FRAME AS 1080172 - Caterpillar

Measuring Endplay, Setting Split Ring Gap, And Rough Alignment
Illustration 2 g03824065
Insert a 25.4 mm (1 inch) by 190.5 mm (7.5 inch) long threaded rod through the coupling and generator hub.
Install a nut on each end of the threaded rod. Tighten the two nuts to pull the crank towards the rear to reach full travel of crank endplay.Note: Rotate the engine if necessary.
Illustration 3 g03824134
Use a dial indicator and set to zero on the rear of the flywheel. Reposition the nuts to the area between the coupling and the generator hub.
Spread the nuts to push the crankshaft forward.
After the crankshaft is fully forward, release any pressure on the rod and the two nuts.
Read the dial indicator, this reading is the crankshaft endplay. Record the measurement.
Repeat Step 1 to Step 6 except reposition the dial indicator to the generator hub. This measurement is the generator endplay.
Take the measurements and add the measurements together to get the total endplay.
Divide the total endplay by two and record the measurement.
Measure the thickness of the split ring and add that measurement to the total found in Step 9. Record this measurement, this reading is the ring split gap reading needed for this engine and generator set.Note: The split ring gap reading is used to set the gap between the coupling hub and the generator hub. The gap is with the crankshaft all the way forward and the generator hub all the way to the rear.
Adjust the gap if needed by moving the whole generator forward or towards the rear by the generator push blocks welded on the base.Note: After this procedure is complete, rough generator alignment can begin.
Loosen the generator weld plates and add shims between the weld plates and generator.Note: Do not use partial shims.
After adding shims to fill the clearance, torque the weld plate to 900 100 N m (665 75 lb ft).
Recheck the split ring gap to ensure that the generator has not moved forward or backwards.Welding The Generator And Final Alignment
Once the rough alignment is complete, tack weld the generator in place.
Recheck the split ring gap prior to the final weld to make sure that the generator has not moved forward or backwards.
Illustration 4 g03824140
If only the three outer sides are welded, care must be used to keep the temperature of the weld pass as low as possible.
Use multiple passes to obtain an 18 mm (0.71 inch) fillet with 2.5 mm (0.10 inch) of penetration.Note: Use a 7024 Welding Rod with a diameter of 2.38 mm (0.094 inch). Alternatively, use a flux cored wire with a gas shielding and a diameter of 2.38 mm (0.094 inch).
For the root pass, do not exceed 260° C (500° F) and allow the welds to cool after each additional pass.Note: If too much heat is driven in the plate outside edge without welding the inside, the plate will tip outwards. The tipping will pull the mating surface between the weld plate and base out of parallel. If the weld plate and the base plate surfaces