Caterpillar G3616 Generator Set

Tools: laser tool, dial indicators

1. Perform face runout and bore runout alignment using laser tool or dial indicators.
2. Measure face runout at 12:00-6:00 and 3:00-9:00 positions.
3. Measure bore runout.
4. Results must be within coupler manufacturer's recommendation or Caterpillar tolerance.

Tools: deflection gauge

1. Perform cold and hot crankshaft deflection tests.
2. Place tool within 10 mm (0.39 in) of counterweight end.
3. Deflection at middle section must be within +/- 0.0406 mm (0.0016 in).
4. TIR must not exceed 0.08128 mm (0.0032 in).
5. If exceeded, loosen mounting bolts, correct soft foot, and ensure thermal growth not constrained.

⚠ Engine must be prelubed before rotating crankshaft.

Tools: dial indicator

1. Perform cold and hot crankshaft endplay checks.
2. Follow REHS0423 section 3 procedure.
3. Endplay shall be 0.4 ±0.2 mm (0.016 ±0.008 in).
4. Ensure driven equipment endplay is within manufacturer's recommendation.

⚠ Do not use partial shims.

Tools: dial indicator, shims

1. Place dial indicator support on base and tip against upper flat section of engine foot.
2. Ensure all jack-up bolts are raised.
3. Loosen engine foot while observing dial indicator.
4. Measured deflection must not exceed 0.0762 mm (0.003 in).
5. Add shims if necessary; repeat for all feet.

Tools: pressure gauges, pressure fittings

1. Perform static pressure checks with engine stopped at water pump inlet and auxiliary water pump inlet.
2. Perform dynamic pressure checks with temperature regulators fully open at locations A through H.
3. Record all results.

⚠ Both engine and driven equipment should be doweled closest to coupler and on same side.

Tools: drill, reamer

1. Dowel designated engine and driven equipment mounting feet after hot alignment is within spec.
2. Drill dowel hole to 25.37 ± .02 mm at depth 80 mm.
3. Ream holes to 25.405 mm diameter.
4. Insert dowels and drive until contact with bottom.

Tools: jack-up bolts, IE2254 lubricant, sleeves, dam material, grout

1. Attach mounting plates to engine feet; set engine on base.
2. Apply IE2254 lubricant to jack-up screws and turn until they touch base.
3. Place sleeves around jack-up bolts and mounting bolts.
4. Adjust jack-up bolts to level engine; perform cold coupler alignment and crankshaft endplay test.
5. Build dam around each mounting plate for grout.
6. Fill each dam with grout until 1/4 plate thickness is exposed.
7. Allow grout to cure per manufacturer.
8. Remove jack-up bolts and tighten mounting bolts to Table 7 torques.
9. Start engine and perform hot alignment.

⚠ Oil pan is not designed to withstand engine load in operation.

1. Use designated lifting eyes only.
2. Ensure oil pan rests on level surface if temporarily supporting engine.
3. Never support engine from oil pan in permanent setup.

⚠ Significant experience required to maintain alignment during welding.

Tools: jack-up screws, shims, welder

1. Attach mounting plates to engine feet; set engine on base so sole plates contact base.
2. Level engine using jack-up screws and shims.
3. Perform cold coupler alignment and crankshaft endplay test.
4. Weld all mounting plates to base.
5. Remove jack-up screws and tighten mounting bolts to Table 7 torques.

⚠ The linkage can move and form a pinch point which can cause personal injury. Keep hands away from the linkage.

1. Ensure linkage is meant to be lubricated. Applies to air choke, fuel control, and exhaust bypass actuators.
2. Apply Dow Corning 41 Extreme High Temperature Bearing Grease to the rod ends of the control linkage.

1. Ensure that the engine is not running.
2. Remove plugs (1) and (2).
3. Drain the moisture into suitable containers.
4. Install the plugs.

1. Ensure that the air supply to the air lines is OFF.
2. Remove plug (1).
3. Carefully remove screen (2). Clean with nonflammable solvent. Inspect for damage.
4. Install clean, dry screen (2). Clean plug (1). Install the plug.