3000 Frame SR5 Electric Power Generation Caterpillar

Adjust Spring Type Isolators

Note: Caterpillar recommends that all of the generator sets be installed on anti-vibration isolators. The isolators must be adjusted after the generator set is installed properly at the on-site location with all of the auxiliary equipment connected. The isolators must be adjusted correctly in order to ensure that the isolators are level. The isolators must be adjusted correctly to ensure that the generator is properly aligned to the engine. If the generator set is hard mounted to a foundation, the generator must be leveled properly.

1. Refer to Illustration 1. The spring isolators must be adjusted in order to ensure that the weight of the generator is equally distributed on all of the isolators. The springs for the isolators must be adjusted in order to ensure that the generator set is level.

2. The spring for each isolator will be compressed by the weight of the generator set. Use a ruler in order to measure the height (6) of the spring for each isolator. Refer to Illustration 1.
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   Illustration 1	g01599953
   (1) Base rail of generator set (2) Bolt for adjusting the isolator (3) Locknut for the isolator (4) Springs for the isolator (5) Foundation (6) Distance of spring height to be measured

3. Use the adjusting bolt (2) for the isolator in order to adjust the amount of weight that is placed on each isolator. The weight distribution of the generator set should be approximately the same amount for each isolator.

   Loosen the locknut (3) in order to be able to turn the adjusting bolt (2) for the isolator. If the weight distribution is not equal, then the springs for one isolator will be compressed more than the springs of another isolator. Turn the adjusting bolt (2) counterclockwise in order to back the adjusting bolt (2) off for the isolators that have the springs compressed more. Turn the adjusting bolt clockwise on the isolators that have the springs compressed less.

   The total rise of the rail above the foundation will not change but the weight will become distributed more evenly between the isolators.

   Note: If any of the springs are fully compressed and cannot be adjusted, verify that the isolator has been correctly sized for the application. There are springs that are available with a different spring rate.

   Note: Some generator sets may be shipped with larger isolators installed under the generator. Larger isolators are used if the generator is oversized. An oversized generator may cause the center of gravity of the generator set package to shift rearward. If a generator set has been shipped with large isolators installed under the generator, adjust the generator isolators as one set. Then, adjust the isolators under the engine as another set.

4. If the generator set is equipped with a radiator, verify that all of the springs for the radiator isolators are equally compressed. Adjust the springs for the radiator isolators if the springs are not equally compressed. The isolators that are used under the radiator may have a spring rate that is different. The isolators used under the radiator carry only the weight of the radiator. The spring compression of the isolators used for the radiator may not need to be identical to the spring compression for main base rail isolators.

   Note: Make sure that the radiator is filled with coolant prior to the adjustment.

5. After all of the isolators are adjusted, secure the position of each adjusting bolt. Tightening the locknut (3) against the base (1) of the generator stator.

   Note: Do not measure the height of the isolator from the floor. The floor may not be even. Measuring the spring compression will ensure that all of the isolators carry the weight of the generator evenly. If an individual isolator bolt is turned further than required, the adjustment will cause the isolator to carry additional weight. An incorrect adjustment can cause the generator set to rise. If adjusting bolts are used to level the entire generator set, perform the following. Turn all of the isolator bolts that are under the part of the generator set that needs to be elevated. Measure the spring compression after the generator set is level. If necessary, adjust the bolts for the isolators again. Proper adjustment will ensure that all of the isolators carry the weight of the generator evenly.

Adjust Rubber Isolators

1. Ensure that the mounting bolt threads are clean. Ensure that the mounting bolt threads are without damage. Ensure that the threaded holes in the isolator, that are used for the adjusting bolts, are clean. Also, ensure that the same threaded holes are not damaged.
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   Illustration 2	g01601195
   (10) Base rail for the generator set (11) Adjusting bolt for the isolator (12) Locknut for the isolator (13) Foundation (14) Rubber isolator

2. Torque each adjusting bolt (11) to the same value for each isolator. There is no standard value for the adjustment of the bolt torque. The bolt torque will depend on the total weight of the generator set. Stop when a preset torque is reached or when a slight rise of the base rail is observed.

   The adjusting bolts for the isolators must be tightened incrementally until the final torque is reached. Select a desired starting value for the torque that is a value less than the final torque value.

   Start by selecting any one of the adjusting bolts. Adjust the torque of the remaining adjusting bolts, for each remaining isolator, to the same torque as the first adjusting bolt.

   Next, adjust the value of the torque closer to the final torque value. Again, adjust all of the adjusting bolts for each isolator. Repeat this procedure until the final torque value is reached.

   The adjusting bolt for each isolator must be set incrementally to the final torque. If a torque wrench is used, set the starting value of the torque wrench at a value that is less than the final torque value.

   Torque each of the adjusting bolts to the same value. Then, adjust the value of the torque wrench closer to the final torque value. Torque all of the adjusting bolts for each isolator again. Repeat this procedure until the final torque value is reached. If the value of the torque is the same for each isolator, then the weight of the generator set is distributed equally to each of the isolators.

   Note: Do not measure the height of the isolator from the floor. The floor may not be even. The same torque on each of the mounting bolts will ensure that the rubber part of the isolator is extended out from the metal cup. The adjustments will account for irregularities in the surface of the floor. The weight of the generator set will be evenly distributed to each of the isolators after the same torque has been applied to each of the mounting bolts.

   Note: If the adjuster bolt for the isolator is turned more than the required amount, then the isolator will carry excessive weight.

3. If the generator set is equipped with a radiator, then adjust the radiator isolators separately. Use a lower torque value for the adjuster bolts that are used on the radiator since those isolators carry only the weight of the radiator. Verify that the base frame for the radiator is at the same level as the base rail that is used for the generator set.

   Note: Make sure that the radiator is filled with coolant prior to the adjustment.

Illustration 3	g02719986
(20) Generator terminal box (21) Generator (22) Engine (23) Radiator (24) Correctly aligned radiator with base rail (25) Base rail of the generator (26) Spring isolators (27) Incorrectly aligned radiator with base rail

Generator Alignment

Start By:

1. Adjust the anti-vibration isolators. Refer to "Adjust Spring Type Isolators" or "Adjust Rubber Type Isolators" section in this manual. The isolators must be adjusted after the generator set is installed properly at the on-site location with all of the auxiliary equipment connected. The isolators must be adjusted correctly in order to ensure that the isolators are level. The isolators must be adjusted correctly to ensure that the generator is properly aligned to the engine.

2. Refer to Special Instruction, REHS0177 for alignment procedures for generators that use two bearings.

Align Generator Sets

Note: The single bearing generators or the two bearing closed coupled generators do not require optical or laser shaft to crankshaft field realignment. Single bearing generators are designed to locate the rear rotor bearing in the correct position when the generator stator is properly aligned. The method that is described below must be used. The rotor shaft nose pilot that is used for the single bearing generator is designed to eliminate the need for lateral alignment. The main rotor is supported by the bearings that are installed in a two bearing, close coupled, generator set. The support of rotor does not depend on the engine. The coupling will accommodate for slight rotor misalignment due to the manufacturing tolerances when the generator is properly aligned. The method that is described below must be used.

1. Torque all of the mounting bolts , that fasten the generator supports to the base, to half of the final torque.

2. Loosen all of the bolts (40) that fasten the generator to the flywheel housing. Visually ensure that the bolts (40) are centered in the clearance holes. Visually ensure that the raised lip (41) of the front adapter of the generator is centered in the recessed bore of the flywheel housing.
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   Illustration 4	g01585314
   (40) Mounting Bolts for the Front Bracket of the Generator

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   Illustration 5	g01602114

3. Check the gaps at the 3 o'clock, the 6 o'clock, the 9 o'clock, and the 12 o'clock positions. The procedure to set the gap is to ensure that the generator body is vertically and horizontally aligned to the engine flywheel housing.

   The gaps (42) at locations (E), (G), (F), and (H) should be more than 0.03 mm (0.001 inch) and less than 0.13 mm (0.005 inch). If the gaps at locations (E) and (G) are not correct, then loosen the bolts that fasten the generator to the base frame. Raise the generator by using the jacking bolts. Adjust the number of shims under each generator support. If the gaps at locations (F) and (H) are not correct, then loosen the bolts for the generator supports. Move the rear of the generator to the right or left accordingly.

   Note: The 2 o'clock, 4 o'clock, 8 o'clock, and 10 o'clock positions will be adequate if the 12 o'clock, and 6 o'clock positions are inaccessible.

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   NOTICE
   The flywheel housing and the generator housing must be parallel within 0.025 mm (0.001 inch) to 0.127 mm (0.005inch). Refer to Special Instruction, REHS0177 for additional information.

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   Illustration 6	g01602353

4. After a correction has been made to the thickness in the shims, tighten the generator support bolts to half of the final torque. Check the gap at locations (E), (G), (F), and (H). Repeat this procedure until the gap measurements are 0.13 mm (0.005 inch) or less.

5. Install a dial indicator, that has a magnetic base, on the base rail (47) of the generator. The indicator tip must be located next to a support mounting bolt (45). Illustration 7 provides an example of a location (46) for the indicator tip. Check the indicator while you are tightening the bolt to the final torque. If the indicator moves more than 0.13 mm (0.005 inch), the thickness of the shim is incorrect under that bolt. Install the needed shims. Repeat the procedure until all the mounting bolts for the engine support and generator support have been tightened to the final torque. Also, repeat the procedure until the support deflection is within the specification.
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   Illustration 7	g01585333
   (45) Adjusting bolt for the generator (46) Location for indicator tip (47) Base rail for the generator

6. Verify the end play for the two bearings generators.

   1. Set the engine crankshaft end play to the middle position.

   2. Install a dial indicator on the end of the generator shaft or on the PMG rotor.

      Note: Do not pry on the flex coupling or the generator fan.

      Note: Use a large pry bar in order to pry only between the hub that is on the main rotor and the bearing bracket. A significant force may be required in order to move the rotor initially. Care must be taken to ensure that no damage occurs to any electrical components or to the generator windings.

   3. Use a pry bar on the hub that is on the main rotor of the generator. Pry against the bearing bracket. Move the rotor all the way forward. Place the dial indicator to zero.

   4. Move the rotor all the way rearward. Record the dial indicator reading.

   5. Divide the total amount of rotor movement by two. Set the rotor to the center position. The end play for the generator should be approximately 8 mm (0.3150 inch). Set the end play of the generator to the middle position.

      Note: If the rotor cannot be moved due to the inner element of the coupling, then the hub may not be installed correctly. Refer to the "Generator - Install" section subtitle "Install 3000 Frame Two Bearing Generators" for correct hub placement on the main rotor shaft.

      Note: If the generator rotor cannot be moved, but the coupling does not appear to restrict the movement of the rotor, then the outer rings of the bearing may be frozen in the sleeves. Refer to the "Bearing - Remove and Install" section for the removal procedure information.

Reverse Rotation Generators with a Gear Box

The following information applies to those generators with a gear box. The information applies to serial numbers KSJ and GLN.

Illustration 8	g03454004
(50) Engine (51) Gear box (52) Generator

1. Refer to Special Instruction, REHS7854 for alignment information for the reverse rotation generators that utilize a gearbox. Proper alignment of the engine to gearbox and the gearbox to generator is necessary for maximum performance and durability of the generator set.