C18 Generator Set Caterpillar

Generator - Install

Usage:

C18 DDS

Installation Procedure

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Table 1
TOOLS NEEDED
Part Number	Tool	Quantity
8S-2328	Dial Indicator Group	1

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Illustration 1	g00616707
(1) Flywheel Pilot Bore (2) Surface

Note: A typical example

Remove all dirt, burrs, and paint from the contact surfaces of the generator supports and the base. Remove the protection material (compound) from flywheel pilot bore (1) and from surface (2). There should be no protection material that contacts the coupling. All contact surfaces of the engine, the coupling, and the generator must be clean.

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Illustration 2	g00295967
(3) Dial Indicator Group (4) Crankshaft Pulley

Note: A typical example

In order to rotate the engine, remove the timing covers pointer from the engines flywheel housing. Install dial indicator group (3). Refer to Illustration 2. The tip of the indicator must touch the face of crankshaft pulley (4). Use a bar between the flywheel and the flywheel housing in order to push the crankshaft toward the flywheel. The end play will be removed. Put the dial indicator in the ZERO position. Move the crankshaft to the most forward position. Make a record of the total indicator reading (TIR). The TIR is the end play of the crankshaft.

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Illustration 3	g00616727
(5) Shim Pack

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Illustration 4	g00616734
(6) Plate Assembly (7) Bolts

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NOTICE

Do not run the generator set unless the plate assembly has the correct clearance. If the plate assembly does not have the correct clearance, damage can occur to the engine and/or generator.

Before installation, temporarily position plate assembly (6) in the bore of the flywheel to check for clearance. There must be clearance between the plate assemblies outside diameter and the flywheel bores inside diameter. The plate assembly (6) can be a single solid plate or the plate assembly can be numerous flexible plates.

Install a full shim pack (5) and plate assembly (6) on the generator with bolts (7) .
Note: Incorrect torque of bolts (7) can distort the shims which may reduce rotor bearing end play. When the shims are assembled to the drive coupling, the bolts (7) must be tightened to the correct torque.
Note: The total thickness of shims (5) must not cause a reduction of crankshaft end play. When the generator is installed, the total thickness of shims (5) must not cause bending of plate assembly (6) .

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Illustration 5	g00295970
(8) Guide Bolt

Note: A typical example

Install guide bolt (8) in the flywheel.

Put the generator in position on the engine.

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Illustration 6	g00295971
(9) Bolts (10) Bolts

Note: A typical example

Install bolts (9) and (10). Tighten bolts (9) and (10).

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Illustration 7	g00295967

Note: A typical example

Install dial indicator group (3) in order to measure crankshaft end play at crankshaft pulley (4). In order to remove all end play, place a bar between the flywheel and the flywheel housing. Push the crankshaft toward the flywheel. Put the dial indicator in the ZERO position. Move the crankshaft to the most forward position and make a record of the total indicator reading (TIR). Do not use force to hold the crankshaft in position. The TIR is the end play of the crankshaft.
If the amount of end play is equal to the end play that was measured in Step 2, proceed to Step 11.
If the crankshaft end play is NOT equal to the original amount that was measured in Step 2, go to Step 9.

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Illustration 8	g00616727

Remove the generator. Remove shims (5) until the original amount of end play is reached. Refer to Step 2.

Install the generator and again check the crankshaft end play. Repeat Step 8.

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Illustration 9	g00616719
(11) Bolts (12) Generator supports

Note: A typical example

Install all bolts (11) which fasten generator supports (12) to the base. Do not tighten. Align the generator to the engine. Go to the following alignment procedure which corresponds to the particular generator set.

Generator Sets With 3500 Engine Family

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Table 2
TABLE FOR RECORDING MEASUREMENTS AND CALCULATIONS THAT ARE NECESSARY FOR THE INSTALLATION AND THE ALIGNMENT OF GENERATOR SETS WITH SINGLE BEARING GENERATORS
Line	Step	Description	Value
A	Step 2	Crankshaft End Play
B	Step 2	A / 2 =
C	Step 3	Flywheel Housing Surface
D	Step 3	Flywheel Pilot Surface
E	Step 3	C - D =
F	Step 5	Rotor End Play
G	Step 5	F / 2 =
H	Step 6	End Ring
I	Step 6	Drive Coupling
J	Step 6	I - H =
K	Step 7	Average Thickness of Plates
L	Step 8	Shim Gap J − B − E − G − K =
M	Step 8	Total Number of Shims L ÷ 0.8 mm (0.032 inch) = ⁽¹⁾
N	Step 14	Crankshaft End Play After Assembly
P	Step 14	Heat sink End Play After Assembly
Q	Step 14	Compare "N" to "A". If "N" is greater than "A" or equal to "A", the installation is finished. If "N" is less than "A", repeat the installation. Check for calculation errors and check for measurement errors.

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^( 1 )

Round this value up to the nearest whole number.

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Table 3
PARTS NEEDED
Part Number	Part	Quantity
5N-4479	Shim	6
5N-4478	Plate Assembly	1

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Table 4
TOOLS NEEDED
Part Number	Tool	Quantity
8S-2328	Dial Indicator Group	1

Disengage the generator from the engine. Perform the following procedure.

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Illustration 10	g00616707
(1) Flywheel Pilot Bore (2) Surface

Note: A typical example

Remove all dirt, burrs, and paint from the contact surfaces of the generator supports and the base. Remove the protection material (compound) from flywheel pilot bore (1) and from surface (2). There should be no protection material that contacts the coupling. All contact surfaces of the engine, the coupling, and the generator must be clean.

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Illustration 11	g00617579
(1) Dial indicator

Remove two of the engine side covers. Use a bar to rotate the crankshaft. Rotate the crankshaft until one of the crankshaft's throw cheeks is perpendicular to the side covers opening. Place a dial indicator on the perpendicular surface of the throw. Place a bar between the engine block and the crankshaft throw. Use the bar to push the crankshaft toward the flywheel in order to remove all end play. Zero the dial indicator. Turn the crankshaft to the most forward position. The amount of crankshaft end play that is shown on the dial indicator should be 0.178 mm (0.0070 inch) to 0.635 mm (0.0250 inch).
1. Record the measured value of crankshaft end play on "Line A" of Table 2.
1. Divide the value of "Line A" by two. Record this value on "Line B" of Table 2 (A / 2 = B).

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Illustration 12	g00617602
(1) Straight edge (2) Flywheel (3) Flywheel housing

Place the engine crankshaft at the extreme forward position. Position straight edge (1) across the face of flywheel (2). See Illustration 12.
1. Measure the distance between the top of straight edge (1) and flywheel housing (3) (mounting surface "C"). Record the value on "Line C" of Table 2.
1. Measure the distance between the top of straight edge (1) and Flywheel (2) (pilot surface (D) ). Record the value on "Line D" of Table 2.
1. Subtract "Line D" from "Line C". Record the value on "Line E" of Table 2 (C - D = E).

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Illustration 13	g00617609
(5) Coupling bolts (6) Flex plates

Remove coupling bolts (5) and washers. Remove flex plates (6), shims, and the exhaust fan. See Illustration 13. Attach a hoist to the rotor shaft and lift the rotor assembly. Locate the rotor so that the air space between the rotor and the stator is equal. Move the rotor to the rearmost position.

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Illustration 14	g00617618

Place a dial indicator on the vertical surface of the heat sink assembly. The heat sink assembly is located at the rear of the generators rotor shaft. See Illustration 14. The dial indicators plunger should be preloaded so that the forward movement of the rotor can be measured. Use the generator drive coupler to move the rotor forward. The amount of rotor end play that is shown on the dial indicator should be approximately 3.81 mm (0.150 inch) to 7.62 mm (0.300 inch).
1. Record the measured value of rotor end play on "Line F" of Table 2.
1. Divide the value of "Line F" by two. Record this value on "Line G" of Table 2 (F / 2 = G).

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Illustration 15	g00617620
(7) Straight edge (8) End ring (9) Drive coupling

Move the rotor assembly to the rearmost position. Before proceeding, ensure that the air gap is equal between the rotor assembly and the stator. Position straight edge (7) across the diameter of end ring (8). See Illustration 15.
1. Measure the distance from the top of straight edge (7) to the mounting surface (H) of end ring (8). Record this value on "Line H" of Table 2.
1. Measure the distance from the top of straight edge (7) to the mounting surface (I) of drive coupling (9). Record the value on "Line I" of Table 2.
1. Subtract "Line H" from "Line I". Record this value on "Line J" of Table 2 (I - H = J).
  Note: Attachment of the straight edge (ferrous material) can be accomplished by using two magnetic bases from the dial indicator.

Take a standard set of 17 5N-4478 Flex Plates. Bolt the plates together by using the flywheel mounting holes. The bolts should be tight, but not tightened to the final torque. Measure the thickness of the plates in two locations along the border.
1. Calculate the average of the two measurements. Record this value on "Line K" of Table 2.

In order to determine the number of shims that are required to provide proper axial alignment, perform the calculation that is shown on "Line L" of Table 2 (J - B - E - G - K = L). Record this value on "Line L" of Table 2.
1. Divide the value of "Line L" by 0.8 mm (0.032 inch). Record this new value on "Line M" of Table 2. The value that is shown on "Line M" is the total number of shims. This value should be rounded up to the nearest whole number.

Put the coupling plate assembly in position at the flywheel bore in order to check for clearance. There must be clearance between the coupling plate assemblies outside diameter and the inside diameter of the flywheel bore.

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Illustration 16	g00617609
(5) Coupling bolts (6) Coupling plate assembly

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NOTICE

Do not run the generator set unless the plate assembly has the correct clearance. If the plate assembly does not have the correct clearance, damage can occur to the engine and/or generator.

Place the total number of shims onto the drive coupling. The total number of shims was calculated on "Line M" of Table 2. Install coupling plate assembly (6) and bolts (5). Tighten the bolts to the proper torque.

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Illustration 17	g00617679
(10) Bolts

Install guide bolts in the flywheel. Guide bolts will assist in attaching the generator to the engine. Put the generator in position on the engine. Install bolts (10) which fasten the generator housing to the flywheel housing. Tighten bolts (10) to the standard torque.

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Illustration 18	g00617618

Place the crankshaft and the generator rotor in the respective rearmost positions. Place a dial indicator on the vertical surface of the heat sink assembly. The heat sink assembly is located at the rear of the generator rotor shaft. The dial indicators plunger should be preloaded so that the forward movement of the rotor can be measured. Push the generator forward to the midpoint of end play (0.5 mm (0.02 inch)).

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Illustration 19	g00617698
(11) Fan bolts

Install fan bolts (11) into the flywheel. Tighten the fan bolts to standard torque.

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Illustration 20	g00617579

Place a dial indicator on the vertical surface of the crankshaft throw cheek. Place another dial indicator on the vertical surface of the heat sink assembly. Refer to Step 12. Push the crankshaft forward in order to determine the amount of end play. The amount of crankshaft end play that is shown on the dial indicator should be 0.178 mm (0.0070 inch) to 0.635 mm (0.0250 inch). The amount of heat sink end play that is shown on the dial indicator should be 0.076 mm (0.0030 inch) to 0.635 mm (0.0250 inch).
1. After assembly is complete, measure the crankshaft end play. Record this value on "Line N" of Table 2.
1. After assembly is complete, measure the heat sink end play. Record this value on "Line P" of Table 2.
  Note: If the value of "Line N" or the value of "Line P" is less than the value of "Line A", disassemble the generator. Check the coupling plate assembly for bowing. If bowing is present, replace the coupling plate assembly. Check the calculations and measurements of these procedures for errors.

Install the generator and again repeat Step 12 through Step 14. After the correct number of shims have been installed and all measurements are within limits, proceed with installation. Align the generator to the engine. Go to the following alignment procedure which corresponds to the particular generator set.