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ALIGNMENT
Contents
Alignment.............................................................................1
General Alignment Considerations....................................... 2
Types of Misalignment .................................................. 2
Parallel/Bore Misalignment.......................................... 2
Angular/Face Misalignment ........................................ 2
Inaccurate Flanges ........................................................ 2
Alignment Tools ........................................................... 3
Laser Alignment Tools ............................................... 3
Dial Indicators .......................................................... 3
Accuracy of Dial Indicator Readings ............................ 3
Support Brackets ...................................................... 4
Principles of Alignment...................................................... 5
Cold Alignment............................................................. 5
Hot Alignment .............................................................. 5
Crankshaft Position ....................................................... 5
Flywheel Sag or Droop .................................................. 5
Crankshaft Endplay ....................................................... 6
Crankshaft Deflection.................................................... 6
Torque Reaction ........................................................... 7
Thermal Growth ........................................................... 7
Alignment Related Mounting Considerations........................10
Shimming ...................................................................10
Metal Shims ............................................................10
Poured Resin Chocks................................................10
Adjustable Chocks ...................................................11
Mounting Bolts ............................................................11
Mounting Bolt Torque ...............................................11
Procedure for Tightening Engine and Driven Equipment
Mounting Bolts ........................................................12
Flexible Couplings ............................................................13
General Requirements...................................................13
Cat® Couplings ............................................................13
Couplings by Other Manufacturers .................................14
Specific Alignment Considerations .....................................15
Alignment of Close-Coupled Driven Equipment ................15
Alignment of Remote Mounted Gear Driven Equipment.....16
Reference Material ...........................................................19
Foreword
This section of the Application and Installation Guide generally describes
wide-ranging requirements and options for the Alignment of Cat® engines
listed on the cover of this section. Additional engine systems, components
and dynamics are addressed in other sections of this Application and
Installation Guide.
Engine-specific information and data is available from a variety of sources.
Refer to the Introduction section of this guide for additional references.
Systems and components described in this guide may not be available
or applicable for every engine.
Alignment
In order to obtain optimum service life from a Cat® engine and its driven
equipment, correct alignment between the units is required. Improper
alignment results in excessive vibration, short life of driven equipment/
compound bearing and coupling clutch parts, and frequent re-alignment.
Good alignment practices include proper shimming, correct torque on hold-
down bolts, accurate laser or dial indicator usage, allowances for bearing
clearances, thermal growth, and accounting for other characteristics of the
engine. Special instructions, listed under Reference Material at the end of
this section, are available with specific alignment procedures for all Cat
engine and driven equipment combinations.
Cat marine propulsion engine alignment is covered in a separate section of
the Application and Installation Guide.
SECTION CONTENTS
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Application and Installation Guide Alignment
Figure 1
Angular/Face Misalignment
Angular or face misalignment
occurs when centerlines of driven
equipment and engines are not
parallel. Refer to Figure 2.
Angular/Face Misalignment
Figure 3
Inaccurate Flanges
Inaccurate flanges cause apparent
Figure 2 misalignment and make accurate
alignment impossible.
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Alignment Application and Installation Guide
Face runout refers to the distance 0.05 mm (0.002 in) on the flywheel
the hub face is out of perpendicular and 0.13 mm (0.005 in) on adapters
to the shaft centerline. Refer to bolted to the flywheel. Flange face
Figure 4. runout should not be more than
0.05 mm (0.002 in).
Face Runout
Alignment Tools
Laser Alignment Tools
Note: The laser alignment tools
typically measure the actual offsets.
The dial indicators measure a total
indicator reading (TIR).
Follow all the instructions that are
provided by the manufacturer in order
to ensure that the parallel misalign-
ment and the angular misalignment
Figure 4
are within the specifications.
Bore runout refers to the distance Typically, the laser alignment tools
the driving bore of a hub is out of compensate for any axial movement
parallel with the shaft centerline. of the rotor shaft for the generator
Refer to Figure 5. or the crankshaft. If the axial shaft
moves during the angular measure-
Bore Runout ments, consult the literature on the
laser alignment tool for information.
Dial Indicators
A dial indicator measures very small
changes in distance. Alignment of
shafting requires measurement of
small changes in distance dimensions.
The indicator must be rigidly located
so the specified alignment values can
be measured.
Accuracy of Dial Indicator Readings
Figure 5 There is a quick way to check the
validity of dial indicator face align-
The face and bore runouts of ment readings. As Figure 6 shows,
flywheel, clutch or coupling, driven readings are taken at four locations
members, and hubs must be checked designated as A, B, C and D. When
when inconsistent alignment results taking readings, the dial indicator
occur. Face or bore errors must be should be returned to location A to
corrected. Bore-to-pilot diameter be sure the indicator reading returns
runout error should not be more than
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Application and Installation Guide Alignment
Figure 7
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Alignment Application and Installation Guide
Principles of Alignment
flywheel to orbit around its true
Cold Alignment center. Refer to Figure 8.
Since there is no accurate or
Crankshaft Position
practical method of measuring
alignment with an engine running at
operating temperature and under
load, all Caterpillar alignment
procedures must be performed with
the engine stopped and the engine
and driven equipment at ambient
temperature. This is called “cold
alignment.” In order to achieve
correct operating alignment, certain
factors must be taken into
consideration in determining cold
alignment specifications. Depending
Figure 8
on the application, some or all of the
following factors will affect the cold
alignment procedure. Generally, driven equipment will
have ball or roller bearings that do
Hot Alignment
not change their rotational axis
In the past, a hot alignment check
between static and running
may have been used to check the
conditions.
accuracy of the cold alignment
procedure. However, factory tests Flywheel Sag or Droop
have shown that the results of the With the engine not running, the
hot alignment check are flywheel and coupling cause a small
inconsistent; therefore, this deflection of the crankshaft. This
procedure is not recommended results in the checking surface (pilot
except for G3600 engines. Please bore or outside flywheel diameter)
refer to the G3600 Commissioning rotating below centerline of the
Guide for the G3600 Hot Alignment crankshaft bearings. For this reason,
procedure. Caterpillar recommends alignment
checks be performed with the
Crankshaft Position
coupling in place. Refer to Figure 9.
Alignment is made under static
conditions while the crankshaft lies
at the bottom of its bearings. This is
not its position during operation.
Firing pressures, centrifugal forces,
and engine oil pressure all tend to lift
the crankshaft and cause the
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Application and Installation Guide Alignment
Crankshaft Deflection
Cat engines mounted on bases not
supplied by Caterpillar require a
crankshaft deflection test.
This test can be performed on all
Cat engines equipped with
crankcase inspection doors to assure
the engine block is not unduly
stressed. Perform the test under cold
engine conditions before startup.
• Remove an inspection door from
the block to expose the center
crankshaft throw.
• Rotate the crankshaft in the
Figure 9 normal rotation direction. When
the cheeks of the center throw
Crankshaft Endplay are past the connecting rods,
In all applications, after installation install a Starrett No. 696
of the driven equipment the distortion dial indicator, or similar
crankshaft endplay must not be less tool, as shown in Figure 10. As a
than it was before installation of the precaution, tie a string to the
equipment. Crankshaft endplay gauge and secure it outside the
should be checked during cold engine to facilitate retrieval
alignment and again after the engine should the assembly fall into the
is at operating temperature. Endplay oil pan.
at operating temperature must not • Zero the dial indicator's rotating
be less than endplay during cold bezel.
alignment. • Properly seat the indicator
Before taking indicator readings rotating it on its own axis until
during the alignment procedure, it will hold a zero reading.
always move the engine crankshaft
to the end of its endplay, toward the
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Alignment Application and Installation Guide
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Application and Installation Guide Alignment
approximately the same rate. Refer shaft back (towards the rear of the
to Figure 12. base) against thrust bearing. For
Horizontal compensation consists generators without thrust bearings,
of using a coupling allowing the generator must be positioned
sufficient relative movement in the magnetic center. Adjust
between driving and driven generator to half (50%) of the total
members. The equipment must be end-play of the generator and
positioned so the horizontal growth engine. Failure to do so results in
moves into the coupling operating excessive crankshaft thrust bearing
zone, not away from it. One method loading and/or coupling failure.
is to position the engine crankshaft Sufficient clearance has been
all the way forward (towards the allowed if it is determined that the
front of base). Position the generator crankshaft still has end clearance.
Figure 11
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Alignment Application and Installation Guide
Figure 12
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Application and Installation Guide Alignment
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Alignment Application and Installation Guide
Adjustable Chock
Figure 15
Figure 14 Mounting Bolts
The diameter of the clearance-type
Adjustable Chocks bolts used to hold the engine rails or
Mechanical chock systems are feet to the base must be 1.6 mm
self-leveling, height-adjustable (0.06 in) less than the diameter of the
machinery mounting chocks that can holes in the engine rails. This clearance
be used in place of metal shims and is to allow the engine mounting rails or
poured resin chocks. These chocks feet to grow without confinement.
have similar advantages to the Refer to the section on thermal
poured resin chocks along with growth.
several additional advantages.
Mounting Bolt Torque
• The poured resin chock curing A bolt is properly torqued when it is
time is eliminated, making the entire stretched a calculated amount. The
mounting and alignment procedure proper stretch clamps the driven
quicker. device to the base securely. The clamp
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Application and Installation Guide Alignment
Figure 16
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Alignment Application and Installation Guide
Flexible Couplings
analysis. If requested, Caterpillar can
General Requirements perform this analysis.
A flexible coupling is a device used
to transmit power from one shaft to Serviceability
another while accommodating some Ease of installation and service is a
shaft misalignment. Some typical significant factor when selecting a
flexible couplings are: coupling. If required, spacer pieces
can be used to permit removal and
• Couplings with rubber or installation of the coupling without
elastomer elements. disturbing the engine-to-driven
• Couplings with flexible steel equipment alignment.
plates or discs.
• Couplings with spring type Coupling Selection
elements. In any installation, the coupling
• Gear type couplings. should be the design weak link or
• Roller chain type couplings. first part to fail. When failure occurs,
Flexible couplings can be used to the chance of damage to the engine
connect an engine to a driven unit, and driven equipment is minimized.
two engines together, or several Safety measures must be considered
driven units together. to prevent major damage should
coupling failure occur. The use of a
Four (4) distinct characteristics standard, commercially available
must be considered in the selection coupling offers the benefit of parts
of a coupling. availability and reduced downtime in
Misalignment Capability case of failure. When selecting a
The coupling must be capable of coupling, always follow the coupling
compensating for some manufacturer's recommendation
misalignment between two regarding the best coupling for a
connected shafts. It is not the intent specific application.
to correct for shaft misalignment,
but only to compensate for small Cat® Couplings
amounts of shaft misalignment The three types of flexible
normally present due to temperature couplings supplied by Caterpillar are:
fluctuations and operating loads. • Flexible steel plate couplings are
Stiffness used in single-bearing generator
The coupling must be of proper applications.
torsional stiffness to prevent critical • Spider and ring with rubber
orders of torsional vibration from blocks are used in close-coupled
occurring within the operating speed marine transmission applications.
range. To ensure coupling
compatibility, qualified personnel
should perform a torsional vibration
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Application and Installation Guide Alignment
Figure 18
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Alignment Application and Installation Guide
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Application and Installation Guide Alignment
bolted to the flywheel housing. Such Before bolting coupling plates onto
practices stress both the generator the flywheel, always rotate engine
housing and flywheel housing and to the same position. For example,
can cause vibrations. cylinder number 1 TDC. Tighten half
It is not necessary to make this the bolts while the flywheel is in this
check on smaller Cat generator sets position. Then rotate as necessary to
where the engine does not have rear tighten other bolts. This procedure
mounting feet but relies on the assures that any sag in the
generator set support. However, this crankshaft is always at the same
check is necessary on smaller Cat position when the plates are
engines where the driven equipment fastened to the flywheel.
is also rigidly connected to another
Alignment of Remote Mounted
piece of equipment. A common
example of this would be a Gear Driven Equipment
mechanical drive where the clutch Perform final alignment after all
mechanism is bolted to the major equipment has been installed
compound. Poor mounting practices on the base. Engines and driven
with this arrangement can cause equipment should be filled with oil
excessive stresses in the flywheel and water as required and ready to
housing. operate.
Single bearing generators are Remote mounted gear drive units
recommended to have a pilot shaft must be supported by the same base
extension and loose fitting flex or rails as the engine as shown in
plates, or no pilot shaft extension Figure 20. These units are not
with piloted plates. This aids in fastened to the engine except
maintaining proper alignment. through a drive shaft and flexible
coupling. To install these units, the
If vibration is noted at assembly of gear drive must first be aligned with
a generator having coupling plates the equipment that it is driving. Then
piloted into the flywheel, the engine must be aligned with the
repositioning the coupling plates ¼- gear drive unit.
of-a-turn with respect to the original
location can often correct the Alignment between the gear drive
vibration. Start the unit and observe unit and its driven equipment is
the change in vibration. A second or usually line-to-line alignment. The
third relocation may be necessary to centerline of the gear drive output
find the position of lowest vibration. shaft is in line with the centerline
Locate plates at point of lowest of the input shaft of the driven
vibration. This procedure allows equipment. Depending upon the
manufacturing tolerances to attempt application, it may be necessary
to cancel each other. to use a flexible coupling between
the gear drive unit and the driven
equipment.
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Alignment Application and Installation Guide
Alignment Considerations
Figure 20
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Application and Installation Guide Alignment
Figure 22
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Alignment Application and Installation Guide
Reference Material
The following information is
provided as an additional reference
to subjects discussed in this guide.
SEHS7073 (3500)
Special Instruction - Alignment of
Two Bearing Generators
SEHS7259
Special Instruction - Alignment of
Single Bearing Generators
SEHS7654
Special Instruction - Alignment -
General Instructions
REHS0177
Special Instruction - Alignment of
Close Coupled Two Bearing
Generators
REHS0204
Special Instruction - Procedures for
the Installation and Initial Start-Up
of Gas Engine Chiller Drivelines
REHS0423 (3600)
Special Instruction - Alignment of
Two Bearing Generators
REHS0445
Special Instruction - Alignment
Procedures for G3500 Tandem
Generator Sets
REHS0475
Special Instruction - The
Installation and the Alignment of
the Two Bearing Locomotive
Generators
REHS7854
Special Instruction - Alignment of
Genset Package with Gearbox
© 2012 Caterpillar
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