Installation Of General Electric GE-603K Generators, GTA-15, GTA-18, GTA-22, GTA-23, GTA-25 and GTA-26 Alternators{1000, 4450} Caterpillar

Introduction

Correct installation and end play adjustment procedures will ensure greater bearing life and optimum performance from the engine and generator. When new parts are installed, always remove the protective coating, especially from the contact surfaces of all bolted joints. The contact surfaces should also be lightly filed to remove any burrs. The procedure in this instruction is for use with the above engines equipped with the parts in the chart that follows.

Generator Modification

This modification procedure should be used on older trucks where a 3500 Family engine replaces a former engine that used the 2N8470 Adapter on the generator. The 2N8470 Adapter is not required with a 3500 Family engine.

(1) 2N8470 Adapter (Nose Cone). (2) Mounting Bolts.

The 2N8470 Adapter (1) was formerly used to pilot the armature of the generator for earlier engines. In this method, the adapter was bolted to the armature, and used to pilot into the gear pressed on the crankshaft. With the new parts, the generator will pilot on the outer ring of the flywheel.

Before installation of the new parts, remove adapter (1), bolts (2), and the hardened washers. Save the hardened washers for reuse.

Install 8S9092 Bolts along with the hardened washers in place of bolts (2) that were removed.

Tighten the bolts to 265 ± 14 N·m (196 ± 10 lb ft).

Installation

1. With the engine mounted in place, install a dial indicator so the contact point is against the front face of the crankshaft pulley. Mark the contact point on the end of the pulley as shown.

NOTE: All dial indicator supports and adapters must be tightly fastened to the bed plate or engine support.

2. Move the crankshaft rearward to the limit of its end play, then zero the dial indicator. Move the crankshaft forward to the limit of its end play. Write the total indicator reading on line 2 of the data sheet following Step 20.

NOTE: Do Not apply pressure against the crankshaft when reading the indicator.

Measurement locations (1), (2), (3), (4).

3. With the crankshaft still at the forward limit of its end play, install a straight, flat steel bar (5) at four locations shown as (1), (2), (3), and (4).

Measure dimension (A). Dimension (A) is from face (B) of flywheel (6) to face (C) of flywheel housing adapter (7).

Find the average of the eight measurements and enter this dimension on line 1 of the data sheet following Step 20.

4. Subtract one-half the total end clearance of the crankshaft (one-half the reading of Step 2), from the average dimension found in Step 3 and write this dimension on line 4 of the data sheet.

Shim locations.

5. Place the generator in a horizontal position. Put a level on the generator frame and use blocks to level the frame. Install shim stock at the locations shown by the arrows, to get the armature in alignment as close as possible with the generator centerline.

NOTE: Approximately 1.8 mm (0.062") thick shims are required at the four locations.

Dial indicator location.

6. Use the 8S2329 Magnetic Base to fasten a dial indicator on armature coupling adapter (8). Put the contact point of the dial indicator on the front face of generator frame (9) as shown.

Move the armature toward the commutator end as far as possible, and hold the armature in this position. Adjust the dial indicator to zero.

Move the armature toward the coupling adapter end, as far as possible, and read the dimension on the dial indicator (this is total bearing movement).

Repeat Step 6 several times to make sure the dimension is accurate. Write this dimension on line 5 of the data sheet.

7. Move the armature back one-half the distance of the total bearing movement, so the bearing is in the center of the bearing race.

8. Use shims (10) to hold coupling adapter (8) in the center of generator frame (9). Place steel bar (5) on face (D) of coupling adapter (8).

Measure the distance (E) from the bottom face of bar (5) to face (F) of generator frame (9).

NOTE: Move bar (5) on adapter (8), so dimension (E) can be measured at approximately the same eight locations that dimension (E) was measured on the engine in Step 3.

Find the average of the eight measurements, and enter this dimension on line 6 of the data sheet.

9. Make a comparison of the dimensions on line 4 and line 6 of the data sheet. This will determine the amount of shims required, and the location of shim installation.

* Find the difference between the dimensions on line 4 and line 6 and enter this dimension on line 7 of the data sheet.

* If the dimension on line 4 is larger than the dimension on line 6, install the correct amount of small diameter shims (plus dimension of line 7 of data sheet) at location (G) between flywheel (6) and adapter (8).

* If the dimension on line 4 is smaller than the dimension on line (6), install the correct amount of large diameter shims (minus dimension of line 7 of data sheet) at location (H) between adapter (7) for the flywheel housing and the generator frame (9).

100 mm long guide pin.

115 mm long guide pin.

10. Fabricate guide pins from 5/8"-11 bolts according to the dimensions shown above. Make eight 100 mm (4.0 in) long guide pins and four 115 mm (4.5 in) long guide pins.

11. Remove the coupling adapter shims that were installed in Step 8. Put the armature in position so that one of the four corners of the plate is directly under the armature shaft, as shown by the arrow. This procedure will put the armature in its maximum static height position.

100 mm (4.0 in) long guide pin locations.

12. Install eight 100 mm (4.0 in) long guide pins, finger tight, at locations (J).

115 mm (4.5 in) long guide pin locations.

Install four 115 mm (4.5 in) long guide pins, finger tight, at locations (K).

Install shims on the guide pins. Make reference to Step 9 for shim thickness and location for installation.

13. Carefully move the generator into position on the engine. Use care not to lose the shims that were installed on the guide pins.

Remove the eight guide pins, at location (J), one at a time. Install all bolts that fasten the generator to the flywheel housing adapter.

Hole plug location.

Remove the plug from hole (11).

Rotate the flywheel with a ratchet wrench and the manual drive pinion gear.

Remove the four guide pins, one at a time. Install all flywheel-to-armature coupling adapter bolts through access hole (11), in the front face of the flywheel housing.

Inital torque for the flywheel-to-armature coupling adapter bolts is 80 ± 20 N·m (60 ± 15 lb ft).

After all bolts have been tightened to the initial torque, tighten the bolts to a final torque of 245 ± 25 N·m (180 ± 20 lb ft).

Hole plug installation dimension.

Install a new 9S1343 Plug in hole (11). Seat the plug to the dimension shown.

Pulley front face dial indicator location.

14. Install a dial indicator at the front face of the crankshaft pulley. The contact point of the dial indicator must be on the mark on the end of the pulley as shown above.

Install a dial indicator at the rear face of the drive pulley for the generator blower.

NOTE: When dial indicator readings are written down in the steps that follow, be sure to use the identification letter (A) or (B) with each reading. This is to identify each reading with the dial indicator location.

15. To make the first check of end play of the unit, move the generator armature forward to the limit of its travel and hold it in this position.

Move the crankshaft forward to the limit of its travel while maintaining the generator armature position.

Release the pressure on the engine crankshaft only, adjust both dial indicators to zero, then release the pressure on the generator armature.

16. Turn the crankshaft 360° in the direction of normal engine rotation and make a reading of both dial indicators. Record both dial indicator readings (A) and (B) on lines 8A and 8B of the data sheet.

17. Perform a second check of end play by moving the generator armature rearward to the limit of its travel and hold it in this position. While holding the armature position, move the crankshaft rearward to the limit of its travel. Release the pressure on the crankshaft only, adjust both dial indicators to zero, and release the pressure on the armature.

18. Turn the crankshaft 360° in the direction of normal engine rotation and make a reading of both dial indicators. Record both dial indicator readings (A) and (B) on lines 9A and 9B of the data sheet.

19. The installation is complete and acceptable, if the indicator readings taken in Steps 17 and 18 are within ANY of the following specifications:

* If indicator reading 8A is equal to indicator reading 8B.

* If indicator reading 9A is equal to indicator reading 9B.

* If indicator reading 8A is within ± 0.05 mm (0.002") of indicator reading 9A.

If the indicator readings are not within the above specifications, refer to Step 20 for additional shim requirements.

20. If indicator reading 8A is greater than ± 0.05 mm (± 0.002") of indicator reading 9A, additional shims must be installed at location (G) between armature coupling adapter (8) and flywheel (6).

If indicator reading 9A is greater than ± 0.05 mm (± 0.002") of indicator reading 8A, additional shims must be installed at location (H) between flywheel housing adapter (7) and generator frame (9).

Data Sheet