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APPLICATION AND INSTALLATION GUIDE

VIBRATION
Contents

Vibration ............................................................................... 1
Basic Theory...................................................................... 2
Linear Vibration Definitions ............................................. 2
Frequency ................................................................. 3
Displacement ............................................................. 3
Velocity .................................................................... 3
Acceleration .............................................................. 4
Vibration Identification........................................................ 6
Vibration Measurement ................................................... 6
Order of Vibration .......................................................... 8
Vibration Level Guidelines ............................................... 9
Vibration Causes and Corrective Actions ............................ 10
Causes........................................................................ 10
Corrective Actions........................................................ 10
One Component ....................................................... 10
1/2 Order Vibration .................................................. 10
1st Order Vibration................................................... 10
2nd Order Vibration .................................................. 10
Higher Order Vibration .............................................. 10
Non-Engine Vibration ................................................ 10
Excessive Engine Motion............................................... 11
Misalignment/Unbalance ........................................... 11
Resonance............................................................... 12
Torque Reaction....................................................... 12
Balance Procedure........................................................ 13
Reference Material ........................................................... 15
Media List ................................................................... 15
Engine/Driven Equipment Vibration Measurement
Data Sheet .................................................................. 16
Foreword
This section of the Application and Installation Guide generally describes
Vibration, its causes and suggested corrections for Caterpillar 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 are 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.

Information contained in this publication may be considered confidential.


Discretion is recommended when distributing. Materials and specifications
are subject to change without notice.

CAT, CATERPILLAR, their respective logos, Caterpillar Yellow and the


POWER EDGE trade dress, as well as corporate and product identity used
herein, are trademarks of Caterpillar and may not be used without
permission.
Vibration Application and Installation Guide

Vibration
All mechanical systems with mass and elasticity are capable of relative
motion. If this motion repeats itself over a given time period, it is known as
linear vibration. Engines produce linear vibration due to combustion forces,
torque reactions and structural mass and stiffness combinations and
manufacturing tolerances on rotating components. All these forces may
create conditions ranging from unwanted noise to high stress levels, and
possible failure of the engine or driven components. Torsional vibration can
create similar conditions but is caused by the twisting and untwisting of a
shaft. Torsional vibration is discussed in the Mounting Application and
Installation Guide.
This guide:
Reviews the basic theory and nomenclature of linear vibration.
Identifies causes of engine-related linear vibration.
Provides instruction for possible corrective action.

SECTION CONTENTS

Basic Theory ...................... 2 Corrective Actions


Linear Vibration Definitions Excessive Engine Motion
Vibration Identification ......... 6 Balance Procedure
Vibration Measurement
Reference Material ............. 15
Order of Vibration Media List
Vibration Level Guidelines Vibration Measurement
Vibration Causes and Data Sheet
Corrective Actions..............10
Causes

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Application and Installation Guide Vibration

Basic Theory
Engine vibrations are produced housed in a building or close to
and maintained by regular, periodic sensitive instruments or equipment,
driving forces set up by unbalanced such as computers.
moving masses. These are called Other factors influencing vibration
forced vibrations. are foundation design, soil load
Free vibrations have no driving characteristics, and other machinery
force. When set in motion, such operating in close proximity.
vibrations, if undamped, would
continue indefinitely with constant Linear Vibration Definitions
amplitude and natural frequency. Linear vibration occurs as a mass
is deflected and returned along the
If the frequency of a forced
same path. This can be illustrated as
vibration is the same as the natural
a single mass spring system as
frequency of a free vibration, then
shown in Figure 1. While no external
excessive vibration will result. This
force is imposed on the system, the
synchronization of forced and free
weight remains at rest and there is
vibration is called resonance.
no vibration. When the weight is
Resonance stresses can cause moved or displaced and then
serious problems and even reach released, vibration occurs. The
destructive levels. weight travels up and down through
The vibration generated by the its original position until frictional
engine could also result in structural forces cause it to rest.
damage if a rigid installation was

Mass Spring System

Figure 1

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Vibration Application and Installation Guide

Frequency of dynamic stresses and are most


Refer to Figure 2 for an illustration commonly used.
of the following definitions. Displacement
Maximum displacement from the The total distance traveled by
mean position is called amplitude. the weight, from one peak to the
The interval in which the motion is opposite peak, is peak-to-peak
repeated is called the cycle. The displacement, as shown in Figure 2.
time required for the weight to This measurement is usually
complete one cycle is called a expressed in mils, one mil equaling
period. one-thousandth of an inch
If the weight needs one second [0.025 mm (0.001 in.)]. It is
to complete a cycle, the vibration a unit of vibration severity.
frequency is one cycle per second. Average and root-mean-square
If one minute, hour or day were (rms) are sometimes used to
required, its frequency would be measure vibration (rms = 0.707
one cycle per minute, hour or day, times the peak of vibration.) These
respectively. A system completing terms are referred to in theoretical
its full motion 20 times in one discussions, but are of limited
minute would have a frequency of practical value.
20 cycles per minute, or 20 cpm.
Velocity
Establishing frequency is necessary Another method to analyze
when analyzing vibration. It allows vibration is measuring mass velocity.
identification of the engine Note that the weight depicted in
component or condition causing Figure 1 and Figure 2 is not only
the vibration. moving, but changing direction.
Machinery vibration is complex and The speed of the weight is also
consists of many frequencies. constantly changing. At its limit,
Displacement, velocity and the speed is zero. Its speed or
acceleration are all used to diagnose velocity is greatest while passing
particular problems. Displacement through the neutral position.
measurements are better indicators

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Application and Installation Guide Vibration

One Period

Figure 2

Velocity is an extremely important F= Frequency in cycles-per-


characteristic of vibration; but minute (cpm).
because of its changing nature, Acceleration
a single point is commonly chosen Acceleration is another
for measurement. This is peak characteristic of vibration. It is the
velocity and normally expressed in rate of velocity change. In Figure 2,
inches per second. note that peak acceleration is at
Velocity is a direct measure of the extreme limit of travel where
vibration and provides the best velocity is zero. As velocity
overall indicator of machinery increases, acceleration decreases
condition. It does not, however, until it reaches zero at the neutral
reflect the effect of vibration on point.
brittle material. Acceleration is dimensioned in
The relationship between peak units of g (peak), where g
velocity and peak-to-peak equals the force of gravity at the
displacement is compared by: earths surface:
Vpeak = 52.3 x D x F x 10-6 (980.665 cm/s2 = 386 in./s2 = 32.3 ft/s2)
Acceleration measurements, or
Where: gs, are used where relatively large
Vpeak = Vibration velocity in inches forces are encountered. At very high
per second peak. frequencies (60,000 cpm), it is
perhaps the best indicator of
D= Peak-to-peak displacement,
vibration.
in mils. 1 mil (0.001 in.).

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Vibration Application and Installation Guide

Vibration acceleration can be


calculated from peak displacement:
gpeak = 1.42 x D x F2 x 10-8
Note that overall, or total peak-
to-peak displacement, shown in
Figure 3, is approximately the sum
of individual vibrations.

Figure 3

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Application and Installation Guide Vibration

Vibration Identification
If excessive linear vibration motion face of each major piece of
is present or suspected, an initial equipment. For example, an engine
inspection should be performed to driving a two bearing generator set
confirm that: will require measurements at ten
Engine, coupling and driven points, two at each bearing and two
equipment mounting bolts are in an axial direction, as illustrated in
properly torqued, and that all Figure 4.
jacking bolts and set screws Engine only applications and other
are backed off. types of packaged units may require
Engine, coupling and driven fewer measurement points, but the
equipment are properly following descriptions and graphic in
aligned. Figure 4 still apply.
All external piping is properly Marine propulsion applications will
isolated from the engine and also require a measurement in the
driven equipment with vertical direction at the right rear
appropriate flexible couplings. engine mounting foot. This is
required to check for rolling of the
If the initial inspection results do engine. The measurement is taken
not identify the problem, then at the point where the engine is
vibration measurements should be anchored by means of a fitted bolt.
made to determine the source prior
to starting corrective action. The Vibration measurements must be
Vibration Measurement Data Sheet, made at the advertised driven
at the end of this guide, is provided equipment rating (100% load). If
for convenient recording of raw data additional data is desired, it is
at various engine speed and load recommended that measurements
conditions. This form can be used be made at 0% load, 50% load,
for the basic engine as well as any 75% load and, depending on the
packaged unit, including one or two rating, 110% load.
bearing generator sets, marine For generator set applications,
propulsion engine/reduction gear if measurements are taken while a
sets, and pump or compressor generator is loaded, the magnetic
packages. field of the generator leads must be
avoided. In addition, two sets of
Vibration Measurement measurements should be made at
Vibration should be measured in the 0% load condition for generator
both vertical and horizontal set applications; one with the exciter
directions at each bearing location, turned on and one with the exciter
and in an axial direction at the rear turned off.

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Vibration Application and Installation Guide

Vibration Measurement Points

Figure 4

Point 1 EFV (Engine Front Vert.) Point 5 ERA (Engine Rear Axial)
Vertical direction at the front of Axial direction at the rear of the
the engine; locate the probe on the engine; locate the probe on the right
block top deck in the plane of the rear outside edge of the block at the
crankshaft centerline. crankshaft centerline.

Point 2 EFH (Engine Front Hor.) Point 6 XFV (Driven Front Vert.)
Horizontal direction at the front of Vertical direction at the driven
the engine; locate the probe on the equipment front bearing; locate the
side of the block at the crankshaft probe on the bearing housing at the
centerline. shaft centerline.

Point 3 ERV (Engine Rear Vert.) Point 7 XFH (Driven Front Hor.)
Vertical direction at the rear of Horizontal direction at the driven
the engine; locate the probe on the equipment front bearing; locate the
block top deck (or rear housing) in probe on the side of the bearing
the plane of the crankshaft housing at the shaft centerline.
centerline. Point 8 XRV (Driven Rear Vert.)
Point 4 ERH (Engine Rear Hor.) Vertical direction at the driven
Horizontal direction at the rear of equipment rear bearing; locate the
the engine; locate the probe on the probe on the bearing housing at the
side of the block at the crankshaft shaft centerline.
centerline.

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Application and Installation Guide Vibration

Point 9 XRH (Driven Rear Hor.) orders. In other words, individual


Horizontal direction at the driven order motions will add or subtract
equipment rear bearing; locate the to produce the overall. This
probe on the side of the bearing measurement is not used to identify
housing at the shaft centerline. problems or establish limits, but
rather as an indication of the total
Point 10 XRA (Driven Rear Axial)
linear vibration motion.
Axial direction at the driven
equipment rear; locate the probe on Data should be reported in terms
the right rear outside edge of the of peak-to-peak displacement (mils)
driven equipment structure (not at half order frequency, first order
sheet metal) at the shaft centerline. frequency, overall velocity level
(in/s) and overall displacement (mils)
Point 11* - ERR (Engine Rear Rot.)
for each of the measuring locations.
Vertical direction at the right rear
The data sheet at the end of this
engine mounting foot.
guide can be used to record and
* - marine applications only, when
report the measured vibration data.
engine is anchored with fitted bolt.
All measurements must be made
Order of Vibration on the main rigid structural members
In discussions of vibration, the of the engine and driven equipment.
frequency of the motion is The instrument pickups must be
commonly referred to in terms of positioned on the crankshaft
order of vibration. In an engine, the centerline at the previously defined
order of vibration is the number of locations.
vibratory cycles exhibited by a Vibration measurements on large
component during one revolution engine units should be taken using
of the crankshaft. a Caterpillar Vibration Analyzer, part
One-Half Order is two occurrences number 9U5831. This tool may be
per crankshaft revolution. ordered through the Caterpillar Tool
First Order is one occurrence per & Shop Product Guide, Media
crankshaft revolution. Number NENG2500. If Caterpillar
measuring equipment is not
Second Order is one occurrence available, an equivalent device
every two crankshaft revolutions. capable of measuring peak-to-peak
Higher Order describes occurrences displacement at selected
at 1, 2 or more crankshaft frequencies, overall velocity,
revolutions. and overall displacement should
be used.
Vibration Frequency (cpm)
Order=
Engine Speed (rpm)

Overall vibration motion is the


vector sum of the motion of all the

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Vibration Application and Installation Guide

Overall velocity
Vibration Level Guidelines
= 34.3 mm/s (1.35 in/s)
The following vibration level
guidelines are used for assessing the These guidelines apply to both gas
vibration severity of the core engine and diesel engine packages installed
or package installation. with or without isolation mounts. If
linear vibration is higher than these
Attachments to the engine or
guidelines, refer to the Vibration
package installation typically raise
Causes and Corrective Actions
vibration values and are not included
section in this guide.
in these guidelines.
Consult the manufacturer of the
The vibration levels for any load
driven equipment for any such
condition, at any of the measuring
vibration guidelines.
locations, must not exceed the
following guidelines: A vibration worksheet is provided
at the end of this guide.
Peak-to-peak displacement
at half order frequency WARNING: It is not an acceptable
= 0.13 mm (5 mils) practice to lower the package
vibration levels when operating at
Peak-to-peak displacement
stable conditions by tightening the
at first order frequency
snubber bolts on the Caterpillar
= 0.13 mm (5 mils)
vibration isolators. This practice
Overall displacement will only hide vibration problems.
= 0.22 mm (8.5 mils)

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Application and Installation Guide Vibration

Vibration Causes and Corrective Actions


Causes Corrective Actions
Experience has shown that linear
vibration motion problems can be One Component
attributed to: If one component is the only item
with excessive motion, the
Misalignment of engine and component mounting will have to be
driven equipment. altered until the motion is reduced to
Unbalance of rotating parts. an acceptable level at operating rpm.
Resonance from structural 1/2 Order Vibration
mass (weight) and stiffness When the vibration motion
(rigidity) combinations. measurements show that 1/2 order
Torque reaction. is causing the problem, the engine
Cylinder misfiring. fuel and governing system should
be serviced to eliminate engine
Combustion forces. misfiring. No other work should be
Unbalance of reciprocating attempted until engine misfiring is
parts. eliminated.
1st Order Vibration
The following table correlates Refer to the Balance Procedure
vibration characteristics to these in this guide.
possible causes:
2nd Order Vibration
Vibration Correctable When excessive second order
Characteristic Causes vibration occurs on 4-cylinder and
1 component Mounting of vee 8 engines, the timing of the
component second order force balancers should
1/2 x engine rpm Misfiring of one or
be checked.
(one-half order) more cylinders
1 x engine rpm Unbalance, Higher Order Vibration
(first order) misalignment, out-of- Other high order vibration levels
time balance weights,
crankcase overfill
cannot be corrected with flywheel
2 x engine rpm Unbalance, out-of- balance weights or balancer timing.
(second order) time balance weights Usually these orders involve the
1 1/2, 2 1/2, third Normal cylinder and structural characteristics of the
higher orders combustion (not generator and base which will need
correctable)
to be altered.
Large vibration Resonance
motion Non-Engine Vibration
Motion increases as Torque reaction If the vibration motion involves
load is applied insecure mounting or
non-engine mounted structures
inadequate base
and the engine vibration motion is
acceptable, either the off-engine
components must have their

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Vibration Application and Installation Guide

mounting altered or proper vibration


isolators must be installed between
the engine or generator set and the
structure.

Excessive Engine Motion


If the engine unit has excessive
motion, it will generally be due to
misalignment/unbalance, resonance Figure 5
or torque reaction. However, if the
vibration motion for the first and
Misalignment/unbalanced vibration
second order still remain excessive
motion is relatively constant over the
after examination and correction, the
speed range, as shown in Figure 5,
engine should be removed from the
but exceeds accepted limits. For
set and placed on suitable isolators.
generator set applications, this
Another condition that causes may be determined by operating
excessive engine motion is rigid between 45 Hz and 65 Hz.
body mode. Due to sizing and Misalignment/unbalanced vibration
selection of engine or package motion is not changed by load.
mounts, the engine and package will
If misalignment or unbalance is
move as a rigid body. This can only
identified:
be corrected by changing the
package mounts. Check the alignment of the
unit. Refer to Caterpillar
If vibration is present, but the
Special Instructions listed
engine is within limits, a vibration
under Reference Material at
specialist should be consulted. If the
the end of this section.
bare engine exceeds the limits,
engine components rotating at If vibration is still excessive,
engine speed (first order) or twice refer to the Balance Procedure
engine speed (second order) should at the end of this section.
be inspected. If vibration is still present after
Misalignment/Unbalance the balance procedure, mount
Most linear vibrations of generator the unit on isolators and
sets or other packaged units are repeat the balance procedure
caused by misalignment or until a satisfactory level of
unbalance of the rotating members. vibration is obtained.
This typically results in first order
vibration which can be corrected in
the field.

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Application and Installation Guide Vibration

Resonance under Reference Material at


Resonance occurs when a large the end of this section.
vibration motion (amplitude) takes If vibration is still excessive,
place within a narrow speed range, refer to the Balance Procedure
as shown in Figure 6. at the end of this section.
The vibration can occur on the If vibration is still present after
generator set and/or the attached the balance procedure, mount
equipment, such as piping and air the unit on isolators and
cleaners. When vibrations peak out recheck. If the unit is
in a narrow speed range, the satisfactory, the problem is
vibrating component is in resonance. an improper mounting system
which requires changing.
Consult the proper specialist.
Should the balance procedure
fail and the set has excessive
linear vibration motion when
installed on the proper
isolators, repeat the balance
procedure until the linear
vibration motion level is
Figure 6 satisfactory.
Torque Reaction
There are two methods of reducing When the vibration motion
resonance vibration levels. These increases as load is applied, as
are: shown in Figure 7, torque reaction
is the likely problem. With a two-
Changing the natural
bearing generator, it can be caused
frequency of the part that is
by insecure mounting of the engine
resonant.
or generator to its base and/or by
Reduction of the exciting a base not sufficiently rigid to
force. withstand the associated forces.
If the following checks show that
the cause of the problem is the
structure that the engine, generator
set, or other packaged unit is
mounted on, a vibration specialist or
mounting system specialist should
be consulted.
Check the alignment of the
unit. Refer to Caterpillar
Special Instructions listed
Figure 7

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Vibration Application and Installation Guide

Torque reaction problems are not Balance Procedure


found with close-coupled generators. The following correction procedure
The rigid joint between the flywheel can be applied to first order vibration
housing and the generator body is motion:
generally adequate to withstand
The crankshaft must assume
torque.
the same position each time
Assuming that a free standing two- a balance adjustment is made.
bearing generator is mounted on a To assure this identical
weak base, first order motion and location is assumed, position
orders related to the number of flywheel to top dead center
cylinders firing with one crankshaft (TDC) of number 1 cylinder.
revolution are due to torque reaction A chalk mark or scribe across
which, in turn, causes misalignment. flywheel and coupling plates
In this case, the first order motion will provide an easy reference
would be most prevalent. during the balancing
This condition is generally operation.
encountered when the engine is Remove bolts holding
driving a conventional two-bearing generator coupling plates to
generator which is not close- flywheel. Rotate generator
coupled. Check the alignment of rotor with plates attached
the unit. 90 clockwise while flywheel
If the two-bearing generator set remains at number 1 TDC.
utilizes a structural steel base which Replace coupling plate bolts
is point-mounted, for example, pads and retest for vibration.
and isolators, torque reaction can If vibration remains, again
deflect the weak base. This deflection position flywheel at TDC
can cause severe misalignment and number 1 cylinder, index
resulting vibration. generator rotor another 90
If the unit continues to exhibit clockwise (total 180), and
vibration after alignment, the base is retest.
likely not strong enough to hold the If necessary, repeat the
torque reaction and needs previous step by rotating
strengthening. another 90 clockwise.
One method of strengthening is Position coupling assembly
to weld plates on top and bottom of relative to flywheel where
the base across the width of the least amount of vibration
base from 6 in. forward of the rear occurred. If magnitude of
engine supports to 6 in. behind the vibration remains
generator feet closest to the engine. unacceptable, add weight
of 56.70 g (2 oz) under any
single coupling plate to
flywheel bolt. Flat washers

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Application and Installation Guide Vibration

can be used for this purpose.


Bolt must be sufficiently long
to maintain at least 1 1/4
times the bolt diameter of
thread engagement.
Observe vibration level and
relocate weight 90 quadrant
to identify where minimum
vibration occurs.
Add additional weight at point
of minimum vibration
identified in the previous step
until vibration level is no
longer diminished. In no case
should more than 141.75 g
(5 oz) be added under any
one bolt.
If vibration levels are still
unacceptable, a vibration control
specialist should be consulted.

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Vibration Application and Installation Guide

Reference Material
Media List
The following information is
provided as an additional reference
to subjects discussed in this manual.
SEHS7654: Special Instruction
Alignment General Instructions
REHS0423: Special Instruction
Alignment of Two-Bearing
Generators
REHS0177: Special Instruction
Alignment of Close Coupled Two-
Bearing Generators
NENG2500: Tool and Shop
Product Guide

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Application and Installation Guide Vibration

Engine/Driven Equipment Vibration Measurement Data Sheet


Engine/Driven Equipment Description:
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
Rating: _______________________________________________________________
Rated Speed: _________________________________________________________
Load Condition: _______________________________________________________

1/2 Order 1st Order Overall


Overall Velocity
Location Displacement Displacement Displacement
mm/sec (in/sec)
(mils) (mils) (mils)
Point 1 - EFV
Point 2 - EFH
Point 3 - ERV
Point 4 - ERH
Point 5 - ERA
Point 6 - XFV
Point 7 - XFH
Point 8 - XRV
Point 9 - XRH
Point 10 - XRA
Point 11 ERR*
* Marine Applications Only, when engine is anchored with fitted bolt.

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LEBW4972-01 2008 Caterpillar Printed in U.S.A.
All rights reserved.

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