (0.24 ± 0.04 inch) (D) 30° (E) 5/8 inch (11 UNC Thread) (F) 15.88 ± 0.05 mm (0.625 ± 0.002 inch) Diameter

Illustration 10	g00591531
This is an Illustration of the Starrett Dial Indicator (No. 81-141). (1) Gauge Holding Rod (2) Swivel Post Snug And Reducing Bushing (3) Universal Attachment

Illustration 11	g00591537
This is an Illustration of the Drill Bushing and Transfer Punch. (All the fillets must measure 0.5 mm (0.02 inch) at an angle of 45°.) (H) 45.0 ± 0.5 mm (1.77 ± 0.02 inch) (I) 13.0 ± 0.5 mm (0.51 ± 0.02 inch) (J) 20.0 ± 0.5 mm (0.79 ± 0.02 inch) (K) 3.0 ± 0.5 mm (0.12 ± 0.02 inch) (L) 5.0 ± 0.5 mm (0.2 ± 0.02 inch) (M) 30.0 ± 0.5 mm (1.18 ± 0.02 inch) (N) 20.0 ± 0.5 mm (0.79 ± 0.02 inch) (O) 30° (P) 29.5 ± 0.5 mm (1.16 ± 0.02 inch) (Q) 38.0 ± 0.5 mm (1.50 ± 0.02 inch) (R) 4.0 ± 0.5 mm (0.16 ± 0.02 inch) (S) 6.5 mm (0.256 inch) (Diameter) (T) 4.0 ± 0.5 mm (0.16 ± 0.02 inch)

Illustration 12	g00591562
This is an Illustration of a dowel pin which measures 9.5 mm (0.375 inch) by 125 mm (4.9 inch) long. Make this dowel pin from a 5B-9603 Bolt . (U) 125 ± 2 mm (4.9 ± 0.1 inch) (V) 3/8 inch (16 UNC Thread) (W) 9.52 ± 0.05 mm (0.375 ± 0.002 inch) Diameter

Illustration 13	g00591581
This is an Illustration of a Gauge Block that is 69 mm (2.72 inch) in length. (X) 69.0 ± 0.3 mm (2.72 ± 0.012 inch) (Y) 10 ± 1 mm (0.4 ± 0.04 inch) Square

Installation Procedure For The Traction Generator

Illustration 14	g00591643
The end clearance of the coupling must be 10.4 ± 0.8 mm (0.41 ± 0.03 inch) for the traction generator. This end clearance is indicated by Dimension "A". The 3516 engine is shown. (1) Fan (2) Flywheel (3) Outer Coupling (4) Seal (2 places) (5) Cover Plate (6) Rubber Boot (7) Inner Coupling (8) Shims (9) Generator Shaft (A) End Clearance Of The Coupling

Since the traction generator is close coupled to the engine, the amount of shimming that is required to accurately locate the inner coupling must be determined. Perform this task during the initial alignment when the locations for the mounting bolts for the generator are determined.

Remove all the foreign matter from the following locations: the mating surfaces of the generator, the pads for the support bracket of the generator and the mounting holes. Be sure that the following mating surfaces are completely clean: the coupling, the engine and the generator. Remove all the foreign matter from the mating surfaces of the base assembly.

There are two methods that are used to easily determine the correct amount of shimming. Method "A" calculates the correct shimming and Method "B" uses a procedure of trial assembly. Either method will give the required results. Refer to Step 1 for Method "A". Refer to Step 2 for Method "B".

Note: If a new coupling is installed, check the individual components before installation of the generator. If the specifications of the original components are uncertain, check the individual components before installation of the generator. Refer to Table 4 in the ""Specifications" " Section for details.

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Illustration 15	g00591656
(B) Dimension For The Cover Plate (C) Dimension For The Inner Coupling

1. This Step describes Method "A". Measure Dimension "C" of the inner coupling with the 6V-7030 Micrometer Depth Gauge Group . Measure Dimension "B" of the cover plate with the micrometer. Do not install the following components over the generator shaft hub: the inner coupling, the cover plate and the fan.

2. This Step describes Method "B". Place four 6I-1662 Coupling Shims on the generator shaft hub. Place the inner coupling on these components. Install six equally spaced bolts and tighten these bolts to the correct torque. Measure the cover plate (Dimension "B") with the micrometer.

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Illustration 16	g00591676
This is an Illustration of a view of the 3516 engine. (10) Locate the two clearance holes at the bottom. (11) Flywheel Housing (12) Generator Adapter Plate

3. Install the generator adapter plate to the flywheel housing. Be sure that the pilot diameter on the adapter plate engages the housing bore correctly. On the 3516 engine, ensure that the two clearance holes in the outer hole pattern are located at the bottom. Also ensure that the cutouts for the turbocharger drains are located at the top. Tighten the bolts.

4. Use two dowel pins to install the outer coupling on the flywheel. Do not install the inner O-ring at this point. Bolt the outer coupling in place with the following components: six 0S-1592 Bolts and six 5P-8247 Hard Washers . These bolts and washers will be replaced later.

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Illustration 17	g00591689
This is an Illustration of the 3508 and the 3512 package. (13) Flywheel Housing (D) 1201.5 mm (47.3 inch) (E) 906 ± 5 mm (35.7 ± 0.2 inch) (F) 56 ± 5 mm (2.2 ± 0.2 inch) (G) 10 mm (0.4 inch) (2 places) (H) 10 mm (0.4 inch) (2 places) (I) 8 mm (0.3 inch) (2 places)

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Illustration 18	g00591859
This is an Illustration of the 3516 package. (14) Flywheel Housing (J) 1615 mm (63.6 inch) (K) 993 ± 5 mm (39.1 ± 0.2 inch) (L) 248 ± 5 mm (9.8 ± 0.2 inch) (M) 10 mm (0.4 inch) (2 places) (N) 10 mm (0.4 inch) (2 places) (O) 8 mm (0.3 inch) (2 places)

5. Ensure that the mounting bolt holes for the generator are free of all debris in order to permit the installation of the drill bushing. Remove the drip shield and the fan guard from the drive end of the generator. Weld the horizontal alignment bolt blocks in position. Refer to Illustration 18. Take precautions in order to keep the splatter from the weld off of the mounting surfaces for the rubber isolator. Run a thread tap through all the alignment holes in order to ensure free operation.

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Illustration 19	g00591905
This is an Illustration of a section through the generator alignment bolts. (15) Support Bracket For The Generator (16) Vertical Alignment Bolt (17) Base Rail (18) Horizontal Alignment Bolt

6. Place the generator in position on the support pads. Use the vertical and the horizontal alignment bolts on the generator and the base in order to align the generator and the adapter plate. Engage the pilot assembly and install two bolts through the generator mounting flange. This action will ensure that the generator is pulled completely toward the engine.
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   Table 2

   Alignment Values (1)
   	A to C MAX. TIR	B to D MAX. TIR	Indicator Reading At
   			A	C
   Bore	0.75 ± .1 mm (0.030 ± 0.004 inch)	0.4 mm (0.016 inch)	0	+
   Face	0.4 mm (0.016 inch)	0.4 mm (0.016 inch)	0	+ or -

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   ( 1 )

   Use the alignment values only when you initially locate the centers of the mounting holes for the generator.

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Illustration 20	g00591949
This is an Illustration of the locations of the dial indicators. (19) Flywheel (20) Outer Coupling (21) Inner Coupling (22) Generator Shaft (P) Bore (Q) Face

7. Install the alignment tooling on the generator shaft. It is important to locate the dial indicator at the correct distance from the rotational center line. The dial indicator measures the misalignment of the face. Locate the indicator at the position that is shown in Illustration 20. The misalignment of the bore can be measured on the outer diameter of the outer coupling flange. Use the 9S-9082 Engine Turning Tool or the 3R-1937 Barring Tool to rotate the engine in the normal direction of rotation. Periodically release and tighten the bolts that are located between the generator and the generator adapter plate.

8. After the generator is correctly positioned, mark the locations on the base for the mounting holes. Use the drill bushing and transfer punch to mark these holes.

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Illustration 21	g00591966
(23) Outer Coupling (24) Inner Coupling (25) Generator Shaft (R) Dimension (S) Dimension

9. This Step describes Method "A". Move the crankshaft toward the front of the engine in order to remove all of the end play. Move the generator shaft toward the engine in order to remove all the end play. Hold the flat bar against the flange of the generator and use the 6V-7030 Micrometer Depth Gauge Group to measure Dimension "R". This dimension is between the outer face of the generator drive flange and the outer face of the outer coupling.

10. This Step describes Method "B". Move the crankshaft toward the front of the engine in order to remove all of the end play. Move the generator shaft toward the engine in order to remove all of the end play. Use the 6V-7030 Micrometer Depth Gauge Group to measure Dimension "S". This dimension is between the outer face of the outer coupling and the outer face of the inner coupling.

11. This Step describes Method "A". Calculate the required thickness of the shim in accordance with the following formulas.
    • 10.4 - Dimension "C" + Dimension "R" - Dimension "B" = thickness in millimeters for metric dimensions

    • 0.41 - Dimension "C" + Dimension "R" - Dimension "B" = thickness in inches for standard dimensions

    From the resulting thickness, calculate the required number of shims by dividing the total thickness by 0.8 mm (0.03 inch). Round the answer to the nearest whole number.

    • Example: (Metric) 10.4 - 19.0 + 18.5 - 6.4 = 3.5, and 3.5/0.8 = 4.4, Therefore, use four shims.

12. This Step describes Method "B". Calculate the required thickness of the shim (addition or removal) with the following formulas.
    • 10.4 - Dimension "B" - Dimension "S" = thickness in millimeters for metric dimensions

    • 0.41 - Dimension "B" - Dimension "S" = thickness in inches for standard dimensions

    From the resulting number, calculate the number of shims that must be added or removed by dividing the calculated thickness by 0.8 mm (0.03 inch). Round the answer to the nearest whole number.

    • Example: (Inch) 0.41 - 0.25 - 0.23 = -0.07, and -0.07 / 0.03 = -2.3, Therefore, remove two shims.

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Illustration 22	g00591988
(26) Rear (27) Front (28) Base Rail (T) 1 inch (8 UNC Thread) (U) The hole measures 1 inch (8 UNC Thread). The depth of this hole is 44 ± 1 mm (1.73 ± 0.04 inch). (V) 1 inch (8 UNC Thread) (W) This Is A Section Through The Mounting Holes For The 3516 Generator. (X) This Is A Section Through All The Mounting Holes For The 3508 And The 3512 Generators.

13. Remove the generator from the base. Remove the outer coupling from the engine flywheel. Remove the alignment tooling from the generator drive flange. Drill the mounting holes and tap these holes in the base in the previously determined locations. The rear holes on the 3516 engine are tapped through the base rail. The front holes are tapped to the depth that is shown in Illustration 22.

14. If necessary, remove the inner coupling from the drive hub of the generator. Place the fan over the generator shaft and rest the fan against the bearing support. Install the O-ring seal and the cover plate into the bore of the outer coupling. Failure to correctly install this O-ring seal will cause loss of silicone grease and the coupling will fail. Bolt the cover plate to the outer coupling with twelve 5/8 inch bolts (11 UNC). Place this assembly over the generator drive flange.

15. Install the correct pack of shims over the shaft coupling pilot. The thickness of this pack of shims is calculated in Step 11 and Step 12. Install the inner coupling and tighten the twelve 7/8 inch bolts (9 UNC).

16. Apply one tube of silicone grease to all the external tooth surfaces of the inner coupling. Install two rubber boots over the inner coupling. The silicone grease will retain these boots.

17. Apply some additional silicone grease to the outside of the rubber boots. This grease will enable the outer coupling to move into the proper place. Rotate the generator shaft until the two rubber boots are approximately at the top.

18. Install the outer coupling over the rubber boots. Screw two long bolts or dowel pins into the holes for the jacking screws for the outer coupling. This action will ease the handling of the coupling. Add the remainder of the silicone grease. Install the last rubber boot into the remaining space between the inner coupling and the outer coupling.

19. Use a small amount of silicone grease in order to retain the inner O-ring seal in the outer coupling. Ensure that the O-ring is correctly located. Failure to install this O-ring seal will cause loss of silicone grease and the coupling will fail. Remove the two bolts or dowel pins from the outer coupling if these items were used.

20. Install two dowel pins in the flywheel. Reinstall the generator on the base. As the generator is brought up to the engine, be sure that the O-ring seal is correctly located. Be sure that the generator fan is brought into the correct location which is on the coupling mounting flange. Use the dowel pins to guide the outer coupling and the generator fan into position. After the outer coupling is against the flywheel, do not pull the coupling backward onto the dowel pins. This action will cause the O-ring seal to stick to the flywheel. The O-ring seal will then be displaced from the groove. Failure to correctly install this O-ring seal will cause the loss of silicone grease and the coupling will fail. Install ten bolts through the fan and the coupling into the flywheel. Replace the two dowel pins with the remaining two bolts and tighten.

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Illustration 23	g00592080
(29) Face (30) Bore (Y) The radius is measured from the centerline of the engine. 285 mm (11.25 inch) (Z) The radius is measured from the centerline of the engine. 340 mm (13.38 inch) (AA) 3508/3512 (BB) 3516

21. Install the alignment tooling on the generator shaft. Note the location of the dial indicator that measures the misalignment of the face. Ensure that the engine and the generator are in contact and that both the shafts are pushed forward. Fit the shims under the bolts of the support bracket for the main generator.

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Illustration 24	g00592124
This Illustration shows the locations for the mounting bolts for the generator and the locations for the dial indicators. (31) Generator Mounting Bolt (32) Generator Mounting Bolt (33) Generator Mounting Bolt (34) Generator Mounting Bolt (CC) Dial Indicator Position (DD) Dial Indicator Position (EE) Dial Indicator Position (FF) Dial Indicator Position

22. Use the following procedure to ensure that the load on each support bracket for the generator is the same load.

    1. Loosen all the vertical alignment bolts. Install the following mounting bolts for the generator: (31), (32), (33) and (34) .

    2. Tighten the bolts to one-half of the final torque in the following sequence: (31), (32), (33) and (34) .

    3. Rotate the crankshaft until the measuring bore of the dial indicator is at location "CC". Zero the indicator.

    4. Loosen the bolt (33) and tighten the bolt (32) to one-half of the final torque.

    5. If the indicator needle moves 0.05 mm (0.002 inch) or less, tighten the bolt (33) to one-half of the final torque. Then proceed to Step 22.f. If the indicator needle moves more than 0.05 mm (0.002 inch), add shims under the bolt (33) or the other bolt (32). Loosen all the bolts and repeat Step 22.b through Step 22.e.

    6. Loosen the bolt (34) and tighten the bolt (31) to one-half of the final torque.

    7. If the indicator needle moves 0.05 mm (0.002 inch), tighten the bolt (34) to one-half of the final torque. Then proceed to Step 22.h. If the indicator needle moves more than 0.05 mm (0.002 inch), add shims under the bolt (34) or the other bolt (31). Loosen all the bolts and repeat Step 22.b through Step 22.g.

    8. Tighten all the bolts to the final torque. The indicator needle must not move more than 0.05 mm (0.002 inch).

23. Put the dial indicators at position "CC". Move the engine crankshaft toward the front of the engine in order to remove all the end play. Move the generator shaft toward the engine in order to remove the end play. Zero the dial indicators. Rotate the crankshaft in the normal direction of rotation. Make a record of the readings, which are spaced 90 degrees from each other. Take these readings at the following locations: "DD", "EE", "FF" and back to "CC". Before you take the indicator readings at each position, be sure that all the end play is removed from the crankshaft and from the generator shaft.

24. After all the readings have been taken, refer to the ""Analysis Of Measurements For The Traction Generator" " Section for details.

Alignment Check Of An Assembled Unit

Use the following procedure and make a record of all measurements and indicator readings. Do not make corrections for misalignment until all the measurements have been taken. Refer to the ""Analysis Of Measurements For The Traction Generator" " Section for details.

Illustration 25	g00592159
The end clearance of the coupling is indicated by Dimension "A". The end clearance must be 10.4 ± 0.8 mm (0.41 ± 0.03 inch) for the traction generator. This is an Illustration of the 3516. (1) Fan (2) Flywheel (3) Outer Coupling (4) Seal (2 places) (5) Cover Plate (6) Rubber Boot (7) Inner Coupling (8) Shims (9) Generator Shaft (A) Dimension

1. Move the crankshaft toward the front of the engine in order to remove all of the end play. Move the generator shaft toward the engine in order to remove all the end play. Use a 6V-7030 Micrometer Depth Gauge Group to measure the Dimension "A".

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Illustration 26	g00592268
(10) Face (11) Bore (B) The radius is measured from the centerline of the engine. 285 mm (11.25 inch) (C) The radius is measured from the centerline of the engine. 340 mm (13.38 inch) (D) 3508/3512 (E) 3516

2. Install dial indicators with the FT-2449 Indicator Bracket . Refer to Illustration 9. It is important to locate the dial indicator that measures the misalignment of the face at the correct distance from the rotational centerline. Locate the indicator at the position that is shown in Illustration 26.

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Illustration 27	g00592373
(F) Dial Indicator Position (G) Dial Indicator Position (H) Dial Indicator Position (I) Dial Indicator Position (J) Bore (K) Face

3. Put the dial indicators at position "F". Move the engine crankshaft toward the front of the engine in order to remove all the end play. Move the generator shaft toward the engine in order to remove the end play. Zero the dial indicators. Rotate the crankshaft in the normal direction of rotation. Make a record of the readings, which are spaced 90 degrees from each other. Take these readings at the following positions: "G", "H", "I" and back to "F". Before you take any indicator readings at each position, be sure that all the end play is removed from the crankshaft and the generator shaft.

4. After all the readings have been taken, refer to the ""Analysis Of Measurements For The Traction Generator" " Section for details. Refer to Table 6 in the ""Specifications" " Section for details.

Analysis Of Measurements For The Traction Generator

Note: Refer to Table 6 in the ""Specifications" " Section for details.

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Illustration 28	g00592378
(A) Dial Indicator Position (B) Dial Indicator Position (C) Dial Indicator Position (D) Dial Indicator Position (E) Bore (F) Face

1. The bore alignment must be in accordance with the following steps. These steps are applicable to the following engines: 3508, 3512 and 3516.

   1. The total indicator reading (TIR) between location "A" and location "C" must be 0.28 ± 0.05 mm (0.011 ± 0.002 inch) for new units or realigned units.

      Note: The centerline of the generator shaft must be above the centerline of the crankshaft. Therefore, the indicator reading at "C" must be minus when the reading at "A" is zero. The dial indicator must also be located in the position that is shown in Illustration 26.

   2. On used units, the TIR between "A" and "C" must be 0.28 ± 0.25 mm (0.011 ± 0.010 inch) with the minus reading at "C". If the reading is not within these specifications, realignment of the generator will be necessary.

   3. The TIR between "B" and "D" can be a maximum of 0.2 mm (0.008 inch) for new units or for realigned units. The TIR between "B" and "D" can be a maximum of 0.3 mm (0.012 inch) for used units.

   4. In both cases, the readings at "B" plus "D" must equal the reading at "C".

2. The alignment of the face must be in accordance with the following steps.

   The following steps pertain to the 3508 and the 3512 engines.

   1. On new units, a maximum TIR of 0.17 mm (0.0065 inch) is permitted between "A" and "C". On realigned units, a maximum TIR of 0.17 mm (0.0065 inch) is permitted between "A" and "C". On used units, realignment of the generator is not necessary until the TIR between "A" and "C" is more than 0.26 mm (0.01 inch).

   2. On new units, a maximum TIR of 0.17 mm (0.0065 inch) is permitted between "B" and "D". On realigned units, a maximum TIR between "B" and "D" of 0.17 mm (0.0065 inch) is permitted. On used units, realignment of the generator is not necessary until the TIR between "B" and "D" is more than 0.26 mm (0.010 inch).

   3. In both cases, the readings at "B" plus "D" must equal the reading at "C".

      The following steps pertain to the 3516 engine.

   4. On new units, a maximum TIR of 0.2 mm (0.008 inch) is permitted between "A" and "C". On realigned units, a maximum TIR of 0.2 mm (0.008 inch) is permitted between "A" and "C". On used units, realignment of the generator is not necessary until the TIR between "A" and "C" is more than 0.3 mm (0.012 inch).

   5. On new units, a maximum TIR of 0.2 mm (0.008 inch) is permitted between "B" and "D". On realigned units, a maximum TIR of 0.2 mm (0.008 inch) is permitted between "B" and "D". On used units, realignment of the generator is not necessary until the TIR between "B" and "D" is more than 0.3 mm (0.012 inch).

   6. In both cases, the readings at "B" plus "D" must equal the reading at "C".

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Illustration 29	g00592387
(1) Fan (2) Flywheel (3) Outer Coupling (4) Seal (2 places) (5) Cover Plate (6) Rubber Boot (7) Inner Coupling (8) Shims (9) Generator Shaft (G) Dimension

3. The end clearance of the coupling (Dimension "G") must be 10.4 ± .8 mm (0.41 ± 0.03 inch) for the traction generator on all engine models.

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Illustration 30	g00592427
This is an Illustration of the 3516. (H) 0.00 mm (0.000 inch) (I) -0.10 mm (0.004 inch) (J) -0.28 mm (0.011 inch) (K) -0.18 mm (0.007 inch) (L) 0.00 mm (0.000 inch) (M) 0.08 mm (0.003 inch) (N) 0.13 mm (0.005 inch) (O) 0.05 mm (0.002 inch) (P) Bore Readings (Q) Face Readings

4. Refer to Illustration 30 for examples of indicator readings within specification for new units. These examples are also applicable to realigned units.

Realignment Of An Assembled Unit

Use the following procedure to realign the generator, if the measurements are not within the specification that is shown in the ""Analysis Of Measurements For The Traction Generator" " Section. After a correction has been made for a specific misalignment, all measurements must be taken again in order to be sure of the accuracy of the final alignment.

1. If the dimension "G" is not within the specification, shims must be added or removed from the inner coupling and the generator shaft. These shims are located in the space between these two components. Calculate the required thickness of the shim (addition or removal) in accordance with the following formulas.
   • 10.4 - Dimension "C" - Dimension "D" = thickness in millimeters for metric dimensions

   • 0.41 - Dimension "C" - Dimension "D" = thickness in inches for standard dimensions

   From the resulting number, calculate the number of shims that must be added or removed. In order to make this calculation, divide the calculated thickness of the shim by 0.8 mm (0.03 inch). Round the answer to the nearest whole number.

   • Example: (Inch) 0.41 - 0.25 - 0.23 = -0.07, and -0.07 / 0.03 = -2.3, Therefore, remove two shims.

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Illustration 31	g00592446
(1) Generator Mounting Bolt (2) Generator Mounting Bolt (3) Generator Mounting Bolt (4) Generator Mounting Bolt (A) Dial Indicator Position (B) Dial Indicator Position (C) Dial Indicator Position (D) Dial Indicator Position

2. Use the following procedure to be sure that the load is the same load on each support bracket for the generator.

   1. Loosen all the vertical alignment bolts. Install the following mounting bolts for the generator: (1), (2), (3) and (4) .

   2. Tighten the bolts to one-half of the final torque in the following sequence: (1), (2), (3) and (4) .

   3. Rotate the crankshaft until the measuring bore of the dial indicator is at position "A". Zero the indicator.

   4. Loosen the bolt (1) and tighten the other bolt (3) to one-half of the final torque.

   5. If the indicator needle moves 0.05 mm (0.002 inch) or less, tighten the bolt (1) to one-half of the final torque. Then proceed to Step 2.f. If the indicator needle moves more than 0.05 mm (0.002 inch), add shims under the bolt (1) or the other bolt (3). Loosen all the bolts and repeat Step 2.b through Step 2.e.

   6. Loosen the bolt (2) and tighten the bolt (4) to one-half of the final torque.

   7. If the indicator needle moves 0.05 mm (0.002 inch) or less, tighten the bolt (2) to one-half of the final torque. Then proceed to Step 2.h. If the indicator needle moves more than 0.05 mm (0.002 inch), add shims under the bolt (2) or the other bolt (4). Loosen all the bolts and repeat Step 2.a through Step 2.g.

   8. Tighten all the bolts to the final torque. The indicator needle must not move more than 0.05 mm (0.002 inch).

3. Put the dial indicators at position "A". Move the crankshaft toward the front of the engine in order to remove all the end play. Move the generator shaft toward the engine in order to remove the end play. Zero the dial indicators. Rotate the crankshaft in the normal direction of rotation. Make a record of the readings, which are spaced 90 degrees from each other. Take these readings at the following locations: "B", "C", "D" and back to "A". Before you take indicator readings at each position, be sure that all the end play is removed from the crankshaft and from the generator shaft.

4. After all of the readings have been taken, refer to the ""Analysis Of Measurements For The Traction Generator" " Section.

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Illustration 32	g00592483
(1) Generator Mounting Bolt (2) Generator Mounting Bolt (3) Generator Mounting Bolt (4) Generator Mounting Bolt (5) Generator Horizontal Alignment Bolt (6) Generator Horizontal Alignment Bolt (7) Generator Horizontal Alignment Bolt (8) Generator Horizontal Alignment Bolt

5. If the measurements of the bore alignment are not within the specification, use the following procedure.

   The following conditions must exist before you loosen the mounting bolts for the generator. The total indicator reading (TIR) from "A" to "C" must be greater than 0.33 mm (0.013 inch). The reading at "A" must be 0.00 mm (0.000 inch). There must be a minus reading at "C". If these conditions exist, loosen the following mounting bolts for the generator: (1), (2), (3) and (4). If shims are removed, remove an equal thickness of shims from the area under the following bolts: (1), (2), (3) and (4) .

   Note: If the reading at "C" is plus, the generator is too low and an equal thickness of shims must be installed under the following bolts: (1), (2), (3) and (4) .

   The following conditions must exist before you loosen the mounting bolts for the generator. The total indicator reading (TIR) from "A" to "C" is less than 0.23 mm (0.009 inch) with a reading at "A" of 0.00 mm (0.000 inch). There is a minus reading at "C". If these conditions exist, loosen the following mounting bolts for the generator: (1), (2), (3) and (4). If shims are added, install an equal thickness of shims under the following bolts: (1), (2), (3) and (4) .

   Note: If the reading at "C" is plus, the generator is too low and an equal thickness of shims must be installed under the following bolts: (1), (2), (3) and (4) .

   The following conditions must exist before you loosen the mounting bolts for the generator. The total indicator reading (TIR) from "B" to "D" is greater than 0.2 mm (0.008 inch). The reading at "B" is more than the reading at "D". If these conditions exist, loosen the following mounting bolts for the generator: (1), (2), (3) and (4). Loosen the horizontal alignment bolt (5) and loosen the other alignment bolt (6). These bolts are adjacent to the mounting bolt (1) and the other mounting bolt (2). Simultaneously tighten the horizontal alignment bolt (7) and tighten the other alignment bolt (8). These bolts are adjacent to the mounting bolt (3) and the other mounting bolt (4). Tighten these alignment bolts to an equal setting.

   The following conditions must exist before you loosen the mounting bolts for the generator. The total indicator reading (TIR) from "B" to "D" is greater than 0.2 mm (0.008 inch). The reading at "B" is less than the reading at "D". If these conditions exist, loosen the following mounting bolts for the generator: (1), (2), (3) and (4). Loosen the horizontal alignment bolt (7) and loosen the other alignment bolt (8). These bolts are adjacent to the mounting bolt (3) and the other mounting bolt (4). Simultaneously tighten the horizontal alignment bolt (5) and tighten the other alignment bolt (6). These bolts are adjacent to the mounting bolt (1) and the other mounting bolt (2). Tighten these alignment bolts to an equal setting.

6. If the measurements of the face alignment are not within the specification, use the following procedure.

   These following steps pertain to the 3508 and the 3512 engine.

   The following conditions must exist before you loosen the mounting bolts for the generator. The total indicator reading (TIR) from "A" to "C" is greater than 0.17 mm (0.0065 inch) with a minus reading at "C". If these conditions exist, loosen the following mounting bolts for the generator: (1), (2), (3) and (4). If shims are removed, remove an equal thickness of shims from the area under the bolt (2) and the other bolt (3) .

   The following conditions must exist before you loosen the mounting bolts for the generator. The total indicator reading (TIR) that is measured from location "A" to location "C" is greater than 0.17 mm (0.0065 inch) with a plus reading at "C". If these conditions exist, loosen the following mounting bolts for the generator: (1), (2), (3) and (4). If shims are removed, remove an equal thickness of shims from the area under the bolt (1) and the other bolt (4) .

   The following conditions must exist before you loosen the mounting bolts for the generator. The total indicator reading (TIR) from "B" to "D" is greater than 0.17 mm (0.0065 inch). The reading at "B" is less than the reading at "D". If these conditions exist, loosen the following mounting bolts for the generator: (1), (2), (3) and (4). Loosen the horizontal alignment bolt (7) that is adjacent to the mounting bolt (3). Simultaneously tighten the horizontal alignment bolt (6) that is adjacent to the mounting bolt (2) to an equal setting.

   The following conditions must exist before you loosen the mounting bolts for the generator. The total indicator reading (TIR) from "B" to "D" is greater than 0.17 mm (0.0065 inch). The reading at "B" is greater than the reading at "D". If these conditions exist, loosen the following mounting bolts for the generator: (1), (2), (3) and (4). Loosen the horizontal alignment bolt (6) that is adjacent to the mounting bolt (2). Simultaneously tighten the horizontal alignment bolt (7) that is adjacent to the mounting bolt (3) to an equal setting.

   The following steps are applicable to the 3516 engines.

   The following conditions must exist before you loosen the mounting bolts for the generator. The total indicator reading (TIR) from "A" to "C" is greater than 0.2 mm (0.008 inch) with a minus reading at "C". If these conditions exist, loosen the following mounting bolts for the generator: (1), (2), (3) and (4). If shims are removed, remove an equal thickness of shims from the area under the bolt (2) and the other bolt (3) .

   The following conditions must exist before you loosen the mounting bolts for the generator. The total indicator reading (TIR) from "A" to "C" is greater than 0.2 mm (0.008 inch) with a plus reading at "C". If these conditions exist, loosen the following mounting bolts for the generator: (1), (2), (3) and (4). If shims are removed, remove an equal thickness of shims from the area under the bolt (1) and the other bolt (4) .

   The following conditions must exist before you loosen the mounting bolts for the generator. The total indicator reading (TIR) from "B" to "D" is greater than 0.2 mm (0.008 inch). The reading at "B" is less than the reading at "D". If these conditions exist, loosen the following mounting bolts for the generator: (1), (2), (3) and (4). Loosen the horizontal alignment bolt (7) that is adjacent to the mounting bolt (3). Simultaneously tighten the horizontal alignment bolt (6) that is adjacent to the mounting bolt (2). Tighten these alignment bolts to an equal setting.

   The following conditions must exist before you loosen the mounting bolts for the generator. The total indicator reading (TIR) from "B" to "D" is greater than 0.2 mm (0.008 inch). The reading at "B" is greater than the reading at "D". If these conditions exist, loosen the following mounting bolts for the generator: (1), (2), (3) and (4). Loosen the horizontal alignment bolt (6) that is adjacent to the mounting bolt (2). Simultaneously tighten the horizontal alignment bolt (7) that is adjacent to the mounting bolt (3). Tighten this alignment bolt to an equal setting.

7. Tighten all the mounting bolts for the generator to the final torque. Check the face alignment and the bore alignment again. After all corrections have been made for alignment, install the guards over the coupling.

Installation Procedure For The Auxiliary Generator

Illustration 33	g00592518
(1) Resilient Member (Spider) (2) Drive Hub (3) Key (4) Generator Shaft (5) Coupling Half (6) PTO Drive

Since the auxiliary generator is close coupled to the engine, the axial position must be determined in order to provide the correct operational axial clearance within the coupling. Insufficient clearance will lead to premature bearing failure. An excess clearance will result in rapid wear of the resilient member of the coupling. The correct axial position is established during the initial alignment when the locations for the mount bolts are determined. When the axial clearance for the coupling is determined, an allowance for the movement of the shaft within the bearing must be accounted for.

Remove all foreign matter from the following locations: the mating surfaces of the generator, the pads of the support bracket for the generator and mounting holes. Be sure that the following mounting surfaces are clean: the coupling, the engine and the generator. Remove all foreign matter from the mating surfaces of the base assembly.

Note: If a new coupling is installed, check the individual components before installation of the generator. If the specifications of the original components are uncertain, check the individual components before installation of the generator. Refer to the ""Specifications" " Section for details.

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Illustration 34	g00592582

1. The generator drive hub is a shrink fit on the shaft. It will be necessary to heat the hub before installation. The maximum temperature for heating the hub is 370 °C (700 °F). Check for nicks and burrs on the shaft and the key. Remove any nicks and burrs that are found.

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Illustration 35	g00592662
(7) Drive Hub (8) Key (9) Generator Shaft (10) The Shaft And The Key Are Flush With The Hub Face.

2. Ensure that the key is correctly located. Slide the heated drive hub onto the shaft. A hollow, soft metal tool can be used if additional force is required to drive the hub into position. Do not use excessive force. The correct position for the shaft is just flush with the face of the hub. The shaft may also be placed at a position that is slightly below the face of the hub. Use wet rags to minimize the heat flow into the bearing.

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Illustration 36	g00592673
(11) Front Face Of Cylinder Block (12) The Screw Block Is Flush With The Edge Of The Base. (A) 1560 mm (61.4 inch) (B) 748 ± 5 mm (29.4 ± 0.2 inch) (C) 19 mm (0.75 inch) and 25 mm (1.00 inch) (D) 2 mm (0.08 inch) and 6 mm (0.24 inch) (4 places) (E) 170 ± 5 mm (6.78 ± 0.2 inch)

3. Ensure that the mounting bolt holes for the generator are free of all paint and epoxy in order to permit installation of the drill bushing. Refer to Illustration 11. Weld horizontal alignment bolt blocks in position. Refer to Illustration 36. Run a thread tap through all the alignment holes in order to ensure free operation.

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Illustration 37	g00592714
(13) Support Bracket For The Generator (14) Vertical Alignment Bolt (15) Base Rail (16) Horizontal Alignment Bolts (F) This Is A Section Through The Generator Alignment Bolts.

4. Place the generator in position on the support pads of the base. Use the vertical and horizontal alignment bolts in the generator and the base in order to move the generator into position.

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Illustration 38	g00592735
(17) Drive Hub (18) Dowel Pin And Nuts (19) Generator Shaft (Axial Float 2.5 mm (0.1 inch)) (20) Gauge Block (21) PTO Drive (G) 69 ± 1 mm (2.72 ± 0.04 inch)

5. The generator rotor shaft has approximately 2.5 mm (0.1 inch) of free axial float within the bearings. The rotor shaft should be positioned approximately in the middle of the actual measured float. When the rotor shaft is located at the correct axial position, set the distance between the face of the generator drive hub and the drive flange to 69 ± 1 mm (2.72 ± 0.04 inch). Use a gauge block to set this distance. Refer to Illustration 13. Also install the dowel pin and the two nuts on the drive flange in order to rotate the generator shaft. Refer to Illustration 12 and Illustration 38.
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   Table 3

   Alignment Values (1)
   	A to C MAX. TIR	B to D MAX. TIR	Indicator Reading At
   			A	C
   Bore	0.36 ± 0.1 mm (0.014 ± 0.004 inch)	0.26 mm (0.010 inch)	0	+
   Face	0.26 mm (0.010 inch)	0.26 mm (0.010 inch)	0	+ or -

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   ( 1 )

   Use the alignment values only when you initially locate the centers of the mounting hole for the generator.

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Illustration 39	g00593108
(22) Generator Shaft (23) PTO Drive Flange (H) Bore (I) Face

6. Install the following alignment tooling: dial indicators, the bolts and nuts on the generator drive hub and the dowel pin on the drive flange. Locate the dial indicator that measures the face alignment at the correct distance from the rotational centerline. Locate the indicator at the location that is shown in Illustration 39. The bore misalignment can be measured on the outer diameter of the drive flange. Use the 9S-9082 Engine Turning Tool or the 3R-1937 Barring Tool to rotate the engine. The direction of rotation of the drive flange is clockwise when the engine is viewed from the front. Mark four equally spaced reference points on the outside of the drive flange in order to provide a spaced reference of shaft rotation. A simple pointer can be fabricated to work in conjunction with these marks.

7. After the generator is correctly positioned, mark the locations for the holes for the mounting bolts on the base. Mark these locations with the drill bushing and transfer punch.

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Illustration 40	g00593153
This is an Illustration of a section through the mounting screws for the generator. (24) 5/8 inch (11 UNC Thread) (25) Base Rail

8. Remove the generator from the base. Remove the alignment tooling from the generator drive hub. Drill the mounting holes and tap the mounting holes in the base at the previously determined locations.

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Illustration 41	g00593194
(26) Bore (27) Face (28) PTO Drive Flange (J) 80 mm (3.15 inch)

9. Reinstall the generator on the base. Install the following alignment tooling on the generator shaft: bolts, nuts and dial indicators. If necessary, remark four points on the outside of the drive flange. Note the location of the dial indicator which measures the face misalignment. Be sure that the generator rotor shaft is located approximately at the center of the axial float. Be sure that the hub faces are at the correct distance from each other. Use the gauge block to verify these distances. Fit the shims under the bolts for the support bracket of the generator.

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Illustration 42	g00593216
(29) Generator Mounting Bolt (30) Generator Mounting Bolt (31) Generator Mounting Bolt (32) Generator Mounting Bolt (K) Dial Indicator Position (L) Dial Indicator Position (M) Dial Indicator Position (N) Dial Indicator Position

10. Use the following procedure to be sure that the load on each support bracket of the generator is the same load.

    1. Loosen all the vertical alignment bolts. Install the following mounting bolts for the generator: (29), (30), (31) and (32) .

    2. Tighten the bolts to one-half of the final torque in the following sequence: (29), (30), (31) and (32) .

    3. Rotate the drive shaft until the measuring bore of the dial indicator is at location "K". Zero the indicator.

    4. Loosen the bolt (31) and tighten the bolt (30) to one-half of the final torque.

    5. If the indicator needle moves 0.03 mm (0.001 inch) or less, tighten the bolt (31) to one-half of the final torque. Proceed to Step 10.f. If the indicator needle moves more than 0.03 mm (0.001 inch), add shims under the bolt (31) or the other bolt (30). Loosen all the bolts and repeat Step 10.b through Step 10.e.

    6. Loosen the bolt (32) and tighten the bolt (29) to one-half of the final torque.

    7. If the indicator needle moves 0.03 mm (0.001 inch) or less, tighten the bolt (32) to one-half of the final torque. Then proceed to Step 10.h. If the indicator needle moves more than 0.03 mm (0.001 inch), add shims under the bolt (32) or the other bolt (29). Loosen all the bolts and repeat Step 10.b through Step 10.g.

    8. Tighten all the bolts to the final torque. The indicator needle must not move more than 0.03 mm (0.001 inch).

11. Put the dial indicators at position "K". Zero the dial indicators. Rotate the drive flange in a clockwise direction when the engine is viewed from the front. Make a record of the readings, which are spaced 90 degrees from each other. Take these readings at the following locations: "L", "M", "N" and back to "K".

12. After all the readings have been taken, refer to the ""Analysis Of Measurements For The Auxiliary Generator" " Section.

Alignment Check Of An Assembled Unit

Use the following procedure and make a record of all measurements and indicator readings. Do not make corrections for misalignment until you have taken all the measurements. Refer to the ""Analysis Of Measurements For The Auxiliary Generator" " Section.

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Illustration 43	g00593250
(1) Resilient Member (Spider) (2) Drive Hub (3) Key (4) Generator Shaft (5) Coupling Half (6) PTO Drive

1. Remove the two sets of eight bolts (metric threads) that hold the coupling jaws to the drive flange and the generator hub. Close the jaws together. Then remove the jaws and the buffer ring as a complete assembly.

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Illustration 44	g00593352
(7) Bore (8) Face (9) PTO Drive Flange (A) 80 mm (3.15 inch)

2. Install the following alignment tooling: dial indicators, bolts and nuts on the generator drive hub and dowel pin on the drive flange. Locate the dial indicator that measures the face misalignment at the correct distance from the rotational centerline. Use the 9S-9082 Engine Turning Tool or the 3R-1937 Barring Tool to rotate the engine. The direction of rotation of the drive flange is clockwise when the engine is viewed from the front. Mark four equally spaced reference points on the outside of the drive flange. These marks will provide a spaced reference for the rotation of the shaft. A simple pointer can be fabricated to work in conjunction with these marks.

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Illustration 45	g00593372
(B) Dial Indicator Position (C) Dial Indicator Position (D) Dial Indicator Position (E) Dial Indicator Position (F) Bore (G) Face

3. Put the dial indicators at position "A". Zero the dial indicators. Rotate the drive flange in a clockwise direction when the engine is viewed from the front. Make a record of the readings, which are spaced 90 degrees from each other. Take the readings at the following locations: "B", "C", "D" and back to "A".

4. After all the readings have been taken, refer to the ""Analysis Of Measurements For The Auxiliary Generator" " Section for details.

Analysis Of Measurements For The Auxiliary Generator

Note: Refer to Table 6 in the ""Specifications" " Section for details.

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Illustration 46	g00593383
(A) Dial Indicator Position (B) Dial Indicator Position (C) Dial Indicator Position (D) Dial Indicator Position (E) Bore (F) Face

1. The bore alignment must be in accordance with the following steps.

   1. On new units, the TIR between "A" and "C" must be 0.18 ± 0.05 mm (0.007 ± 0.002 inch). On realigned units, the TIR between "A" and "C" must be 0.18 ± 0.05 mm (0.007 ± 0.002 inch). Since the centerline of the generator shaft must be above the centerline of the crankshaft, the indicator reading at "C" must be positive when the reading at "A" is zero. The dial indicator must also be at the location that is shown in Illustration 44.

   2. On used units, the TIR between "A" and "C" must be 0.18 ± 0.15 mm (0.007 ± 0.006 inch) with a plus reading at "C". If the reading is not within these specifications, realignment of the generator will be necessary.

   3. The TIR between "B" and "D" can be a maximum of 0.13 mm (0.005 inch) for new units. The TIR between "B" and "D" can be a maximum of 0.13 mm (0.005 inch) for realigned units. The TIR between "B" and "D" can be a maximum of 0.2 mm (0.008 inch) for used units.

   4. In both cases, the readings at "B" plus "D" must equal the reading at "C".

2. The face alignment must be in accordance with the following steps.

   1. On new units, a maximum TIR of 0.13 mm (0.005 inch) between "A" and "C" is permitted. On realigned units, a maximum TIR of 0.13 mm (0.005 inch) between "A" and "C" is permitted. On used units, realignment of the generator is not necessary until the TIR between "A" and "C" is more than 0.2 mm (0.008 inch).

   2. On new units, a maximum TIR of 0.13 mm (0.005 inch) between "B" and "D" is permitted. On realigned units, a maximum TIR of 0.13 mm (0.005 inch) between "B" and "D" is permitted. On used units, realignment of the generator is not necessary until the TIR between "B" and "D" is more than 0.2 mm (0.008 inch).

   3. In both cases, the readings at "B" plus "D" must equal the reading at "C".

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Illustration 47	g00593408
(G) +0.00 mm (0.000 inch) (H) +0.08 mm (0.003 inch) (I) +0.18 mm (0.007 inch) (J) +0.10 mm (0.004 inch) (K) +0.00 mm (0.000 inch) (L) -0.08 mm (0.003 inch) (M) -0.03 mm (0.001 inch) (N) +0.05 mm (0.002 inch) (O) Bore Readings (P) Face Readings

3. Refer to Illustration 47 for examples of indicator readings that are within the specification for new units. These examples are also applicable to realigned units.

Realignment Of An Assembled Unit

Use the following procedure to realign the generator, if the measurements are not within the specification that is shown in the ""Analysis Of Measurements For The Auxiliary Generator" " Section. After a correction has been made for a specific misalignment, all measurements must be taken again in order to verify the accuracy of the final alignment.

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Illustration 48	g00593423
(1) Generator Mounting Bolt (2) Generator Mounting Bolt (3) Generator Mounting Bolt (4) Generator Mounting Bolt (A) Dial Indicator Position (B) Dial Indicator Position (C) Dial Indicator Position (D) Dial Indicator Position

1. Use the following procedure to verify that the load on each support bracket of the generator is the same load.

   1. Loosen all the vertical alignment bolts. Install the following mounting bolts for the generator: (1), (2), (3) and (4) .

   2. Tighten the bolts to one-half of the final torque in the following sequence: (1), (2), (3) and (4) .

   3. Rotate the drive flange until the measuring bore of the dial indicator is at location "A". Zero the indicator.

   4. Loosen the bolt (1) and tighten the bolt (3) to one-half of the final torque.

   5. If the indicator needle moves 0.03 mm (0.001 inch), tighten the bolt (1) to one-half of the final torque. Then proceed to Step 1.f. If the indicator needle moves more than 0.03 mm (0.001 inch), add shims under the bolt (1) or the other bolt (3). Loosen all the bolts and repeat Step 1.b through Step 1.e.

   6. Loosen the bolt (2) and tighten the bolt (4) to one-half of the final torque.

   7. If the indicator needle moves 0.03 mm (0.001 inch) or less, tighten the bolt (2) to one-half of the final torque. Then proceed to Step 1.h. If the indicator needle moves more than 0.03 mm (0.001 inch), add shims under the bolt (2) or the other bolt (4). Loosen all the bolts and repeat Step 1.b through Step 1.g.

   8. Tighten all the bolts to the final torque. The indicator needle must not move more than 0.03 mm (0.001 inch).

2. Put the dial indicators at position "A". Zero the dial indicators. Rotate the drive flange in a clockwise direction when the engine is viewed from the front. Make a record of the readings, which are spaced 90 degrees from each other. Take the readings at the following locations: "B", "C", "D" and back to "A".

3. After all the readings have been taken, refer to the ""Analysis Of Measurements For The Auxiliary Generator" " Section for details.

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Illustration 49	g00593430
(1) Generator Mounting Bolt (2) Generator Mounting Bolt (3) Generator Mounting Bolt (4) Generator Mounting Bolt (5) Generator Horizontal Alignment Bolt (6) Generator Horizontal Alignment Bolt (7) Generator Horizontal Alignment Bolt (8) Generator Horizontal Alignment Bolt

4. If the measurements of the bore alignment were not within the specification, use the following procedure.

   The following conditions must exist before you loosen the mounting bolts for the generator. The TIR from "A" to "C" is greater than 0.23 mm (0.009 inch). There is a reading at "A" of 0.00 mm (0.000 inch). There is a plus reading at "C". If these conditions exist, loosen the following mounting bolts for the generator: (1), (2), (3) and (4). Remove an equal thickness of shims from the area under the following bolts: (1), (2), (3) and (4) .

   Note: If the reading at "C" is minus, the generator is too low and an equal thickness of shims must be installed under the following bolts: (1), (2), (3) and (4) .

   The following conditions must exist before you loosen the mounting bolts for the generator. The TIR from "A" to "C" is less than 0.13 mm (0.005 inch). The reading at "A" is 0.00 mm (0.000 inch). There is a plus reading at "C". If these conditions exist, loosen the following mounting bolts for the generator: (1), (2), (3) and (4). If shims are added, install an equal thickness of shims under the following bolts: (1), (2), (3) and (4) .

   Note: If the reading at "C" is minus, the generator is too low and an equal thickness of shims must be installed under the following bolts: (1), (2), (3) and (4) .

   The following conditions must exist before you loosen the mounting bolts for the generator. The TIR from "B" to "D" is greater than 0.13 mm (0.005 inch). The reading at "B" is more than the reading at "D". If these conditions exist, loosen the following mounting bolts for the generator: (1), (2), (3) and (4). Loosen the horizontal alignment bolt (5) and loosen the other alignment bolt (6). These bolts are adjacent to the mounting bolt (1) and the other mounting bolt (2). Simultaneously tighten the horizontal alignment bolt (7) and tighten the other alignment bolt (8). These bolts are adjacent to the mounting bolt (3) and the other mounting bolt (4). Tighten these alignment bolts to an equal setting.

   The following conditions must exist before you loosen the mounting bolts for the generator. The total indicator reading (TIR) from "B" to "D" is greater than 0.13 mm (0.005 inch). The reading at "B" is less than the reading at "D". If these conditions exist, loosen the following mounting bolts for the generator: (1), (2), (3) and (4). Loosen the horizontal alignment bolt (7) and loosen the other alignment bolt (8). These bolts are adjacent to the mounting bolt (3) and the other mounting bolt (4). Simultaneously tighten the horizontal alignment bolt (5) and tighten the other alignment bolt (6). These bolts are adjacent to the mounting bolt (1) and the other mounting bolt (2). Tighten these alignment bolts to an equal setting.

5. If the measurements of the face alignment are not within the specification, use the following procedure.

   The following conditions must exist before you loosen the mounting bolts for the generator. The TIR from "A" to "C" is greater than 0.13 mm (0.005 inch). There is a minus reading at "C". If these conditions exist, loosen the following mounting bolts for the generator: (1), (2), (3) and (4). If shims are removed, remove an equal thickness of shims from the area under the bolt (2) and the other bolt (3) .

   The following conditions must exist before you loosen the mounting bolts for the generator. The TIR from "A" to "C" is greater than 0.13 mm (0.005 inch). There is a plus reading at "C". If these conditions exist, loosen the following mounting bolts for the generator: (1), (2), (3) and (4). If shims are removed, remove an equal thickness of shims from the area under the bolt (1) and the other bolt (4) .

   The following conditions must exist before you loosen the mounting bolts for the generator. The TIR from "B" to "D" is greater than 0.13 mm (0.005 inch). The reading at "B" is less than the reading at "D". If these conditions exist, loosen the following mounting bolts for the generator: (1), (2), (3) and (4). Loosen the horizontal alignment bolt (7) that is adjacent to the mounting bolt (3). Simultaneously tighten the horizontal alignment bolt (6) that is adjacent to the mounting bolt (2). Tighten these alignment bolts to an equal setting.

   The following conditions must exist before you loosen the mounting bolts for the generator. The TIR from "B" to "D" is greater than 0.13 mm (0.005 inch). The reading at "B" is greater than the reading at "D". If these conditions exist, loosen the following mounting bolts for the generator: (1), (2), (3) and (4). Loosen the horizontal alignment bolt (6) that is adjacent to the mounting bolt (2). Simultaneously tighten the horizontal alignment bolt (7) that is adjacent to the mounting bolt (3). Tighten these alignment bolts to an equal setting.

6. Tighten the mounting bolts for the generator to the final torque. Check the face alignment and the bore alignment again. After all the corrections have been made for alignment, install the guard over the coupling.

Specifications