Single Bearing Generator Installation Procedures _ LeTourneau, Inc.

SIL 186

SINGLE BEARING GENERATOR 4B, 7B, 9B, 12B-E INSTALLATION PROCEDURES

SINGLE BEARING GENERATOR INSTALLATION PROCEDURES

CONTENTS OF BOOK INTRODUCTION SECTION 1. GENERATOR ROTOR ENDPLAY MEASUREMENT SECTION 2. PRE INSTALLATION CHECKS SECTION 3. ROTOR ADAPTER PLATE POSITIONING CHECKS SECTION 4. ROTOR ADAPTER PLATE SHIMMING SECTION 5. INSTALL GENERATOR AND SHIM GENERATOR FEET SECTION 6. FINAL CHECKOUT APPENDIX

1


2


INTRODUCTION

3


4


INTRODUCTION This booklet details the procedures and tool requirements for installing and aligning a single bearing type of LeTourneau generator. LeTourneau, Inc. makes several sizes of single bearing generators. These have a single bearing on the slip ring end and the drive end is connected directly to the engine by means of a flexplate. The 4B, 7B, 9B, and 12B-E series generators make use of many common components. The diameter of the 4B, 7B and 9B generators is the same while the length is different. The 12 series generators are of a larger diameter than the other numbers and have various lengths. Figures 1 and 2 show the general layout of the main components required for a single bearing generator installation. Figure 1 shows the typical layout for 4B, 7B, and 9B generators. Figure 2 shows the typical layout for 12B-E generators.

PROCEDURES The installation and alignment of a single bearing LeTourneau generator can be broken down into several basic steps. To assure proper installation, the following steps must be followed.

1 2 3 4 5 6

GENERATOR ROTOR ENDPLAY MEASUREMENT PRE INSTALLATION CHECKS ROTOR ADAPTER PLATE POSITIONING CHECKS ROTOR ADAPTER PLATE SHIMMING INSTALL GENERATOR AND SHIM GENERATOR FEET FINAL CHECKOUT

These procedures are detailed in the following SIL and accompanied with diagrams and photos. Also supplied in the appendix of this booklet are the following: Generator alignment worksheet. The worksheet should be filled out as a guide and also to maintain a record of each installation. Tool and parts listing NOTE: Dial indicators shown in the various photos and diagrams are

5


representations only. Many types of dial indictors are suitable. A dial indicator with a scale from 0-10 and graduations of .0001" is recommended. It should be noted that a dial indicator with a lever head of some sort will be required for the pilot shoulder O.D. measurements. WARNING: Be aware of the wight of the total generator assembly before slinging hoisting and moving assembly. Failure to employ adequate lifting facilities and fixtures may result in personal injury or damage to the equipment. Weight and dimensions are provided in the following table.

GENERATOR WEIGHTS: 4B

3,200 lbs.

7B

5,000 lbs.

9B

6,150 lbs.

12B

9,000 lbs.

12C

9,900 lbs.

12D/E

11,100 lbs.

FIGURE 27 - GENERATOR WEIGHTS

6


FIGURE 1 - LAYOUT FOR 4B, 7B AND 9B GENERATORS

DRIVE END

FIGURE 2 - 12B-E GENERATOR LAYOUT

7


8


9


- SECTION 1 GENERATOR ROTOR ENDPLAY MEASUREMENT

10


11


1) ROTOR ENDPLAY MEASUREMENT The rotor in a single bearing generator is designed to have some endplay to allow for expansion due to normal heating of the rotor. The endplay comes from two areas: 1) the internal clearance of the bearing and 2) from limited axial movement of the outer bearing race. When properly assembled the outer race of the bearing should be free to slip back and forth for a limited amount. One goal of these procedures is to orient the generator rotor in the center of its endplay when connected to the engine. 1.1) Check the engine end of the rotor shaft, the ID of the rotor adapter and the rotor shims to be sure that all mating surfaces are clean and free from any protective coatings or burrs. 1.2) Mount the rotor adapter along with the proper number of rotor shims in such a way that the shims are positioned between the adapter and shaft. Torque the 3/4 fasteners to 50 ft.-lbs. NOTE:

Make sure that the two .531 diameter holes in the shim pack line up with the pusher holes in the rotor adapter. See Figure 25 for a diagram of the shims.

NOTE:

The typical shim pack for each rotor will be: 12B-E (SAE 0 flywheel)

NOTE:

6ea .007" shims = .042"

4B, 7B & 9B (SAE 0 flywheel)

10ea .007" shims = .070"

4B & 7B (SAE 1 flywheel)

10ea .007" shims = .070" 2ea 1/32" shims = .063" 1ea 1/16" shims = .063"

The SAE 0 type flywheel is a larger diameter and is used on larger engines and generators. The SAE 1 is a smaller diameter and is used on smaller engines with lower HP requirements. The following table gives a brief comparison of the rotor adapter plates used for the SAE 0 and SAE 1 types of flywheels.

12


Rotor adapter plate

O.D.

Flexplate shoulder I.D.

SAE 0

416-4542

21.69"

18.876"

SAE 1

421-4419

17.250"

15.000"

1.3) Obtain the rotor endplay and stator to adapter dimension using one of the following methods:

METHOD 1 (Preferred method for all generators) a. Orient the generator horizontally. Support the stator on blocks with sufficient clearance to mount the endplay brace as shown in FIGURE 3. Note that the smaller 4B, 7B and 9B generators will need more clearance. b. Install the P/N 418-6533 Horizontal Endplay Brace and 2 ea Studs - P/N 416-4695 for SAE 0 and P/N 421-4472 for SAE 1 - on the drive end of the generator as shown in Figure 3. The brace must be installed vertically as shown. NOTE:

The brace is provided with two sets of holes so that it can be used on both the smaller diameter (4B, 7B and 9B) generators and the larger diameter (12B-E) generators.

NOTE:

The rotor adapter shoulder on the brace is also machined so that it can be used with the rotor adapter for either the SAE 0 or SAE 1 size of flywheel.

13


FIGURE 3 - ENDPLAY BRACE INSTALLATION

c. Install the rotor shifting tools on the slip ring end of the generator as shown in Fig. 4.

FIGURE 4 - ROTOR SHIFTING TOOLS

14


d. Use a crane to lift the rotor slightly on the drive end of the generator to relieve the load on the studs. CAUTION:

Do not wrap any sort of lifting equipment (chain for example) around the shaft that might cause damage to the shaft. The shaft surface in this area must be undamaged and unmarked for use in the final checkout.

e. Mount a dial indicator on the slip ring end of the generator with the tip resting against the face of the outer seal race as shown in Fig 5.

FIGURE 5 - MEASURING TOTAL ROTOR ENDPLAY

15


f. Pry the rotor all the way toward the slip ring end and zero the indicator. Pry the rotor all the way toward the drive end of the generator. Record the total endplay on line 1.1 of the Generator Installation Worksheet. Repeat several times to verify consistency. (Note: Total rotor endplay should be between .070 and .100 inches.) g. Pry the rotor all the way toward the slip ring end of the generator. h. Measure the distance between the face of the rotor adapter and the stator mount face using an appropriate straight edge as shown in Fig. 6. Measure on both ends of the straight edge and average the results. Record these measurements on line 1.2 of the Generator Installation Worksheet labeled "Adapter to Stator Dim".

FIGURE 6 - MEASUREMENT BETWEEN ROTOR ADAPTER AND STATOR

i. Add 1/2 of the total rotor endplay to the previous dimension. Record this "new" dimension on line 1.3 of the Generator Installation Worksheet labeled "SETUP ADAPTER TO STATOR DIM". This is shown FIGURE 7.

16


FIGURE 7 - "SETUP ADAPTER TO STATOR DIMENSION"

NOTE: Typical "SETUP ADAPTER TO STATOR DIMENSION" with normal component tolerances should be in the following ranges: 12B-E:

2.971" - 3.037"

4B, 7B and 9B (SAE 0 Flywheel housing):

5.433" - 5.499"


5.630" - 6.290"

17


METHOD II (Suitable if rotor shifting tools are not available) This procedure is not the preferred method as there is a strong possibility that the measurement will include endbell flex along with rotor endplay. However it is usable if the proper shifting tools are not available. Two dial indicators must be used in order to compensate for the flex of the endplate. a. Up end the generator and set it, endbell (slip ring end) down, on an appropriate stand. b. Fasten a dial indicator mounting base to the endbell and position the button so that it rests against the face of the outer seal race and zero the dial. (Reference Fig. 5) c. Fasten a second dial indicator to a steel plate or other solid structure sitting on the floor under the generator. Position the button so that it rests against the endbell near the base of the first dial indicator. d. With a crane, pick up on the drive end of the rotor until there is no further movement shown on the indicators. Note the displacement and release the load on the crane and verify that the indicators return to zero. Repeat this process until consistent readings are recorded. Reset the dial indicators to zero as necessary. e. Subtract the reading on dial indicator 2 from the reading on dial indcator 1. f. Record the final reading obtained in the previous step on line 1.1 of the Generator Inatallation Worksheet labeled "Total Rotor Endplay". (Note: The total rotor endplay will typically be between .070 inches and .100 inches.) g. With the generator in the upright position and the rotor set all the way down, measure the distance between the face of the rotor adapter and the face of the stator mount face as follows: Use a long straight edge and set it on the rotor adapter in such a way that it spans the majority of the diameter of the rotor adapter as well as two points on the stator bolt ring. See Figure 6. Measure the distance between the bottom of the straight edge and the face of the stator mount face using a 2-1/2 to 3 inch inside micrometer. Measure the same distance at the other end of the straight edge. If the two measurements are not equal, then use the crane to shift the rotor and level the rotor adapter. When equal measurements are obtained, record the measurements on line 1.2 of the Generator Inatallation Worksheet labeled "Adapter to Stator Dim". f. Divide the rotor endplay dimension obtained in Step d by two and add it to the dimension previously obtained in Step e. Record this "new" dimension on line 1.3 of the Generator Inatallation Worksheet labeled "SETUP ADAPTER TO STATOR

18


DIM". NOTE: Typical "SETUP ADAPTER TO STATOR DIMENSION" with normal component tolerances should be in the following ranges: 12B-E:

2.971" - 3.037"


5.433" - 5.499"


5.630" - 6.290"

19


- SECTION 2 PRE INSTALLATION CHECKS

20


21


2) PRE INSTALLATION CHECKS Note: If you are reinstalling a generator into a piece of equipment where the engine has not been removed some of the following steps may not be necessary. The procedures are written from the standpoint of bringing an engine and generator together for the first time. The procedure was written this way as most generators will be overhauled or changed at the same time that the engine is overhauled. (*The items that may not be necessary in the following procedure are listed in italics.) 2.1)

Ensure that the engine flexplate, flywheel housing, stator adapter plate, stator frame mounting face and rotor adapter face are clean and free from any dirt or protective coating. Pay particular attention to the various pilot diameters to ensure that they are free from nicks and burrs.

2.2)

Ensure that the mating faces on the cradle arms and the flywheel housing are clean and free from paint and oil. *Clean out all tapped holes on the flywheel housing.

2.3)

*Support the engine at the front near the front mount and at the rear near the mounts at the flywheel housing. Install both rear engine mounts. Ensure that the mounts are pushed up tight against the shoulders provided on the flywheel housing and properly torque the bolts.

2.4)

Position jacks under the front and rear of the mounts (Ref. Fig. 8). These jacks are required to balance the load on the flywheel housing until the generator has been installed. Continue to support the rear of the engine in this fashion throughout the installation. This should be done in all cases of generator installation - those done on a stand and also those done in the machine.

22


FIGURE 8 - JACK SUPPORTING REAR ENGINE MOUNT DURING GENERATOR INSTALLATION

2.5)

Remove the cover from the rear of the engine which allows access to the clearance holes in the flexplate. Where necessary, also remove the starter.

2.6)

Remove the rotor adapter plate from the generator and check the outer bore I.D. with a vernier caliper. The bore dimension should be 18.876 ± .001. Record the I.D. measurement obtained on line 2.1 of the Generator Installation Worksheet

CAUTION:

If the rotor adapter plate is not within the specified tolerances the rest of this procedure will not produce the desired alignment effect. The adapter must be replaced or machined to meet specifications.

Check the pilot O.D. on the flexplate. The dimension should be 18.874 ± .001 for Cummins and 18.8755 ± .0015 for Detroit Diesel. Record the I.D. measurement obtained on line 2.2 of the Generator Installation Worksheet See Figure 9 for the location of the bore and pilot shoulder. CAUTION:

If flexplate is not within the specified tolerances the rest of this

23


procedure will not produce the desired alignment effect. It is critical that these two parts have the proper fit. A loose fit will make it difficult to obtain proper alignment. Even if alignment is obtained it will eventually result in misalignment and excessive vibration. It is important that the rotor adapter plate bore and flexplate pilot shoulder be within tolerance. A slight interference fit is desired between these two parts in order to ensure proper alignment between rotor and crank. If the fit is within specifications it will typically be necessary to pull the adapter plate onto the pilot shoulder with the bolts ( and push it off with the pusher holes). The pilot shoulder on the flexplate is designed to carry the weight of the rotor.

FIGURE 9 - BORE AND O.D. DIMENSIONS

NOTE:

NOTE:

It is recommended that where possible the flexplate and rotor adapter be checked and brought together prior to doing the actual installation. This will allow all measurements to be checked (and repairs or modifications done) prior to doing stopping the machine for the actual generator installation and alignment. This would particularly apply in the case of a #7 to 7B generator conversion. The two short dowel pins that are permanently mounted in the face of the flexplate were not designed to positively locate the rotor adapter

24


on the flexplate. The pins are a loose fit into the rotor adapter plate for guidance purposes only. 2.7)

Check the runout of the pilot O.D. on the flexplate as shown in Figures 10 and 12. Use a dial indicator mounted on the flywheel housing and rotate the flexplate from the front of the engine. The maximum allowable is 0.004 inches TIR. Record the measurement obtained on line 3.3 of the Generator Installation Worksheet. If the flexplate TIR is higher than the .004" limit the problem should be rectified prior to continuing with the alignment procedure. Contact your local engine distributor for instructions to verify proper fit or obtain another flexplate.

NOTE:

In extreme cases and under local engine distributor direction, it may be necessary to realign or repair the flexplate. To do so, remove the flexplate from the engine and mount in a three jaw chuck. Loosen the flexplate bolts and shift the flexplate in the required direction. Check radial runout and repeat as necessary. Retorque bolts per engine manufacturer's specs. Other repair procedures may also be required per recommendations of your local engine distributor.

FIGURE 10 - MEASUREMENT OF RADIAL RUNOUT OF ENGINE FLEXPLATE

FIGURE 11 - ROTATING ENGINE CRANKSHAFT WITH MANUAL DRIVE GEAR

25


FIGURE 12 - CHECKING FLEXPLATE PILOT O.D. (RADIAL RUNOUT) AND FACE (AXIAL RUNOUT)

NOTE:

2.8)

Rotating from the front end of the engine will minimize the flexplate distortion which occurs when the engine is rotated via the manual drive gear typically provided (Ref. Figure 10). Rotating from the front end of the engine will require a torque multiplier. Rotating from the front of the engine is the preferred method whenever possible. The engine must be rotated in the direction that will tighten the bolt. A special tool (P/N 421-3898) is availble to rotate Cummins engines. A diagram of this tool follows at the end of the SIL.

Check the axial runout of the face of the flexplate in a similar fashion. To ensure a true axial runout is being taken, simultaneously monitor the axial endplay of the crankshaft as shown in Figure 13. As the crankshaft is rotated, watch both dial indicators. Add the two dial indicator readings as the maximum and minimum readings are taken as shown in Fig. 14. The maximum allowable axial runout is

26


.010. Record the measurement obtained for maximum runout on line 3.4 of the Generator Installation Worksheet.

FIGURE 13 - DIAL INDICATOR ON FRONT OF CRANKSHAFT

Example: Both dial indicators were set to zero at the starting position and the crankshaft was rotated. The following chart summarizes the readings of both dial indicators.

27


Crankshaft Rotation

Crankshaft Indicator Reading

Flexplate Indicator Reading

Actual Flexplate Axial Runout

start

.000"

.000"

.000"

1/8 revolution

.001"

-.002"

-.001"

1/4 revolution

.000"

-.002"

-.002"

3/8 revolution

-.001"

-.003"

(min) -.004"

1/2 revolution

-.002"

-.001"

-.003"

5/8 revolution

-.003"

.001"

-.002"

3/4 revolution

-.003"

.003"

.000"

7/8 revolution

-.004"

.005"

(max) .001"

1 revolution

-.004"

.004"

.000"

FIGURE 14 - USING TWO DIAL INDICATORS FOR AXIAL CHECKS

In this example, the minimum reading was -.004" at 3/8 revolution and the maximum reading was .001" at 7/8 revolution. The total axial runout is .005". NOTE:

2.9)

If the sum of the dial indicators after one full revolution of the crankshaft does not add to zero, one of the indicators has moved and the axial runout must be checked again.

The following step is applicable to the 12B-E only: Examine the position of the air holes in the stator adapter plate relative to the engine and the rear engine mounts. The adapter plate has two adjacent air holes which allow access into the generator by means of bolt on screens. Orient these two holes in a location that will allow assembly personnel to utilize them during the alignment procedure. (Note: Normally these holes are located at the bottom and used along with a mirror to observe the engagement of the rotor adapter and flexplate.) Also, ensure that the screens welded to the inside of the stator adapter plate will not interfere with the long stem dial indicator used to check final runout.

2.10) Mount the stator adapter plate (and spacer on 4B, 7B, and 9B) and properly torque the bolts. Visually verify that there is no interference between the adapter plate and the rear engine mounts. 2.11) Check the perpendicular alignment of the rear engine mount to the stator adapter plate as shown in Figure 15. Place a large square against both mounting surfaces.

28


Using a feeler gauge, check for any gaps larger than .015" between the square and the mounting surfaces. If a gap of over .015" exists, the engine mounts must be machined. This measurement is critical as excessive angular misalignment between engine and generator will cause excessive vibration. Record the measurement obtained for left and right mount on line 3.5 of the Generator Installation Worksheet.

FIGURE 15 - CHECKING ALIGNMENT OF ENGINE MOUNTS

29


2.12) Check the alignment of the generator mount feet and the stator mount face as shown in figure 16. Place a large square against both mounting surfaces. Using a feeler gauge, check for any gaps larger than .010" between the square and the

FIGURE 16 - CHECKING ALIGNMENT OF GENERATOR FEET

mounting surfaces. If a gap of over .010" exists, the generator mount foot must be machined. Record the measurement obtained for the left and right mount feet on line 3.6 of the Generator Installation Worksheet.

30


2.13) Fasten a dial indicator mounting base to the face of the flexplate. Position the button so that it rests against the pilot O.D. on the stator adapter plate, as shown in Figure 17, and manually rotate the engine crankshaft from the damper end of the engine. The maximum radial runout should not exceed 0.026 inches TIR. (Note: The TIR may be adjusted slightly by loosening the bolts and moving the stator adapter plate.) Record the radial measurement obtained in this step on line 3.7 of the Generator Installation Worksheet.

FIGURE 17 - MEASURING PILOT O.D. (RADIAL RUNOUT) OF STATOR ADAPTER PLATE

31


2.14) Reposition the button so that it rests axially against the mounting face of the stator adapter plate as shown in Figure 18. Locate another dial indicator at the front of the engine positioned with the button on the harmonic balancer (as close to the center as possible). Rotate the engine in the same manner as before and verify that the maximum axial runout is less than 0.014 inches TIR. Monitor both indicators to determine how much the crankshaft is "walking" and how much of the reading is true runout. Refer to the procedure previously discussed in Figure 14.) Record the axial measurement obtained in this step on line 3.8 of the Generator Installation Worksheet.

FIGURE 18 - MEASURING FACE (AXIAL RUNOUT) OF STATOR ADAPTER PLATE

2.15) If either of Steps 13 or 14 produce readings that are not within tolerance, remove the stator adapter plate and check the flywheel housing. Maximum allowable runout and axial runout on the housing are 0.020 inches TIR and 0.010 inches TIR, respectively. Record the measurements obtained on lines 3.9 and 3.10 of the Generator Installation Worksheet.

32


33


- SECTION 3 ROTOR ADAPTER PLATE POSITIONING CHECKS

34


35


3) ROTOR ADAPTER PLATE - POSITIONING CHECKS 3.1)

Install the rotor adapter to the flexplate using four evenly spaced fasteners. Carefully apply a small amount of anti-seize compound to the pilot bores of stator adapter plate and the rotor adapter plate. Be sure that the face of the rotor adapter is free from protective coatings, nicks and dirt and will sit tight against the face of the flexplate. Note that there are four possible orientations of the rotor adapter relative to the flexplate because there are four holes in the adapter to accept the two dowel pins in the flexplate. Distinctively mark the orientations on the rotor adapter with a grease pencil ("1", "2", "3", "4") with reference to one of the flexplate dowel pins.

NOTE:

3.2)

A snug fit is required between these two parts in order to ensure proper alignment between rotor and crank. If the fit is within specifications it will typically be necessary to pull the adapter plate onto the pilot shoulder with the bolts ( and push it off with the pusher holes). The pilot shoulder on the flexplate is designed to carry the weight of the rotor.

Check the runout of the ID of the rotor adapter. Mount a dial indicator on an extension bar bolted to the stator adaptor plate as shown in Figures 19 and 20. Rotate the flexplate from the front of the engine. Record the measured TIR on the rotor adapter by # "1" and also on the worksheet. Record the measurement obtained in this step on line 4.1 of the Generator Installation Worksheet.

FIGURE 19 - CHECKING I.D. OF ROTOR ADAPTER PLATE

36


FIGURE 20 - CHECKING ROTOR ADAPTER PLATE BORE

3.3)

If the runout is greater than .001 inches, then rotate the rotor adapter 90 degrees relative to the reference dowel pin on the flexplate to the # "2" position. Repeat the previous step. Be sure to record this new TIR by # "2" and on line 3.1 of the Generator Installation Worksheet.

3.4)

Repeat Step 3.3 for the next two orientations ("3" & "4"), as required. Record the measurements obtained in these steps on line 3.1 of the Generator Installation Worksheet.

3.5)

If none of the orientations produce a radial runout of less than .001 inches, then choose the orientation that produced the least amount of runout lower than .003 inches. If none of the orientations produced a runout of less than .003 inches, then a different rotor adaptor plate must be used. If another plate is available then repeat the above steps (3.1 to 3.4) with the new rotor adaptor. The goal is to minimize runout in order to minimize vibration.

NOTE:

If a new rotor plate is not available then the flexplate and adapter plate will have to be checked to determine the source of the problem. The problem must be corrected prior to continuing with installation.

37


3.6)

Once the orientation is chosen, manually rotate the engine so that the high side of the bore is at the twelve o'clock position. (This will cause the weight of the rotor to take up any clearance between rotor adapter and flexplate in a direction which will minimize the final radial runout.) Punch mark the rotor adapter and the flexplate at the twelve o'clock position. This will provide a permanent record and will aid in future alignments. Remove the rotor adapter from the flexplate.

38


39


- SECTION 4 ROTOR ADAPTER PLATE SHIMMING

40


41


4) ROTOR ADAPTER PLATE SHIMMING 4.1)

Bolt the stator adapter plate straight edge in place on the stator adapter plate. Mount a dial indicator as shown in Figure 21 and Figure 22 so that the button rests on the center part of the flexplate.

FIGURE 21 - MEASURING ENGINE ENDPLAY

4.2)

Remove a crankshaft inspection cover on the side of the engine. Measure the engine endplay by prying the crankshaft "In" (towards the front of the engine) as far as possible, zeroing the indicator and then prying the crankshaft "Out" as far as possible using a steady even push on the pry bar (pry on a counterweight only). (Note: Endplay should be between .004 and .018.) Record the measurement obtained on line 4.1 of the Generator Installation Worksheet.

4.3)

Center the crankshaft in the middle of the engine endplay.

4.4)

Using an inside micrometer, measure the distance between the stator adapter plate straight edge and the face of the flexplate as shown in Figure 23 and 24. Measure the distance at the other end of the straight edge. Add these two dimensions together and divide by two for an average dimension. Record all measurements on line 4.2 of the Generator Installation Worksheet.

42


FIGURE 22 - CHECKING ENGINE ENDPLAY

FIGURE 24 - MEASURING DISTANCE BETWEEN STATOR ADAPTER PLATE AND FLEXPLATE

43


FIGURE 23 - DISTANCE BETWEEN STRAIGHT EDGE AND FLEXPLATE FACE

4.5)

Record this number as dimension "A" on line 4.3 of the Generator Installation Worksheet.

4.6)

Record the dimension from Generator Installation Worksheet line 1.3 labeled "SetUp Adapter to Stator Dim" as dimension "B" on line 4.3 of the worksheet.

4.7)

Subtract dimension "B" from dimension "A". If the difference is less than plus or minus 0.007, proceed to Step 6, otherwise, to Step 8.

4.8)

If the difference is negative, then remove the appropriate amount of shims from between the rotor adapter and the rotor shaft (remove an amount approximately equal to the difference). If the difference is positive, then add the appropriate number of shims in the same manner.

44


Note: The typical shim pack for each rotor will usually be about the same as that shown in the following data. A large difference from the following data may indicate a problem with the measurements taken or fit of a component. 12B-E (SAE 0 flywheel)

6ea .007" shims = .042"

4B, 7B & 9B (SAE 0 flywheel)

10ea .007" shims = .070"

4B & 7B (SAE 1 flywheel) and and

4.9)

10ea .007" shims = .070" 2ea 1/32" shims = .063" 1ea 1/16" shims = .063" TOTAL = .196"

Ensure that the ground portion of the generator shaft (where the long stem dial indicator rides for the final checkout) is free from burrs and epoxy.

4.10) Ensure that all mating surfaces between shims, shaft and rotor adapter are free from dirt and burrs. Ensure that the threads on the 3/4 inch bolts and the threads in the end of the shaft are clean and dry. 4.11) Use high temperature thread lock (P/N 409-9390 Loctite RC 620) on the bolt threads and mount the rotor adapter and the correct number of shims on the rotor shaft. Make sure that the permanent mark on the rotor adapter is oriented correctly with respect to the mark on the flexplate (twelve o'clock). Also make sure that the two smaller .531 diameter holes in the shim pack line up with the pusher holes in the rotor adapter as shown in Figure 25.

45


413-2174 SHIM 4B, 7B, 9B AND 12B GENERATORS

416-4561 SHIM 12C-E GENERATORS

FIGURE 25 - PUSHER HOLES IN SHIMS

4.9)

Properly torque all bolts (per torque chart lubricated specs in maintenance manual) and safety wire the bolts in place (per Fig. 26). Do not use lockwashers under the head of the bolts. P/N 410-1471 .041" diameter safety wire is used. A thicker wire may be used if the .041" is not available. The safety wire used must be an aircraft grade stainless steel wire meeting the following specs: .041" .062"

262,000-292,000 psi tensile strength 250,000-280,000 psi tensile strength

The pattern that is preferred for the safety wire is a three bolt overlap pattern. Each bolt head at each end of a group of three is wired to the next bolt head in a pattern to keep the bolt head from coming loose. On bolts with a single .125" hole in the head - two wires will go through the head with one wire connected to the bolt head on one side and the other wire connected to the bolt head on the other side. This will give the effect of supporting the bolt head from both sides.

46


FIGURE 26 - TYPICAL SAFETY WIRE INSTALLATION

47


- SECTION 5 INSTALL GENERATOR AND SHIM GENERATOR FEET

48


49


5) INSTALL GENERATOR AND SHIM GENERATOR FEET 5.1)

Carefully apply anti-seize compound to the pilot bores of stator adapter plate and the rotor adapter plate. Do not apply anti-seize compound to the mounting face of these plates.

5.2)

Install the two alignment studs opposite one another, in the horizontal plane, in the rotor adapter. Be sure to thread them in as far as possible.

NOTE:

The alignment studs for the 4B and 7B connected to an SAE 1 flywheel housing are a smaller diameter (1/2 vs 5/8) and longer (3.625 vs 2.5). The two types of alignment studs are shown in diagrams at the end of this SIL.

WARNING:

5.3)

5.4)

5.5)

Be aware of the wight of the total generator assembly before slinging hoisting and moving assembly. Failure to employ adequate lifting facilities and fixtures may result in personal injury or damage to the equipment. Weight and dimensions are provided in the following table.

Install the proper lifting bar fixture and rigging to the top of the generator to support the weight. Typical weights for the various generators are shown in Figure 27. With a hoist, bring the generator to the engine with its horizontal centerline in line with the centerline of the engine. Note the position of the alignment studs. Make sure that the permanent mark on the rotor adapter is oriented correctly with respect to the mark on the flexplate (twelve o'clock). If a slight adjustment is required, rotate the flexplate.

GENERATOR WEIGHTS: 4B

3,200 lbs.

7B

5,000 lbs.

9B

6,150 lbs.

12B

9,000 lbs.

12C

9,900 lbs.

12D/E

11,100 lbs.

FIGURE 27 - GENERATOR WEIGHTS

Advance the generator towards the engine. The alignment studs in the rotor adapter should enter their respective holes in the flexplate. When the stator frame is touching the stator adapter plate, adjust the frame so that the pilot boss is inside the pilot bore.

50


FIGURE 28 - INSTALLING GENERATOR TO ENGINE

5.6)

Insert the top and bottom mounting bolts into the stator frame through the corresponding stator adapter holes. Tighten these bolts a sufficient amount so that the boss cannot disengage from the bore.

5.7)

Install shims of equal thicknesses (0.012"0.020" thick is suggested) between the stator frame and adapter plate at the three o'clock and nine o'clock positions (Ref. Fig. 29 and Fig. 30). Secure these shims with two bolts installed into the stator frame, in the same positions.

5.8)

Back the top and bottom mounting bolts out 1/4". Check the angular alignment of the generator relative to the engine using a feeler gauge between the stator adapter and frame in the six o'clock and twelve o'clock positions (Ref. Figure 29 and 30). Install shim stock under each of the generator mounting feet (Ref. Figure 30 and 31) until a difference of 0.004" or less is attained

51

FIGURE 29 - INSTALLATION OF SHIMS AT 3:00 AND 9:00 POSITIONS


between feeler gauge readings at the six o'clock and twelve o'clock positions. Tighten the bolts on the mount feet and recheck the feeler gauge readings and top and bottom. The .004" tolerance must be held when the mount feet are properly secured. Record the final gap at top and bottom on line 5.1 of the Generator Installation Worksheet. Record the thickness of shims required under each mounting foot on line 5.2 of the Generator Installation Worksheet.

FIGURE 30 - CHECKING STATOR ALIGNMENT

5.9)

Loosen the generator mount feet bolts. Loosen the two mounting bolts in the three o'clock and nine o'clock positions and remove the shims. Install the remaining 4 mounting bolts in the generator adapter plate and properly torque all eight bolts to the specifications in the maintenance manual.

52


FIGURE 31 - GAP MEASUREMENT BETWEEN GENERATOR AND STATOR ADAPTER PLATE

FIGURE 32 - SHIM PACK INSTALLED UNDER GENERATOR MOUNT FOOT

5.10) Properly torque the mount feet bolts. (Some generators have 1 bolt on each foot

53


as shown in Figure 32 while others may have 3 bolts on each foot.)

5.11) Using the hole created by the absence of the cover or the starter, install and torque the flexplate coupling bolts. Torque to specs in the maintenance manual. 5.12) Remove the alignment studs in the process of installing the bolts..

54


55


- SECTION 6 FINAL CHECKOUT

56


57


6) FINAL CHECKOUT 6.1)

Check for abnormal pre-loading of the engine crankshaft by performing the following steps:

6.1a

Mount a dial indicator on the front of the engine with the button resting on the face (center, if possible) of the harmonic balancer.

6.1b

Check the axial endplay of the crank per previous procedures. The endplay should be the same as what was previously measured. Record the measurement obtained on line 6.1 of the Generator Installation worksheet.

6.1c

Measure the axial movement of the crankshaft with the crankshaft and generator rotor shifted all the way forward and rotated 360 degrees in the direction of normal engine rotation. Rotor shifting tools may be used to shift the rotor. (Ref. Figure 3)

6.1d

Measure the axial movement of the crankshaft with the crankshaft and generator rotor shifted all the way rearward and rotated 360 degrees in the opposite direction of normal engine rotation. Record the measurement obtained on line 6.2 of the Generator Installation worksheet.

6.1e

If the axial movement in Step c. or d. is greater than .004" then abnormal preloading has occurred. The assembly procedure must be reviewed and corrective action taken.

6.2)

Bolt the remaining screens in place (only applicable to #12B-E).

6.3)

Using a long stem dial indicator, measure the radial runout of the rotor shaft as shown in Figure 33 and Figure 34. Mount the indicator in the threaded hole in the stator bolt flange and manually rotate the engine. The maximum runout should not exceed .005". Record the measurement obtained on line 6.3 of the Generator Installation worksheet.

Note:

On generators located in trucks the threaded hole will be horizontal. The

58

FIGURE 33 - GAP MEASUREMENT BETWEEN GENERATOR AND STATOR ADAPTER PLATE


holes need to be at an angle on generators used in other applications.

6.4)

Remove the dial indicator and reinsert the threaded plug.

FIGURE 34 - FINAL RADIAL RUNOUT CHECK

6.5)

Place the worksheet in the proper machine or component file for future reference.

59


APPENDIX

60


61

GENERATOR INSTALLATION WORKSHEET

DATE:

ENGINE S/N:

ENGINE TYPE:

GENERATOR TYPE:

GENERATOR S/N:

EQUIPMENT TYPE:

EQUIPMENT NUMBER:

1) GENERATOR ROTOR ENDPLAY CHECKS 1.1 Total rotor endplay 1.2 Adapter to stator DIM: Position 1 (Rotor shifted to the slip ring end)

Position 2

Average:

1.3 SET-UP ADAPTER TO STATOR DIM:

2) PRE INSTALLATION CHECKS 2.1 Rotor Adapter Plate bore ID: (18.875" - 18.877"):

2.2 Flexplate pilot OD (18.873" - 18.877"):

2.3 Radial runout of flexplate pilot bore OD (0.004" max):

2.4 Axial runout of flexplate (0.010" max):

2.5 Perpendicular alignment of rear engine mounts (.015" max): 2.6 Perpendicular alignment of generator feet (.010" max):

Left:

Right:

Left:

Right:

2.7 Radial runout of stator adapter plate (0.026" max):

2.8 Axial runout of stator adapter plate (0.014" max):

*2.9 Radial runout of flywheel housing (.020" max):

*2.10 Axial runout of flywheel housing (.010" max):

3) ROTOR ADAPTOR POSITIONING CHECKS 3.1 Radial runout of the ID on mounted rotor adapter bore (less than 0.001" prefered, 0.003 max) Position 1

Position 2

Position 3

Position 4

4) ROTOR ADAPTER PLATE SHIMMING 4.1 Engine endplay (.004-".018") 4.2 Distance between straight edge and flexplate face Position 1 4.3 Shim pack:

Position 2

Average distance between straight edge and flexplate SETUP ADAPTOR TO STATOR DIM Difference

Average:

(Dimension A)

=

(Dimension B)

=

=

4.4 Total number of shims and thickness of each used in the assembly:

5) INSTALL GENERATOR AND SHIM GENERATOR FEET 5.1 Gap at top and bottom: Top 5.2 Shim pack thickness under generator feet:

Bottom

Difference

Left:

Right:

5.3 Used Loctite, and torque wrench and safety wire to secure the rotor adaptor.

YES

/

NO

6) FINAL CHECKS 6..1 Engine endplay (.004-".018")

6.2. Axial movement less than .004 when checked for abnormal preload: YES / NO /

6.3. Radial runout of generator shaft (less than 0.003" preferred, .005" max):

APPROVED:

INSTALLER:

SUPERVISOR:

/


63


REQUIRED TOOLS: 12B-E Generator endplay tools 1 415-6532 Kit - Rotor Shifting Tools (12B-E) 1 415-1451 Eye bolt 3/4" UNF X 2 1/4 1 415-1459 Eye bolt, 1"-14 UNS X 2 3/4" 1 415-6538 Lever bar, 1 1/2" HD pipe X 60" 1 416-4696 Kit - Horizontal endplay measuring tools 2 002-1630 Bolt .625 UNC X 2.000 2 416-4695 Stud for horizontal endplay brace 1 418-6533 Horizontal Endplay brace with eye

4B, 7B & 9B Generator endplay tools 1 418-6779 Rotor Shifting Tools (4B, 7B & 9B) 418-6793 Eye bolt, 5/8" UNC 415-1459 Eye bolt, 1"-14 UNS X 2 3/4" 415-6538 Lever bar, 1 1/2" HD pipe X 60" 1 416-4696 Kit - Horizontal endplay measuring tools 2 002-1630 Bolt .625 UNC X 2.000 2 416-4695 Stud for horizontal endplay brace 1 418-6533 Horizontal Endplay brace with eye

MISC ALIGNMENT TOOLS 1 409-7099 Large Square 1 409-7097 Stator Adapter Plate, Straight Edge (12B-E) 1 418-0730 Stator Adapter Plate, Straight Edge (7B & 9B) 1 414-2599 Long Stem Dial Indicator 1 414-2674 SAE 0 Alignment Stud 1 421-4472 SAE 1 Alignment Stud 1 N.PN. Dial indicator with lever actuator

REQUIRED PARTS: AR 413-2174 7B, 9B, 12B Rotor Shim AR 416-2561 12C-E Rotor Shim AR 409-9390 High Temperature Thread Lock AR 410-1471 . 041 Diameter S/S Safety Wire AR 410-3945 Generator foot shim .007" AR 410-3946 Generator foot shim .036" AR 410-3947 Generator foot shim 3/16"

64

Single Bearing Generator Installation Procedures _ LeTourneau, Inc.

Recommend Documents