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Home›Repair guides›Caterpillar›Installation Of The Generator For Generator Sets That Are Equipped With A 3500 Engine

Caterpillar — Installation Of The Generator For Generator Sets That Are Equipped With A 3500 Engine

Installation

From a Caterpillar service manual covering: 3208, 3304, 3306B, 3406, 3408C, 3412, 3412C, 3508, 3512, 3516, D330, D333…. Check it applies to your exact model before use.

Applies to: Caterpillar 3208, Caterpillar 3304, Caterpillar 3306B, Caterpillar 3406, Caterpillar 3408C, Caterpillar 3412, Caterpillar 3412C, Caterpillar 3508, Caterpillar 3512, Caterpillar 3516

Before you start

  • Damage to engine and generator can result if electric set is operated with a plate assembly that does not have proper clearance.
  • If N or O is less than initial A, disassemble and check coupling plate for bowing; replace if bowed.

Procedure

  1. Ensure generator is disengaged from engine; clean generator support and base contact surfaces; remove protective material from flywheel pilot bearing bore and coupling contact surface.
  2. Remove two engine side covers; rotate engine until no. 1 crankshaft throw is perpendicular; measure crankshaft end play with dial indicator; record as A and divide by two for B.
  3. With crankshaft at extreme forward position, measure distance from straight edge to flywheel housing mounting surface (C) and flywheel pilot surface (D); subtract D from C for E.
  4. Remove coupling bolts and washers; remove plates, shims, and exhaust fan; lift rotor; locate rotor so air gap equal; move rotor to extreme rear.
  5. Place dial indicator on vertical surface of heat sink at rear of rotor shaft; measure rotor end play (approximately 3.81 to 7.62 mm); record F and divide by two for G.
  6. Move rotor to extreme rear; position straight edge across mounting ring diameter; measure distance to mounting ring surface (H) and hub mounting surface (I); subtract H from I for J.
  7. Bolt a standard set of 17 5N-4478 Plates together; measure thickness in two locations along contour; average as K.
  8. Determine number of shims: subtract B, E, G, K from J for L; divide L by 0.8 mm (0.03 inch) for M; round up.
  9. Put coupling plate in flywheel bore; check clearance between coupling plate outside diameter and flywheel bore inside diameter.
  10. Install coupling plate assembly, bolts (6) and calculated shims; tighten bolts (5) in 180 degree intervals in three stages to 525 + 25 N-m (390 + 20 lb ft).
  11. Install guide bolts in flywheel; put generator on engine; install bolts (10); tighten to 100 N-m (75 lb ft) in pairs at 180 degree intervals in three stages.
  12. While crane supports generator, place dial indicator on heat sink vertical surface; push generator forward within + 0.50 mm (+ 0.0200 inch) of midpoint of end play.
  13. Install fan mounting bolts (11) into flywheel; tighten to 200 N-m (150 Ib ft) in pairs at 180 degree intervals in three stages.
  14. Place dial indicators on no. 1 crankshaft throw and heat sink; push crankshaft forward; check crankshaft end play 0.178 to 0.635 mm and heat sink end play 0.076 to 0.635 mm; record N and O.
  15. If N or O is less than initial A, disassemble; check coupling plate for bowing; replace if bowed; check calculations; install generator and repeat steps 13 and 15.

Tools required

Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.

Specs & values

  • crankshaft end play: .178 to .635 mm (0.0070 to 0.0250 inch)
  • rotor end play: approximately 3.81 to 7.62 mm (.150 to .300 inch)
  • 525 + 25 N-m (390 + 20 lb ft)
  • 100 N-m (75 lb ft)
  • 200 N-m (150 Ib ft)
  • 0.178 to 0.635 mm (0.0070 to 0.0250 inch)
  • 0.076 to 0.635 mm (0.0030 to 0.0250 inch)
  • + 0.50 mm (+ 0.0200 inch)
  • 0.8 mm (0.03 inch)

Full service-parts list: Caterpillar 3208 →, Caterpillar 3304 →, Caterpillar 3406 →, Caterpillar 3408C →, Caterpillar 3412 →, Caterpillar 3412C →, Caterpillar 3508 →, Caterpillar 3512 →, Caterpillar 3516 →

Source: Caterpillar service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.

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