Guidelines for Servicing Flexible Couplings on Certain C175-16 Locomotive and Petroleum Engines{3252} Caterpillar

Engine:

C175-16 (S/N: P6L1-UP; R1X1-UP)

Introduction

This Special Instruction provides the Disassembly and Assembly, the Inspection, and the Troubleshooting needed for servicing the flexible couplings for the above C175-16 Locomotive and Petroleum Engines.

Note: Do not damage the coupling with tools (wrench, hammer, etc.) during assembly and installation. Do not step on the coupling.

Note: Any impacts to the surface of the coupling can lead to damages of the fiber reinforced plastic. These impacts are not necessarily visible from the outside. These impacts may reduce the service life of the coupling.

Disassembly and Assembly

Disassembly of the 329-0236 Flexible Coupling Gp , 350-7171 Flexible Coupling Gp , 350-7182 Flexible Coupling Gp , and 396-3847 Flexible Coupling Gp .

1. Remove the flexible coupling gp guards.

2. Disconnect the generator from the flexible coupling gp.

3. Using a suitable lifting device, remove the generator from the engine. The generator weighs approximately 6804 kg (15000 lb).

   Note: Always refer to the manufacture's identification plate on the generator for the correct weight.

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Illustration 1	g03354490
(1) 349-5263 Flywheel As (2) Flexible coupling gp (3) Inner star flange (4) 166-1880 Bolt (5) 199-7107 Spring

4. Remove two bolts (4) and two springs (5) from flexible coupling gp (2) .

   Note: The two bolts and springs need to be opposite from one another.

5. Install two M20 x 2.5 dowels into flywheel (1) where bolts (4) were removed.

6. Remove the remaining bolts (4) and springs (5) .

Note: Approximately 4 L (1 US gal) of oil will drain from the flexible coupling gp when separated from the flywheel.

Note: Use the threaded holes on the face of the coupling for lifting.

7. Using a suitable lifting device, remove flexible coupling gp (2). The flexible coupling gps weigh approximately:
   • 329-0236 Flexible Coupling Gp 102 kg (225 lb)

   • 350-7171 Flexible Coupling Gp 102 kg (225 lb)

   • 350-7182 Flexible Coupling Gp 102 kg (225 lb)

   • 396-3847 Flexible Coupling Gp 102 kg (225 lb)

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Illustration 2	g03440142
(2) Flexible coupling gp (6) Spring pack assembly

8. Rest the flexible coupling gp (2) onto the inner star flange with the spring pack assembly side facing up. Refer to Illustration 2 for the correct placement of the flexible coupling gp.

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Illustration 3	g03356290
(2) Flexible coupling gp (3) Inner star flange (7) Bolt (8) Washer (9) Centering ring (10) Outside O-ring (11) End cover

9. Remove O-ring (10) from the flexible coupling gp (2) .

   Note: The O-ring may be stuck to the flywheel.

10. Remove bolts (7) and washers (8) from end cover (11) .

11. Remove end cover (11) from inner star flange (3) and center ring (9) .

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Illustration 4	g03440540
(2) Flexible coupling gp (9) Centering ring (12) Inside O-ring (13) 337-3140 Seal

12. Remove O-ring (12) from centering ring (9) .

13. Remove seal (13) from centering ring (9) .

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Illustration 5	g03441117
(2) Flexible coupling gp (3) Inner star flange (9) Centering ring

14. Rest flexible coupling gp (2) on centering ring (9) .

15. Remove inner star flange (3) from flexible coupling gp (2) .

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Illustration 6	g03441536
(14) Outer coupling flange (15) Bolt (16) Washer

16. Remove bolts (15) and washers (16) from the flexible coupling gp.

17. Rest the flexible coupling gp on outer coupling flange (14) .

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Illustration 7	g03356654
(2) Flexible coupling gp (9) Centering ring (17) Bolt (18) Washer

18. Remove bolts (17) and washers (18) from centering ring (9) .

19. Remove centering ring (9) from flexible coupling gp (2) .

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Illustration 8	g03356561
(6) Spring pack assembly (10) Outside O-ring (14) Outer coupling flange

20. Remove spring pack assembly (6) from outer coupling flange (14) .

21. Remove O-ring (10) from outer coupling flange (14) .

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Illustration 9	g03354492
(3) Inner star flange (11) End cover (19) O-ring

22. Remove one O-ring (19) from inner star flange (3) and end cover (11) .

Disassembly of the 377-2138 Flexible Coupling Gp , 385-7508 Flexible Coupling Gp , and 372-5244 Flexible Coupling Gp .

1. Remove the flexible coupling gp guards.

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Illustration 10	g03457898
(1) 349-5263 Flywheel As (2) Flexible coupling gp (20) Membrane (21) Generator hub (22) Hub adapter

2. Remove hub adapter (22) from generator hub (21) and membrane (20) .

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Illustration 11	g03422705
(2) Flexible coupling gp (20) Membrane (23) Bolt (24) Assembly sleeve

3. Remove two bolts (23) and two assembly sleeves (24) from membrane (20) .

   Note: The two bolts and springs need to be opposite from one another.

4. Install two M8 X 1.25 dowels into flexible coupling gp (2) where bolts (23) were removed.

5. Remove the remaining bolts (23) and assembly sleeves (24) .

6. Remove membrane (20) from flexible coupling gp (2) .

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Illustration 12	g03422682

7. Remove two bolts (4) and two springs (5) from flexible coupling gp (2) .

   Note: The two bolts and springs need to be opposite from one another.

8. Install two M20 x 2.5 dowels into flywheel (1) where bolts (4) were removed.

9. Remove the remaining bolts (4) and springs (5) .

Note: Approximately 4 L (1 US gal) of oil will drain from the flexible coupling gp when separated from the flywheel.

Note: Use the threaded holes on the face of the coupling for lifting.

10. Using a suitable lifting device, remove flexible coupling gp (2). The flexible coupling gps weigh approximately:
    • 377-2138 Flexible Coupling Gp 109 kg (240 lb)

    • 385-7508 Flexible Coupling Gp 109 kg (240 lb)

    • 372-5244 Flexible Coupling Gp 109 kg (240 lb)

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Illustration 13	g03441336
(2) Flexible coupling gp (6) Spring pack assembly

11. Rest the flexible coupling gp (2) onto inner star flange (3) with the spring side facing up. Refer to Illustration 13 for the correct placement of the flexible coupling gp.

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Illustration 14	g03422727
(2) Flexible coupling gp (3) Inner Star Flange (9) Centering ring (10) Outside O-ring (25) Bolt (26) Washer (27) End cover

12. Remove O-ring (10) from the flexible coupling gp (2) .

    Note: The O-ring may be stuck to the flywheel.

13. Remove bolts (25) and washers (26) from end cover (27) .

14. Remove end cover (27) from inner star flange (3) and centering ring (9) .

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Illustration 15	g03441360
(2) Flexible coupling gp (9) Centering ring (12) Inside O-ring (13) 337-3140 Seal

15. Remove O-ring (12) from centering ring (9) .

16. Remove seal (13) from centering ring (9) .

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Illustration 16	g03441364
(2) Flexible coupling gp (3) Inner star flange (9) Centering ring

17. Rest flexible coupling gp (2) on centering ring (9) .

18. Remove inner star flange (3) from flexible coupling gp (2) .

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Illustration 17	g03441536
(14) Outer coupling flange (15) Bolt (16) Washer

19. Remove bolts (15) and washers (16) from the flexible coupling gp.

20. Rest the flexible coupling gp on outer coupling flange (14) .

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Illustration 18	g03356654
(2) Flexible coupling gp (9) Centering ring (17) Bolt (18) Washer

21. Remove centering ring (9) from flexible coupling gp (2) .

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Illustration 19	g03356561
(6) Spring pack assembly (10) Outside O-ring (13) Outer coupling flange

22. Remove spring pack assembly (6) from outer coupling flange (14) .

23. Remove O-ring (10) from outer coupling flange (14) .

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Illustration 20	g03422775
(3) Inner star flange (9) End cover (19) O-ring (27) End cover

24. Remove one O-ring (19) from inner star flange (3) and end cover (27) .

Assembly of the 329-0236 Flexible Coupling Gp , 350-7171 Flexible Coupling Gp , 350-7182 Flexible Coupling Gp , and 396-3847 Flexible Coupling Gp .

1. Clean and inspect every part carefully before assembly.

   Note: Venting holes as well as oil supply and return holes must be free of dirt and contamination. Thoroughly remove any carbon deposits that may be present in the spring chambers.

2. Replace all bolts up to and including thread size M20.

   Bolts larger than M20 may only be reused if the following criteria are met:

   • The bolt head must not be damaged.

   • The bolt thread must not be damaged or stretched.

   • The surface on which the bolt head rests must not be damaged.

   • The bolt must be cleaned completely.

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Illustration 21	g03356561
(6) Spring pack assembly (10) Outside O-ring (14) Outer coupling flange

3. Coat one O-ring (10) and the O-ring groove of outer coupling flange (14) with Molykote 111 or equivalent.

4. Install one O-ring (10) into the O-ring groove of outer coupling flange (14) .

5. Install spring pack assembly (6) onto outer coupling flange (14) .

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Illustration 22	g03356667
(6) Spring pack assembly (7) Bolt (8) Washer (9) Centering ring (14) Outer coupling flange

Note: Make sure that the oil return hole in centering ring (9) and the oil return groove in the intermediate piece of spring pack assembly (6) are aligned.

6. Attach centering ring (9) to outer coupling flange (14) with four bolts (7) and four washers (8). Use Loctite 243 on bolts (7) .

   Torque bolts ... 30 ± 3 N·m (22 ± 2 lb ft)

7. Coat the O-ring running surface of outer coupling flange (15) with Molykote 2484 or equivalent.

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Illustration 23	g03356388
(6) Spring pack assembly (14) Outer coupling flange (15) Bolt (16) Washer

8. Attach outer coupling flange (14) to spring pack assembly (6) with two bolts (15) and two washers (16) .

   Torque bolts ... 71 ± 7 N·m (52 ± 5 lb ft)

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Illustration 24	g03356694
(2) Flexible coupling gp (3) Inner star flange (19) O-ring

9. Coat one O-ring (19) and the O-ring groove of inner star flange (3) with Molykote 111 or equivalent.

10. Install one O-ring (19) onto inner star flange (3) .

11. Protect all outer surfaces (surfaces which are later inside the coupling) of inner star flange (3) including the grooves against rust with a thin coat of Tectyl oil.

12. Rest inner star flange (3) onto a flat surface. Refer to Illustration 31 for the correct orientation.

13. Install flexible coupling gp (2) onto inner star flange (3) .

    Note: Make sure that the spring packs are aligned with inner star flange grooves.

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Illustration 25	g03356704
(2) Flexible coupling gp (9) Centering ring (11) End cover (17) Bolt (18) Washer (19) O-ring

14. Coat one O-ring (19) and the O-ring groove of end cover (11) with Molykote 111 or equivalent.

15. Install one O-ring (19) onto end cover (9) .

16. Coat the O-ring running surface of centering ring (11) with Molykote 2484 or equivalent.

17. Install end cover (11) into centering ring (9) .

18. Attach end cover (9) to inner star flange (3) with seven bolts (17) and seven washers (18). Use Loctite 243 on bolts (18) .

    Torque bolts ... 14 ± 1.4 N·m (124 ± 12 lb in)

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Illustration 26	g03425291
(9) Centering ring (12) Inside O-ring (13) 337-3140 Seal

19. Install one seal (13) into centering ring (9) .

20. Install one O-ring (12) into centering ring (9) .

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Illustration 27	g03357141
(1) 349-5263 Flywheel As (2) Flexible coupling gp (4) 166-1880 Bolt (5) 199-7107 Spring

21. Install two M20 x 2.5 dowels into flywheel (1) .

    Note: The two dowels need to be opposite from one another.

Note: Do not lift the coupling on possible existing inserts in the flanges.

22. Using a suitable lifting device, install flexible coupling gp (2). The flexible coupling gps weigh approximately:
    • 329-0236 Flexible Coupling Gp 96 kg (212 lb)

    • 350-7171 Flexible Coupling Gp 96 kg (212 lb)

    • 350-7182 Flexible Coupling Gp 96 kg (212 lb)

    • 396-3847 Flexible Coupling Gp 106 kg (234 lb)

Note: Apply Loctite 243 onto both sides of springs (5) .

23. Attach flexible coupling gp (2) to flywheel (1) with 12 bolts (4) and 12 springs (5) .

    Torque bolts ... 540 ± 70 N·m (398 ± 52 lb ft)

24. Remove the two dowels from flywheel (1) .

Note: Apply Loctite 243 onto both sides of springs (5) .

25. Install the remaining two bolts (4) and two springs (5) into flywheel (1) .

    Torque bolts ... 540 ± 70 N·m (398 ± 52 lb ft)

26. Using a suitable lifting device, attach the generator to the engine. The generator weighs approximately 6804 kg (15000 lb).

    Note: Always refer to the manufacture's identification plate on the generator for the correct weight.

27. Align the generator with the engine.

28. Connect the generator hub to the flexible coupling gp.

    Torque bolts ... 240 ± 24 N·m (177 ± 18 lb ft)

29. Install the flexible coupling gp guards.

Assembly of the 377-2138 Flexible Coupling Gp , 385-7508 Flexible Coupling Gp , and 372-5244 Flexible Coupling Gp .

1. Clean and inspect every part carefully before assembly.

   Note: Venting holes as well as oil supply and return holes must be free of dirt and contamination. Thoroughly remove any carbon deposits that may be present in the spring chambers.

2. Replace all bolts up to and including thread size M20.

   Bolts larger than M20 may only be reused if the following criteria are met:

   • The bolt head must not be damaged.

   • The bolt thread must not be damaged or stretched.

   • The surface on which the bolt head rests must not be damaged.

   • The bolt must be cleaned completely.

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Illustration 28	g03356561
(6) Spring pack assembly (10) Outside O-ring (14) Outer coupling flange

3. Coat one O-ring (10) and the O-ring groove of outer coupling flange (14) with Molykote 111 or equivalent.

4. Install one O-ring (10) into the O-ring groove of outer coupling flange (14) .

5. Install spring pack assembly (6) onto outer coupling flange (14) .

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Illustration 29	g03356667
(6) Spring pack assembly (7) Bolt (8) Washer (9) Centering ring (14) Outer coupling flange

Note: Make sure that the oil return hole in centering ring (9) and the oil return groove in the intermediate piece of spring pack assembly (6) are aligned.

6. Snuggly attach centering ring (9) to outer coupling flange (14) with four bolts (7) and four washers (8). Use Loctite 243 on bolts (7) .

7. Rotate assembled parts on a turn table to align centering ring (9) .

   Use a dial indicator to check the alignment. The maximum concentricity is 0.2 mm (0.008 inch).

   When a high spot is found, lightly tap the high spot until centering ring (9) is within the maximum concentricity.

8. Finish tightening bolts (7) .

   Torque bolts ... 30 ± 3 N·m (22 ± 2 lb ft)

9. Coat the O-ring running surface of outer coupling flange (15) with Molykote 2484 or equivalent.

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Illustration 30	g03356388
(6) Spring pack assembly (14) Outer coupling flange (15) Bolt (16) Washer

10. Attach outer coupling flange (14) to spring pack assembly (18) with two bolts (15) and two washers (16) .

    Torque bolts ... 71 ± 7 N·m (52 ± 5 lb ft)

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Illustration 31	g03356694
(2) Flexible coupling gp (3) Inner star flange (19) O-ring

11. Coat one O-ring (19) and the O-ring groove of inner star flange (3) with Molykote 111 or equivalent.

12. Install one O-ring (19) onto inner star flange (3) .

13. Protect all outer surfaces (surfaces which are later inside the coupling) of inner star flange (3) including the grooves against rust with a thin coat of Tectyl oil.

14. Rest inner star flange (3) onto a flat surface. Refer to Illustration 31 for the correct orientation.

15. Install flexible coupling gp (2) onto inner star flange (3) .

    Note: Make sure that the spring packs are aligned with inner star flange grooves.

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Illustration 32	g03424896
(2) Flexible coupling gp (3) Inner star flange (9) Centering ring (13) Bolt (14) Washer (19) O-ring (25) Bolt (26) Washer (27) End cover

16. Coat one O-ring (19) and the O-ring groove of end cover (27) with Molykote 111 or equivalent.

17. Install one O-ring (19) onto end cover (27) .

18. Coat the O-ring running surface of centering ring (9) with Molykote 2484 or equivalent.

19. Install end cover (27) into centering ring (9) .

20. Attach end cover (27) to inner star flange (3) with eight bolts (25) and eight washers (26). Use Loctite 243 on bolts (23) .

    Torque bolts ... 71 ± 7 N·m (52 ± 5 lb ft)

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Illustration 33	g03425007
(9) Centering ring (12) Inside O-ring (13) 337-3140 Seal

21. Install one seal (13) into centering ring (9) .

22. Install one O-ring (12) into centering ring (9) .

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Illustration 34	g03357141
(1) 349-5263 Flywheel As (2) Flexible coupling gp (4) 166-1880 Bolt (5) 199-7107 Spring

23. Install two M20 x 2.5 dowels into flywheel (1) .

    Note: The two dowels need to be opposite from one another.

Note: Do not lift the coupling on possible existing inserts in the flanges.

24. Using a suitable lifting device, install flexible coupling gp (2). The flexible coupling gps weigh approximately:
    • 377-2138 Flexible Coupling Gp 148 kg (326 lb)

    • 385-7508 Flexible Coupling Gp 148 kg (326 lb)

    • 372-5244 Flexible Coupling Gp 148 kg (326 lb)

Note: Apply Loctite 243 onto both sides of springs (5) .

25. Attach flexible coupling gp (2) to flywheel (1) with 12 bolts (4) and 12 springs (5) .

    Torque bolts ... 540 ± 70 N·m (398 ± 52 lb ft)

26. Remove the two dowels from flywheel (1) .

Note: Apply Loctite 243 onto both sides of springs (5) .

27. Install the remaining two bolts (4) and two springs (5) into flywheel (1) .

    Torque bolts ... 540 ± 70 N·m (398 ± 52 lb ft)

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Illustration 35	g03422884
(20) Membrane (23) Bolt (24) Assembly sleeve (28) Retaining washers

28. Clean the glued surface on membrane (20) with Aceton.

29. Grind glued surfaces with 120 or 180 grit sandpaper.

30. Remove sandpaper grains with a vacuum.

31. Clean the glued surface on membrane (20) with Aceton.

32. Grind the glued surface on retaining washers (28) and clean with Aceton.

33. Apply Araldite 2014 onto retaining washers (28) .

34. Install all retaining washers (28) into membrane (20) hand tight use one bolt (23) and assembly sleeve (24) per retaining washer.

35. Remove the bolt and assembly sleeve, keep retaining washer in position by hand and remove surplus glue in the hole.

36. Install the bolt and assembly sleeve hand tight. Make sure that the assembly sleeve rests right on the membrane surface.

37. Heat the glue in an oven at following temperatures and times:
    • 60° C (140° F) for 40 minutes

    • 40° C (104° F) for 90 minutes

    • 20° C (68° F) for 6 hours

38. Remove bolt and assembly sleeve

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Illustration 36	g03422705
(20) Membrane (23) Bolt (24) Assembly sleeve

39. Attach membrane (20) to flexible coupling gp (2) with 14 bolts (23) and 14 assembly sleeves (24) .

    Torque bolts ... 30 ± 3 N·m (22 ± 2 lb ft)

40. Remove the two dowels from the flexible coupling gp (2) .

41. Install the remaining two bolts (23) and two assembly sleeves (24) into flexible coupling gp (2) .

    Torque bolts ... 30 ± 3 N·m (22 ± 2 lb ft)

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Illustration 37	g03458138
(20) Membrane (21) Generator hub (22) Hub adapter

42. Attach hub adapter (22) to membrane (20) .

    Torque bolts ... 30 ± 3 N·m (22 ± 2 lb ft)

43. Connect generator hub (21) to hub adapter (22) .

    Torque bolts ... 610 ± 61 N·m (450 ± 45 lb ft)

44. Install the flexible coupling gp guards.

Inspection

1. Inspect the membrane for the following:
   • Scratches

   • Cracks

   • Defects

   • Damage

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Illustration 38	g03354493
(6) Spring pack assembly (29) Intermediate piece

2. Check the divergence from concentricity at the inside diameter of all intermediate pieces (29). Refer to Table 1 for the correct dimension.
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   Table 1

   Maximum Concentricity for the Inner Diameter
   0.2 mm (0.008 inch)

   If the inside diameter is out of tolerance, contact customer service or a customer service location to discuss the issue in more detail.

   Note: Replace all O-rings at least 6 years after the start of operation.

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Illustration 39	g03354489
Middle blades (29) Intermediate piece (30) Spring blade (31) Bronze shim

Note: Wear or deformation of bronze shims (31) (in the case of multiple blades), which are inserted between the spring blades, is normal and therefore no reason to service or exchange the spring packs.

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Illustration 40	g03355502
(A) Permissible wear (B) Thickness of middle blade.

Note: Maximum permissible wear at the inner ends is half the thickness of the middle blade.

3. Measure the permissible wear (A) per contact side of middle blade (B) .

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Illustration 41	g03354896
Inner star flange (C) The wear value to the groove flanks

4. Measure the wear value (C) on the groove flanks. Refer to Table 2 for the correct dimension.
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   Table 2

   Maximum Dimension (C)
   1 mm (0.039 inch)

   If damage or wear is identified but not described above, contact customer service or a customer service location to discuss the issue in more detail.

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Illustration 42	g03422709
(D) Radial bearing clearance (3) Inner star flange (14) Outer coupling flange (32) Bearing in the outer coupling flange

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Illustration 43	g03422728
(D) Radial bearing clearance (9) Centering ring (27) End Cover (33) Bearing in the centering ring

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Illustration 44	g03424946
(E) Axial bearing clearance (2) Flexible coupling gp (3) Inner star flange

5. Measure radial bearing clearance (D) and axial bearing clearance (E). Refer to Table 3 for the correct bearing clearance.

   Note: Axial bearing clearance (E) is the total back and forth movement of inner star flange (3).

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   Table 3

   Bearing Condition	Radial Bearing Diameter Clearance	Axial Bearing Total Clearance
   New	0.11 mm (0.004 inch) to 0.27 mm (0.011 inch)	0.3 mm (0.012 inch) to 0.4 mm (0.016 inch)
   Used	Max. 0.54 mm (0.021 inch)	Max. 0.8 mm (0.032 inch)

Troubleshooting

Mechanical damage to the coupling can be caused by the following:

• Impact from heavy objects like tools and so on

• Overload of the coupling

• Other unknown sources

Due to the smaller wall thickness and the higher stress level compared to the conical shaft region, damages on the membrane are more critical for the structural integrity of the coupling than damages on the conical shaft.

Note: If other damage or wear to the product is identified but not described in this table, contact customer service or a customer service location.