3000 Frame SR5 Electric Power Generation Caterpillar

Two bearing Generator Flexible Coupling - Install

Rubber in Shear Type Coupling Installation

Note: Do not use any lubricant between inner and outer hubs of the coupling.

1. Verify the generator rotor end play. The rotor is to be located in the nominal center position during this process. The front face of the coupling, that is, the machined surface where the flexible disc bolts to, is 25 mm (1 inch) from the face of the flywheel.

2. Assemble the outer ring (1) to the flywheel. Refer to Illustration 1. Assemble the correct washers, that are supplied with the coupling, to the bolts. Position the washers with the beveled edge toward the bolt head. Torque the bolts to 200 N·m (148 lb ft).
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   Illustration 1	g03385747

3. Install the flexible inner element (2) on the generator drive hub. Refer to Illustration 2. Torque the mounting bolts to 490 N·m (361 lb ft) using the alternating pattern.

   Note: The flexible inner hub of the coupling is to be oriented with the steel flange facing toward the engine.

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   Illustration 2	g03385752
   (2) Coupling installed

4. Slide the generator toward the engine, making sure the flexible rubber inner element (2) is correctly engaged in the teeth of the outer ring (1).

   Note: There is a small clearance between the driving and driven teeth in order to allow easier assembly. Do not use any lubricant during the assembly or during the use of the coupling.

5. Verify the axial position of the flexible rubber inner element (2). The element must not protrude out from the outer ring, or press against the flywheel. The element must be at the nominal position. The nominal position is approximately in the center of the outer ring (1). Adjust the generator rotor end play if necessary.

6. Align the generator and torque the rest of the assembly bolts as required.

Rubber in Compression Type Coupling Installation

Note: Do not use any lubricant between inner and outer hubs of the coupling.

1. Adjust the generator end play.

   Note: Use a large pry bar in order to pry between the generator drive hub and the bearing bracket only. A significant force may be required to move the rotor initially. Ensure that there is no damage to any of the electrical components or to the generator windings.

   1. Move the main rotor all the way forward.

   2. Measure the axial distance from the mounting face of the close coupled adapter to the front mounting face of the generator drive hub.

   3. Move the rotor all the way rearward.

   4. Measure the axial distance from the mounting face of the close coupled adapter to the front mounting face of the generator drive hub.

   5. Center the rotor by positioning the front mounting face of the generator drive hub at a point halfway between the two measurements plus or minus 1 mm (0.04 inch).

2. Prepare the coupling.

   1. Place a wooden block on the floor that is the same width as the bolt pattern that is on the inner hub (6). Set the coupling on the wooden block with the cover plate (4) facing down.

      Note: The block should be supporting the inner member but not touching any part of the cover plate.

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      Illustration 3	g01578343
      Exploded View of the Coupling (4) Cover Plate (5) Silicone Blocks (6) Inner Hub (7) Outer Hub

   2. Apply sufficient downward force to the outer hub (10) until the blades of the inner hub (11) come into contact with the outer hub. Refer to Illustration 4.
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   Illustration 4	g01579081
   (10) Outer Hub (11) Inner Hub (12) Pressure to be Applied at these Points (13) Block of Wood

3. Install the coupling. Bolt the inner hub of the coupling to the generator hub.

4. Install the generator.

   1. Align the generator and bolt the generator to base and to the flywheel housing.

   2. Do not bolt the coupling to the flywheel until the close coupled adapter parts are aligned and are properly torqued.

5. Attach the outer hub of the coupling to engine flywheel. Bolt the outer hub to the engine flywheel.

6. Verify that the generator end play is still in the nominal position.

Generator Drive Hub Installation

Note: The hub is a heavy shrink fit installation. Do not use any other method to install the hub. Always wear protective gloves when handling parts that have been heated.

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Always wear protective gloves when handling parts that have been heated.

1. Evenly heat the hub to 370 °C (700 °F) for 2 to 3 hours. An oven is the preferred method for heating the hub.
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   Illustration 5	g00615513

2. Slide the hub on the rotor shaft.

   Note: The hub must be located in the correct position on the shaft. Refer to Illustration 6 for the correct position of the hub on the main rotor shaft. An axial position jig may be required in order to prevent the hub from sliding to far onto the shaft during installation.

   Note: The front face of the hub must be installed flush with the end of the main rotor shaft.

Illustration 6	g01360301