Single Bearing Generator Installation Procedures _ LeTourneau, Inc.

7/27/2019 Single Bearing Generator Installation Procedures _ LeTourneau, Inc.

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SINGLE BEARING

GENERATOR

4B, 7B, 9B, 12B-E

INSTALLATIONPROCEDURES

SIL 186


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SINGLE BEARING GENERATOR INSTALLATION PROCEDURES

1

CONTENTS OF BOOK

INTRODUCTION

SECTION 1. GENERATOR ROTOR ENDPLAYMEASUREMENT

SECTION 2. PRE INSTALLATION CHECKS

SECTION 3. ROTOR ADAPTER PLATEPOSITIONING CHECKS

SECTION 4. ROTOR ADAPTER PLATE SHIMMING

SECTION 5. INSTALL GENERATOR AND SHIMGENERATOR FEET

SECTION 6. FINAL CHECKOUT

APPENDIX


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INTRODUCTION


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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 singlebearing on the slip ring end and the drive end is connected directly to the engine by meansof 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 variouslengths.

Figures 1 and 2 show the general layout of the main components required for a singlebearing generator installation. Figure 1 shows the typical layout for 4B, 7B, and 9Bgenerators. Figure 2 shows the typical layout for 12B-E generators.

PROCEDURES

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

1 GENERATOR ROTOR ENDPLAY MEASUREMENT

2 PRE INSTALLATION CHECKS

3 ROTOR ADAPTER PLATE POSITIONING CHECKS

4 ROTOR ADAPTER PLATE SHIMMING

5 INSTALL GENERATOR AND SHIM GENERATOR FEET

6 FINAL CHECKOUT

These procedures are detailed in the following SIL and accompanied with diagrams andphotos.

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 ofeach installation.

Tool and parts listing

NOTE: Dial indicators shown in the various photos and diagrams are


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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

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.


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DRIVE END


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FIGURE 2 - 12B-E GENERATOR LAYOUT

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


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- SECTION 1 -

GENERATOR ROTOR

ENDPLAY MEASUREMENT


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1) ROTOR ENDPLAY MEASUREMENT

The rotor in a single bearing generator is designed to have some endplay to allow forexpansion due to normal heating of the rotor. The endplay comes from two areas: 1) theinternal clearance of the bearing and 2) from limited axial movement of the outer bearingrace. When properly assembled the outer race of the bearing should be free to slip backand forth for a limited amount.

One goal of these procedures is to orient the generator rotor in the center of its endplaywhen connected to the engine.

1.1) Check the engine end of the rotor shaft, the ID of the rotor adapter and the rotorshims 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 waythat the shims are positioned between the adapter and shaft. Torque the 3/4fasteners 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) 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"

NOTE: 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 briefcomparison of the rotor adapter plates used for the SAE 0 and SAE 1 types

of flywheels.


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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 followingmethods:

METHOD 1 (Preferred method for all generators)

a. Orient the generator horizontally. Support the stator on blocks with sufficientclearance 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 416-4695for SAE 0 and P/N 421-4472 for SAE 1 - on the drive end of the generator as shownin 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.


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FIGURE 3 - ENDPLAY BRACE INSTALLATION

FIGURE 4 - ROTOR SHIFTING TOOLS

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


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FIGURE 5 - MEASURING TOTAL ROTOR ENDPLAY

d. Use a crane to lift the rotor slightly on the drive end of the generator to relieve theload 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 restingagainst the face of the outer seal race as shown in Fig 5.


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FIGURE 6 - MEASUREMENT BETWEENROTOR ADAPTER AND STATOR

f. Pry the rotor all the way toward the slipring end and zero the indicator. Pry the

rotor all the way toward the drive end ofthe generator. Record the total endplayon line 1.1 of the Generator InstallationWorksheet. Repeat several times toverify consistency. (Note: Total rotorendplay should be between .070 and.100 inches.)

g. Pry the rotor all the way toward the slipring end of the generator.

h. Measure the distance between the faceof the rotor adapter and the stator mountface using an appropriate straight edgeas shown in Fig. 6. Measure on bothends of the straight edge and averagethe results. Record these measurementson line 1.2 of the Generator InstallationWorksheet labeled "Adapter to StatorDim".

i. Add 1/2 of the total rotor endplay to the

previous dimension. Record this "new" dimension on line 1.3 of the GeneratorInstallation Worksheet labeled "SETUP ADAPTER TO STATOR DIM". This isshown FIGURE 7.


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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"



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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 theproper shifting tools are not available. Two dial indicators must be used in order tocompensate for the flex of the endplate.

a. Up end the generator and set it, endbell (slip ring end) down, on an appropriatestand.

b. Fasten a dial indicator mounting base to the endbell and position the button so thatit 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 endbellnear 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 movementshown on the indicators. Note the displacement and release the load on the craneand verify that the indicators return to zero. Repeat this process until consistentreadings 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 endplaywill 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 thestator mount face as follows: Use a long straight edge and set it on the rotoradapter in such a way that it spans the majority of the diameter of the rotor adapteras well as two points on the stator bolt ring. See Figure 6. Measure the distancebetween the bottom of the straight edge and the face of the stator mount face usinga 2-1/2 to 3 inch inside micrometer. Measure the same distance at the other endof 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 Worksheetlabeled "Adapter to Stator Dim".

f. Divide the rotor endplay dimension obtained in Step d by two and add it to thedimension previously obtained in Step e. Record this "new" dimension on line 1.3of the Generator Inatallation Worksheet labeled "SETUP ADAPTER TO STATOR


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DIM".

NOTE: Typical "SETUP ADAPTER TO STATOR DIMENSION" with normal

component tolerances should be in the following ranges:

12B-E: 2.971" - 3.037"




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2) PRE INSTALLATION CHECKS

Note: If you are reinstalling a generator into a piece of equipment where the enginehas 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 n ecessary in the fo l lowing

proced ure are l isted in i tal ics.)

2.1) Ensure that the engine flexplate, flywheel housing, stator adapter plate, stator framemounting face and rotor adapter face are clean and free from any dirt or protectivecoating. 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 cleanand 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 themounts at the flywheel housing. Install both rear engine mounts. Ensure that themounts are pushed up tight against the shoulders provided on the flywheel housingand 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 beeninstalled. Continue to support the rear of the engine in this fashion throughout theinstallation. This should be done in all cases of generator installation - those doneon a stand and also those done in the machine.


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FIGURE 9 - BORE AND O.D. DIMENSIONS

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 withintolerance. A slight interference fit is desired between these two parts in order to ensureproper alignment between rotor and crank. If the fit is within specifications it will typicallybe necessary to pull the adapter plate onto the pilot shoulder with the bolts ( and push itoff with the pusher holes). The pilot shoulder on the flexplate is designed to carry theweight of the rotor.

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.

NOTE: The two short dowel pins that are permanently mounted in the face of

the flexplate were not designed to positively locate the rotor adapter


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FIGURE 11 - ROTATING ENGINECRANKSHAFT WITH MANUAL DRIVE GEAR

FIGURE 10 - MEASUREMENT OF RADIAL RUNOUT OFENGINE FLEXPLATE

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 fromthe front of the engine. The maximum allowable is 0.004 inches TIR. Record themeasurement 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 priorto continuing with the alignment procedure. Contact your local engine distributor forinstructions 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 theflexplate 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.


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

NOTE: 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.

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


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FIGURE 13 - DIAL INDICATOR ON FRONT OF CRANKSHAFT

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

Example: Both dial indicators were set to zero at the starting position and the

crankshaft was rotated. The following chart summarizes the readings ofboth dial indicators.


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Crankshaft Crankshaft Flexplate Actual Flexplate

Rotation Indicator Reading Indicator Reading 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 maximumreading was .001" at 7/8 revolution. The total axial runout is .005".

NOTE: 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.

2.9) 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 engineand the rear engine mounts. The adapter plate has two adjacent air holes which allowaccess into the generator by means of bolt on screens. Orient these two holes in alocation that will allow assembly personnel to utilize them during the alignmentprocedure. (Note: Normally these holes are located at the bottom and used along witha mirror to observe the engagement of the rotor adapter and flexplate.) Also, ensurethat the screens welded to the inside of the stator adapter plate will not interfere withthe 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 torquethe bolts. Visually verify that there is no interference between the adapter plate andthe rear engine mounts.

2.11) Check the perpendicular alignment of the rear engine mount to the stator adapterplate as shown in Figure 15. Place a large square against both mounting surfaces.


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FIGURE 15 - CHECKING ALIGNMENT OF ENGINE MOUNTS

Using a feeler gauge, check for any gaps larger than .015" between the square andthe mounting surfaces. If a gap of over .015" exists, the engine mounts must bemachined. This measurement is critical as excessive angular misalignment

between engine and generator will cause excessive vibration. Record themeasurement obtained for left and right mount on line 3.5 of the GeneratorInstallation Worksheet.


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FIGURE 16 - CHECKING ALIGNMENT OF GENERATOR FEET

2.12) Check the alignment of the generator mount feet and the stator mount face asshown 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

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


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

2.13) Fasten a dial indicator mounting base to the face of the flexplate. Position thebutton so that it rests against the pilot O.D. on the stator adapter plate, as shownin 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 statoradapter plate.) Record the radial measurement obtained in this step on line 3.7 ofthe Generator Installation Worksheet.


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- SECTION 3 -

ROTOR

ADAPTER PLATE

POSITIONING CHECKS


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

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 statoradapter plate and the rotor adapter plate. Be sure that the face of the rotor adapteris free from protective coatings, nicks and dirt and will sit tight against the face of theflexplate. Note that there are four possible orientations of the rotor adapter relativeto the flexplate because there are four holes in the adapter to accept the two dowelpins in the flexplate. Distinctively mark the orientations on the rotor adapter with agrease pencil ("1", "2", "3", "4") with reference to one of the flexplate dowel pins.

NOTE: 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 withthe bolts ( and push it off with the pusher holes). The pilot shoulder on the

flexplate is designed to carry the weight of the rotor.

3.2) Check the runout of the ID of the rotor adapter. Mount a dial indicator on anextension 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 therotor adapter by # "1" and also on the worksheet. Record the measurementobtained in this step on line 4.1 of the Generator Installation Worksheet.


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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 theprevious step. Be sure to record this new TIR by # "2" and on line 3.1 of theGenerator Installation Worksheet.

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

3.5) If none of the orientations produce a radial runout of less than .001 inches, thenchoose the orientation that produced the least amount of runout lower than .003inches. 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 thenrepeat the above steps (3.1 to 3.4) with the new rotor adaptor. The goal is tominimize 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.


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- SECTION 4 -

ROTOR ADAPTER

PLATE SHIMMING


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FIGURE 21 - MEASURING ENGINE ENDPLAY

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 restson the center part of the flexplate.

4.2) Remove a crankshaft inspection cover on the side of the engine. Measure theengine endplay by prying the crankshaft "In" (towards the front of the engine) as faras possible, zeroing the indicator and then prying the crankshaft "Out" as far aspossible using a steady even push on the pry bar (pry on a counterweight only).(Note: Endplay should be between .004 and .018.) Record the measurementobtained 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 platestraight edge and the face of the flexplate as shown in Figure 23 and 24. Measurethe distance at the other end of the straight edge. Add these two dimensionstogether and divide by two for an average dimension. Record all measurementson line 4.2 of the Generator Installation Worksheet.


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FIGURE 22 - CHECKING ENGINE ENDPLAYFIGURE 24 - MEASURING DISTANCEBETWEEN STATOR ADAPTER PLATE ANDFLEXPLATE


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FIGURE 23 - DISTANCE BETWEEN STRAIGHT EDGE AND FLEXPLATE FACE

4.5) Record this number as dimension "A" on line 4.3 of the Generator InstallationWorksheet.

4.6) Record the dimension from Generator Installation Worksheet line 1.3 labeled "Set-Up 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 orminus 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 approximatelyequal to the difference).

If the difference is positive, then add the appropriate number of shims in the samemanner.


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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) 10ea .007" shims = .070"

and 2ea 1/32" shims = .063"

and 1ea 1/16" shims = .063"

TOTAL = .196"

4.9) 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 freefrom dirt and burrs. Ensure that the threads on the 3/4 inch bolts and the threadsin 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 boltthreads and mount the rotor adapter and the correct number of shims on the rotorshaft.

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 upwith the pusher holes in the rotor adapter as shown in Figure 25.


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413-2174 SHIM

4B, 7B, 9B AND 12B GENERATORS416-4561 SHIM

12C-E GENERATORS


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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 thehead 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 steelwire meeting the following specs:

.041" 262,000-292,000 psi tensile strength

.062" 250,000-280,000 psi tensile strength

The pattern that is preferred for the safety wire is a three bolt overlap pattern. Eachbolt head at each end of a group of three is wired to the next bolt head in a patternto keep the bolt head from coming loose.

On bolts with a single .125" hole in the head - two wires will go through the headwith one wire connected to the bolt head on one side and the other wire connectedto the bolt head on the other side. This will give the effect of supporting the bolthead from both sides.


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FIGURE 26 - TYPICAL SAFETY WIRE INSTALLATION


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- SECTION 5 -

INSTALL GENERATOR

AND SHIM

GENERATOR FEET


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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

5) INSTALL GENERATOR AND SHIM GENERATOR FEET

5.1) Carefully apply anti-seize compound to the pilot bores of stator adapter plate andthe rotor adapter plate. Do not apply anti-seize compound to the mounting face ofthese plates.

5.2) Install the two alignment studs opposite one another, in the horizontal plane, in therotor 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: Be aware of the wight of the total generator assembly before slinginghoisting 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.

5.3) Install the proper lifting bar fixture andrigging to the top of the generator tosupport the weight. Typical weights for thevarious generators are shown in Figure 27.

5.4) With a hoist, bring the generator to theengine with its horizontal centerline in linewith the centerline of the engine. Note theposition of the alignment studs. Make surethat the permanent mark on the rotoradapter is oriented correctly with respect tothe mark on the flexplate (twelve o'clock).If a slight adjustment is required, rotate theflexplate.

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


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FIGURE 28 - INSTALLING GENERATOR TO ENGINE

FIGURE 29 - INSTALLATION OF SHIMSAT 3:00 AND 9:00 POSITIONS

5.6) Insert the top and bottom mounting bolts into the stator frame through thecorresponding stator adapter holes. Tightenthese bolts a sufficient amount so that theboss cannot disengage from the bore.

5.7) Install shims of equal thicknesses (0.012"-0.020" thick is suggested) between the statorframe and adapter plate at the three o'clockand nine o'clock positions (Ref. Fig. 29 andFig. 30). Secure these shims with two boltsinstalled into the stator frame, in the samepositions.

5.8) Back the top and bottom mounting bolts out1/4". Check the angular alignment of the

generator relative to the engine using afeeler gauge between the stator adapter andframe in the six o'clock and twelve o'clockpositions (Ref. Figure 29 and 30). Installshim stock under each of the generatormounting feet (Ref. Figure 30 and 31) until adifference of 0.004" or less is attained


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FIGURE 30 - CHECKING STATOR ALIGNMENT

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 properlysecured.

Record the final gap at top and bottom on line 5.1 of the Generator InstallationWorksheet. Record the thickness of shims required under each mounting foot online 5.2 of the Generator Installation Worksheet.

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 4mounting bolts in the generator adapter plate and properly torque all eight bolts tothe specifications in the maintenance manual.


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FIGURE 31 - GAP MEASUREMENT BETWEEN GENERATOR ANDSTATOR ADAPTER PLATE

FIGURE 32 - SHIM PACK INSTALLED UNDER GENERATOR MOUNTFOOT

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


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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 torquethe flexplate coupling bolts. Torque to specs in the maintenance manual.

5.12) Remove the alignment studs in the process of installing the bolts..


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- SECTION 6 -

FINAL

CHECKOUT


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FIGURE 33 - GAP MEASUREMENTBETWEEN GENERATOR AND STATORADAPTER PLATE

6) FINAL CHECKOUT

6.1) Check for abnormal pre-loading of the engine crankshaft by performing the followingsteps:

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 shouldbe the same as what was previously measured. Record the measurement obtainedon 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 normalengine 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 generatorrotor shifted all the way rearward and rotated 360 degrees in the opposite directionof normal engine rotation. Record themeasurement obtained on line 6.2 of theGenerator Installation worksheet.

6.1e If the axial movement in Step c. or d. isgreater than .004" then abnormalpreloading has occurred. The assemblyprocedure must be reviewed andcorrective action taken.

6.2) Bolt the remaining screens in place (onlyapplicable to #12B-E).

6.3) Using a long stem dial indicator, measurethe radial runout of the rotor shaft asshown in Figure 33 and Figure 34. Mountthe indicator in the threaded hole in thestator bolt flange and manually rotate theengine. The maximum runout should notexceed .005". Record the measurementobtained on line 6.3 of the GeneratorInstallation worksheet.

Note: On generators located in trucks the

threaded hole will be horizontal. The


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FIGURE 34 - FINAL RADIAL RUNOUT CHECK

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

6.4) Remove the dial indicator and reinsert the threaded plug.

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


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APPENDIX


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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 Position 2 Average:(Rotor shifted to the slip ring end)

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 f lexplate (0.010" max):

2.5 Perpendicular alignment of rear engine mounts (.015" max): Left: Right:

2.6 Perpendicular alignment of generator feet (.010" max): 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 f lywheel housing (.020" max): *2.10 Axial runout of f lywheel 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 Position 2 Average:

4.3 Shim pack: Average distance between straight edge and flexplate (Dimension A) =

SETUP ADAPTOR TO STATOR DIM (Dimension B) =

Difference =

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 Bottom Difference

5.2 Shim pack thickness under generator feet: 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:


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Single Bearing Generator Installation Procedures _ LeTourneau, Inc.

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