SR4 Generator with VR3 or VR4 Voltage Regulator Caterpillar

Installation Procedure

Note: The generator must not restrict the end play of the engine crankshaft. Damage to the generator and damage to the engine can occur.

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Illustration 1	g00856163
(1) Tooling

1. Attach tooling (1) to the flywheel. Move the engine crankshaft all the way to the rear. Put the dial indicator of tooling (1) in the ZERO position. Move the crankshaft to the most forward position, and record the crankshaft end play.

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Illustration 2	g00856166
(2) Shim Pack (3) Plate Assembly (4) Fan (5) Guide Bolts

Note: All contact surfaces of the following components must be clean: the rotor, the shim pack, the coupling plates and the flywheel.

2. Attach a hoist to the generator. The point of attachment and the weight vary with the size of the generator. A strap must be used on smaller generators when a shackle is not provided.

3. Install two guide bolts (5) and place fan (4) loosely in the generator.

Note: The number of plates and shims within plate assembly (3) varies with the generator set. The number of plates and shims within shim pack (2) varies with the generator set. Ensure that the correct quantity is installed.

4. Place shim pack (2) and coupling plates (3) on the rotor shaft. Install the bolts and tighten the bolts which fasten shim pack (2) to the rotor. Install the bolts and tighten the bolts which fasten coupling plates (3) to the rotor. Remove guide bolts (5). Replace guide bolts (5) with the bolts which fasten the shim pack (2) and coupling plates (3) .

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Illustration 3	g00856167
(6) Guide Bolt

5. Install guide bolt (6) in the flywheel. Put the generator in position on the engine.

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Illustration 4	g00856168
(7) Bolt (8) Bolt

6. Install the bolts and tighten bolts (8) that fasten the generator to the flywheel housing.

7. Install the bolts and tighten bolts (7) that fasten the vent fan and plate assembly to the engine flywheel. Remove the guide bolt and replace the guide bolt with bolt (7) .

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Illustration 5	g00856169
(1) Tooling (9) Bolt

8. Measure the crankshaft end play at the generator fan.

   1. Move the crankshaft all the way to the rear by loosening bolt (9) and by prying between the bolt head and the generator mounting flange.

   2. Attach tooling (1) to the generator with the tip of the indicator on the fan. Put the dial indicator of tooling (1) in the ZERO position. Move the crankshaft to the most forward position, and record the crankshaft end play.

9. If crankshaft end play is less in Step 8 than in Step 1, an adjustment of the end play is required. Remove the generator from the engine. Remove enough shims to get the original amount of end play as recorded in Step 1. Subtract the value from Step 8 from the value from Step 1. The calculated value equals the thickness of the shims to remove.

10. Install the generator and again check the crankshaft end play. Continue adjusting shims until the correct end play is obtained.

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Illustration 6	g00856170
(10) Drip Cover (11) Screen Assembly (12) Bolts

11. Install bolts (12) that fasten the generator supports to the base. Do not tighten bolts (12). Align the generator. Refer to Disassembly and Assembly, "Generator - Align".

Note: In order to obtain the maximum service life from the generator and the engine, correct alignment between these units is necessary. Refer to Disassembly and Assembly, "Generator - Align".

12. Install screen assemblies (11) and drip cover (10) on the generator. Tighten the mounting bolts for the screen assembly to 12 ± 4 N·m (9 ± 3 lb ft).