Installation And Mounting System For Locomotive Engine/Generator Packages{1021} Caterpillar

Engine:

3508 (S/N: 6TJ)

3512 (S/N: 2WK)

3516 (S/N: 9KF)

Introduction

This Special Instruction describes the installation and the mounting system for 3500 locomotive engines. These engines have a base which uses a four-point resilient mount. The base assembly consists of structural steel rails with integral welded crossmembers and bottom plating. The engine is supported in the base assembly by angle ledges that are bolted to the oil pan. The angle ledges are then bolted into the top flange of the base assembly.

Do not perform any procedure in this Special Instruction until you have read this information and you have understood this information.

General Information

The traction alternator is close coupled to the engine. The traction alternator is bolted directly to the top flange of the base assembly. Shims are used to adjust the alignment. The auxiliary alternator is directly coupled to the front power take-off. This unit is also bolted to an extension of the base assembly. Shims are used to adjust the alignment.

The type of resilient mount and the configuration are very different between the 3516 and the 3508/3512 packages. Therefore, each package must be considered separately. Refer to the following illustrations for more information: illustration 1, illustration 2 and illustration 3.

Note: The 3500 engine can be temporarily rested on the oil pan. However, the oil pan is not intended to support the engine during shipment nor during the final installation. The engine can rest on the oil pan, but the engine should not rest on the oil pan when the engine is assembled into the base. This case is especially true when the assembly contains the two alternators. Suitable blocking must be used under the rails of the base assembly.

Illustration 1	g00581478
This is a view of the front 3516 resilient mount. (1) Angle Ledge (2) Base Assembly (3) Mount (4) Oil Pan (5) Support (6) Locomotive Frame (A) Front View (B) Side View

Illustration 2	g00581693
This is a view of the rear 3516 resilient mount. (7) Base Assembly (8) Angle Ledge (9) Mount (10) Support (11) Oil Pan (12) Locomotive Frame

Illustration 3	g00583427
This Illustration shows the resilient mount for the 3508 and the 3512 engines. (13) Angle Ledge (14) Base Assembly (15) Oil Pan (16) Mount (17) Support (18) Locomotive Frame

3516 Engine Package

On installations that were previously powered by EMD 16 cylinder engines, the mounting pads on the locomotive frame are retained. Refer to illustration 4 for details. These pads require some modification and the screw threads (holes) will probably need to be repaired. If the old pads are retained, the correct vertical location and the correct horizontal location can be achieved. The top surface provides a level plane that can be used to extend the pad, even if the surface is worn.

Illustration 4	g00586383
(1) 8 holes (25.4 mm (1 inch) - 8 THD) (A) 406.4 mm (16 inch) (B) 76.2 mm (3 inch) (C) 990.6 mm (39 inch) (D) 1168.4 mm (46 inch) (E) 254 mm (10 inch) (F) 3035.3 mm (119.5 inch) (G) 254 mm (10 inch)

Modification Procedure For EMD Locomotives

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Illustration 5	g00586420
(A) 114.3 mm (4.5 inch) (B) 6.35 mm (0.25 inch) x 45° (C) Thickness As Required (D) 9.5 mm (0.4 inch) x 45°

1. Cut four plates to the same length as the existing pads. These plates may be cut from a steel bar or from a steel plate. The width of the plate should be 114.3 mm (4.5 inch). The thickness of the plate is the same thickness as the existing pads. One edge on each side of the plate should be prepared for butt welding and for clearance for the existing weld. Prepare this edge with a suitable chamfer on each corner. Refer to illustration 5 for details.

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Illustration 6	g00586438
(1) Check For Level (2) Larger Chamfer (3) Shim As Required

2. Place the new plates against the outside of the existing pads. The larger chamfer must be on the bottom of the plate. Ensure that the new plate does not rest on any irregularities on the surface or that the new plate does not rest on the old weld. Shim the plate, if necessary. Check for a level plane across the locomotive. Spot weld the plate in place. Refer to illustration 6 for details.

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Illustration 7	g00586468
(E) 6.4 mm (0.25 inch) (The "G" signifies "Ground Flush".) (F) 12.7 mm (0.5 inch) (3 sides)

3. Check for a level plane across the locomotive again. Finish welding the plates. Refer to illustration 7 for details.

4. Grind the butt weld flush. Check for a level plane across the locomotives. The pads should be level, but the maximum uneven dimension is 0.75 mm (0.03 inch). Correct the level, if necessary.

5. Cut back the four old pads to approximately 63.5 mm (2.5 inch). Increase the distance between each pair of pads to 1170.6 mm (46 inch). Refer to illustration 6 for details.

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Illustration 8	g00586490
(G) 1117.6 mm (44 inch) (H) 63.5 mm (2.5 inch)

6. Repair the old threads (25.4 mm (1 inch) - 8 UNC), if necessary.

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Illustration 9	g00586529
(4) Eight new tapped holes (25.4 mm (1 inch) - 8 UNC) (I) 1447.8 mm (57 inch)

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Illustration 10	g00587078
(J) 1447.8 mm (57 inch) (K) 254 mm (10 inch) (L) 3035.3 mm (119.5 inch) (M) 254 mm (10 inch)

7. Drill eight new holes and tap these holes through the new pad and the locomotive frame. Locate the additional holes that are shown in illustration 9 and illustration 10.

Modification Procedure For Non EMD Locomotives

1. Cut four plates from a steel bar or from a steel plate with the following dimensions: 203.2 mm (8 inch) wide, 19 mm (0.75 inch) thick and 406.4 mm (16 inch) long. The required minimum thickness of the plate is a thickness that is above the highest point on the locomotive platform. This platform lies under the entire base.

2. Determine the location of the base with one of the following items: the outlet flange of the cooling fan, the desired location of the carbody bulkhead and the center of gravity of the package.

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Illustration 11	g00587099
(A) 203.2 mm (8 inch) (B) 1117.6 mm (44 inch) (C) 406.4 mm (16 inch) (D) 2882.9 mm (113.5 inch)

3. Position the plates at the desired location, and tack weld the plates in place. Refer to illustration 11. Check for a level plane across the locomotive and along the locomotive. Finish welding the plates. The pads should be level, but the maximum uneven dimension is 0.75 mm (0.03 inch). Correct the level, if necessary.

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Illustration 12	g00587116
(E) 1447.8 mm (57 inch) (F) 1168.4 mm (46 inch) (G) 254 mm (10 inch) (H) 3035.3 mm (119.5 inch) (I) 254 mm (10 inch)

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Illustration 13	g00587126
(1) Sixteen new tapped holes (25.4 mm (1 inch) - 8 UNC) (2) Plate (3) Rail

4. Locate the four holes in each plate and on the locomotive frame. Refer to illustration 12. Drill and tap these holes. If the holes in the plates already exist, continue the holes through the locomotive frame before you tap the holes. Refer to illustration 13.

Base Installation

1. The base should have the resilient mounts and the support trunnions attached.

2. The base of the engine-generator can be lowered into position. Guide pins can be made by cutting the head off a standard bolt. Shims should be used if a clearance of more than 0.75 mm (0.03 inch) exists.

3. Use 1D-4638 Bolts with the following dimensions: 1 inch (8 UNC) and 90 mm (3.5 inch) long. Also use 5P-8250 Washers . Tighten to the correct torque.

4. The use and the installation of collision blocks is at the discretion of the rebuilder. Any blocking should be at least 3.5 mm (0.14 inch) away from the assembly.

5. Loosen the front support trunnions from the mounting pads of the locomotive after the following tasks have been accomplished: the complete package has been installed, the locomotive has been correctly ballasted and the main frame is in the operating position. The base will now slide and the base will not bind when the frame of the locomotive straightens under load. This procedure is more important on the longer wheelbase units. These units have a large amount of built-in camber when these units are in the free state.

3508/3512 Package

Several compromises must be made when the 3508 is installed or the 3512 is installed in the EMD switcher type locomotives. These compromises are due to the changing floor plan. The package is intended to directly replace the EMD twelve cylinder engine by the use of an adapter plate. Refer to illustration 14. All crossmembers that are welded to the platform must be removed.

Illustration 14	g00587147
(1) Eight holes (25.4 mm (1 inch) - 8 UNC) (A) 457.2 mm (18 inch) (B) 101.6 mm (4 inch) (C) 939.8 mm (37 inch) (D) 1168.4 mm (46 inch) (E) 254 mm (10 inch) (F) 2044.7 mm (80.5 inch) (G) 254 mm (10 inch)

Exercise care if you attempt to close up the fish belly by welding in a heavy plate. Excessive heat and shrinkage could cause distortion of the mounting feet of the engine.

Modification Procedure For EMD Locomotives

1. The existing mounting pads of the engine must be extended to 12.7 mm (0.5 inch) beyond the adapter plate at each end. Prepare the plates in order to clear the existing weld. This preparation will also clear the plates for the butt weld. Refer to illustration 15.

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Illustration 15	g00587156
(A) Length as required (B) 6.35 mm (0.25 inch) x 45° (C) Thickness as required (D) 9.5 mm (0.4 inch) x 45°

2. Place the new plates against the end of the existing pads. The larger chamfer must be on the bottom of the plate. Ensure that the new plate does not rest on any irregularities on the surface or that the new plate does not rest on the old weld. Shim the plate, if necessary. Check for a level plane across the locomotive. Tack weld the plate in place. Refer to illustration 16.

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Illustration 16	g00587169
(E) 12.7 mm (0.5 inch) (F) Adapter Plate (G) Check for level (H) Locomotive Frame (I) Larger chamfer (J) Shim as required

3. Check for a level plane across the locomotive again. Finish welding the blocks. Refer to illustration 17.

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Illustration 17	g00587215
(K) 6.4 mm (0.25 inch) (The "G" signifies "Ground Flush".) (L) 12.7 mm (0.5 inch) (3 sides) (M) Locomotive Frame

4. Grind the butt weld flush. Check for a level plane across the locomotives. The pads should be level, but the maximum uneven dimension is 0.75 mm (0.03 inch). Correct the level, if necessary.

5. Refer to ""Base Installation" " before you weld the adapter plate to the pads.

Base Installation

1. The base should have the resilient mounts and the supports attached.

2. The adapter plate can be bolted to the existing holes in the mounting pads of the old engine. Bolts are only used to locate the plates during the initial installation and the bolts may be removed later.

3. The base of the engine-generator can be lowered into position. Guide pins can be made by cutting the head off a standard bolt. Shims should be used if a clearance of more than 0.75 mm (0.03 inch) exists.

4. Use the bolts and the hard washers that are supplied in order to secure the supports to the adapter plate. Tighten to the recommended torque. Some minor adjustment of the location of the adapter plate may be required in order to center these bolts.

5. Tack weld the adapter plates to the mounting pads of the old engine. Remove the base of the engine-generator and remove the supports with the package. Finish welding the plates. The maximum uneven level that is permitted across the top surface of the adapter plates is 0.75 mm (0.03 inch). Correct this level, if necessary.

6. The use and installation of the collision blocks is at the discretion of the rebuilder. Any blocking should be at least 3.5 mm (0.14 inch) away from the assembly.

7. Loosen the front and rear supports from the adapter plates after the following tasks have been accomplished: the complete package has been installed, the locomotive has been correctly ballasted and the main frame is in the operating position. The base will now slide and the base will not bind when the frame of the locomotive straightens under load. This procedure is more important on the longer wheelbase units. These units have a large amount of built-in camber when the units are in the free state.