Petroleum Base Upgrade Installation{7060} Caterpillar

Engine:

3516B (S/N:: 2FW1-UP)

3516BHD (S/N:: CBN1-UP)

3516 (S/N:: 73Z1-UP)

Introduction

The following procedures cover the required steps in order to install the 282-3251 Rework Kit to a 7W-7919 Inner Base .

The following procedures are applicable to standard production Caterpillar 3516, 3516B, or 3516BHD series petroleum gensets. The information in this document applies to petroleum gensets that use free standing, two bearing generators on a 7W-7919 inner base only when used in offshore applications at 1200 rpm.

The use of the 282-3251 Rework Kit and the procedures will add:

• an additional torque tube assembly

• reinforcement to the generator

• reinforcement to the engine mountings

• an additional stiffener spring to the rear isolator mount

These procedures require a large number of critical welds that are to be made, therefore:

• An AWS D1.1 certified welder is required do all of the welding.

• All welds are required to be needle peened.

• All weld segments need to be started and finished near the center of a straight section and not at the corners.

Illustration 1	g01215646
Inner Base Rails Before and After Modifications

Parts List

Engine Preparation

Note: This preparation applies to all machines and engines with electronic controls. Also, this is the procedure to use for the service or storage of a machine.

Proper welding procedures are necessary in order to avoid damage to electronic controls. The following steps should be complied with when welding on any machine or engine with electronic controls.

1. Turn off the engine and place the key start switch in the OFF position.

2. Disconnect the negative battery cable at the battery. Or, if the machine or engine has a battery disconnect switch, then, turn the switch to the Open position.

3. Connect the welder ground cable directly to the actual machine that is to be welded.

   Note: Place the welder ground cable clamp as close as possible to the location where a weld is to be done in order to reduce the possibility of welding current damage to the generator bearings or electrical components like ECM's and other machine components.

   Note: DO NOT USE ELECTRICAL COMPONENTS LIKE ECM'S and SENSORS or ELECTRONIC COMPONENT GROUND POINTS FOR GROUNDING THE WELDER.

4. Protect any of the wiring harnesses from welding debris or spatter.

Weld Repair

Repair all existing cracks. Trim the " tip" off all of the engine mount gussets. Refer to TIBU, 4580.

1. Weld all joints with a low hydrogen process and a matched electrode. Refer to table 2 for the allowed metal filler.

2. The fillet welds that are along the sides of the angled gusset, should extend 12.7 mm (0.5 inch) beyond the end of the gusset.

   Note: The end of the gusset must remain open and not welded.

3. Clean the weld surface between each pass.

4. Visually inspect each pass for surface defects.

   Note: The weld procedure used must meet or exceed the following specifications for allowed filler metal.

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   Table 2

   Allowed Filler Metal
   AWS	(A5.1)	E7018
   AWS	A5.18	ER70S-2	ER70S-3	ER70S-6	ER70C-6M
   AWS	A5.20	E70T-1	E70T-5	E71T-1
   AWS	A5.17	F7A2-EM12K	F7A2-EM13K

Sub-Assembly Work

Illustration 2	g01215834
281-4693 Torque Tube Assembly (10) 281-4694 Tube (11) 281-4695 Tube (12) 281-4696 Tube (13) Threaded Holes in 281-4694 Tube (14) 281-5591 Hanger Plate (17) 281-5597 Hanger Plate

Due to the amount of variation in the 7W-7919 Inner Rails , the 281-4694 torque tube , the 281-4695 torque tube , and the 281-4696 torque tube can not be cut to final length until the distance between the inner rails is known.

The measurement of the inner rail dimension (3) must be made as described in the following steps. Refer to illustration 3, illustration 4, and illustration 5.

Note: The torque tube length must be equal to the distance between the inner rails minus 25.4 mm (1 inch). The final length of the torque tubes must allow for the hanger plate thickness. Each hanger plate is 12.7 mm (0.5 inch).

Illustration 3	g01215876
(1) Engine Flywheel and Housing (2) Face Plate (3) Inner Rail Width (4) Inner Base Rails (5) Drip Pan (6) Generator Mount

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Illustration 4	g01219338
Suggested Locations of Where to Measure Inner Rail Dimensions

1. Measure inner base rail distance. Refer to illustration 4 and to illustration 5.
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   Illustration 5	g01218127
   Suggested Locations of Where to Measure Inner Rail Dimensions

   1. It is suggested that measurements be taken at locations F1, F2, F3, R2, and R1 as shown in illustration 5. This will ensure proper dimensions for the torque tube length that is needed.
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      Table 3

      Inner Base Rail Measurements
      Location	Measurement
      F1
      F2
      F3
      R1
      R2

   2. Record measurements in table 3.

2. Trim the torque tubes to length.

3. After the tubes have been trimmed, the torque tube brace assembly can be sub-assembled. Refer to the 281-4693 Torque Tube Assembly drawing in the "Drawings" section of this document for reference.

Torque Tube Subassembly

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Illustration 6	g01216150
(10) 281-4694 Tube (11) 281-4695 Tube (12) 281-4696 Tube (13) Threaded Holes in 281-4694 Tube (14) 281-5591 Hanger Plate (17) 281-5597 Hanger Plate

1. Place the 281-4694 Tube (10), which has threaded holes (13) for lifting, in the center.

2. Place one 281-4695 Tube (11) on each side of the 281-4694 Tube (10).

3. Weld each of the 281-4695 Tubes (11) to the 281-4694 Tube (10) .

4. Place the 281-4696 Tube (12) on top of the 281-4695 Tube (11) as shown in illustration 6.

5. Weld the 281-4696 Tube (12) to the top of the 281-4695 Tube (11) as shown in illustration 6 section A-A.

   Note: Make sure the threaded holes of the 281-4694 Tube are accessible.

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Illustration 7	g01216194
(11) 281-4695 Tube (12) 281-4696 Tube (14) 281-5591 Hanger Plate and 281-5597 Hanger Plate (15) Beveled Edge (16) Flush Weld (17) 281-5597 Hanger Plate

6. Orient the bevel (15) on the outer edge of the 281-5591 Hanger Plate (14) and the 281-4697 Hanger Plate (17) in order to allow clearance for the welds that hold the face plate (2) to the base rails (4). Refer to illustration 7.

   Note: A bevel (16) will need to be ground into the edge of the 281-4695 Tube (11) at both ends, on the edge that is toward the face plate (2). This bevel is intended to provide clearance for the welds that are used to fasten the face plate to the base rails. Refer to illustration 7.

7. Weld the entire torque tube assembly together.

Installation Preparation

1. Remove the generator from the inner base rails (4). Refer to Service Manual, SENR5359, "SR4B Generators".

   Refer to Special Instruction, SEHS9031 for short-term storage requirements.

2. Verify that all peripheral components or plumbing components that are installed close to the rails, have been either rerouted or removed.

Engine Mount Reinforcement

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Illustration 8	g01216358
(20) Example of Paint Removed to Expose Bare Metal

1. Remove paint from the area around each engine mount.

2. Trim the engine 282-3520 Brace Assembly and the engine 281-5589 Brace Assembly as needed in order to fit snugly onto the inner base rail around each of the engine mounts. There must be a 6mm gap (23) that is between the brace assembly and the original engine brace (21) .

3. Put each engine brace assembly in place on the rail frame.

4. Grind bevels (21) in the original engine mount angle plates in order to match the bevels (26) that are in the angle plates of the new engine braces. Refer to illustration 9 and illustration 10.

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Illustration 9	g01216370
Part of brace assembly in this illustration has been removed for clarity. (21) Bevel outer edge of original engine brace (22) Continuous weld completely around the access hole (23) 6mm gap (24) 282-3520 Brace Assembly or 281-5589 Brace Assembly

5. Weld completely around the circumference of each brace.

   Note: Verify all weld segments are started and finished near the center of a straight section and not at the corners.

   Note: Special attention should be given to the welds that are next to the original engine brace. These welds should not extend above the face of the brace assembly. The engine mount doubler angle 281-4690 Plate and the 281-4691 Plate will be placed above the welds that are next to the original engine brace.

6. Weld around the inner surface of the access hole (22). Also, if needed, refer to the 281-4684 Drawing .

7. Install the two engine mount doubler angle plates (26) over the 6mm gap (23) that is between the original angle plates and the brace assembly. This procedure allows the angle plates to be located flush with brace surface.

   Note: The doubler angle plates (26) must be placed with their beveled edges against the beveled edges or the original engine mounts (21).

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Illustration 10	g01216400

8. Tack weld the engine mount doubler angle 281-4690 Plate and the 281-4691 Plate .

   Verify these plates fit snugly to the angled plates of the original engine mount.

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Illustration 11	g01216412
(30) 281-4690 Plate and 281-4691 Plate (31) 281-4689 Backing Plate (32) 281-4688 Rib Plate and 281-4687 Rib Plate (33) 281-5589 Brace Assembly or the 282-3520 Brace Assembly

9. Machine each 281-4689 Backing Plate (31) in order to fit between the doubler angle 281-4690 Plate (30) and the 281-4691 Plate and the rib plates (32) of each of the engine brace assemblies.

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Illustration 12	g01216402
(35) Finish Welds of Angle Plates, Backing Plates, and Rib Braces

10. Finish welding (35) the angle plates (30) and the backing plates (31) to the original engine mounts and to the engine brace assemblies (33) .

Drip Pan Modification

Illustration 13	g01216419
(2) Face Plate (5) Drip Pan (6) Generator Mounts (36) Section of Drip Pan to Remove

1. Remove a 610 mm (24 inch) portion (36) of the drip pan. The section of the drip pan that is to be removed starts at the face plate (2) and is toward generator mounts (6). Refer to illustration 13.

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Illustration 14	g01216423
(36) Drip Pan Section Removed

2. Remove enough paint at the edges of the remaining drip pan section in order to weld the drip pan to the torque tube assembly and to the inner rail frame.

Torque Tube Install

1. Mount the 281-4693 Torque Tube Assembly to the 7W-7919 Inner Base Rail Assembly . Place the torque tube assembly in the location where the drip pan section was removed.

   Note: The front of the 281-4693 Torque Tube Assembly should be in contact with the face plate (2) for the entire length. The rearward side of the 281-4693 Torque Tube Assembly should be in contact with the remaining portion of the cut drip pan (5) for its' entire length.

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Illustration 15	g01216424
(5) Remaining Portion of Drip Pan (37) Weld Location For Drip Pan

2. Weld (37) the remaining portion of the drip pan (5) to the 7W-7919 Inner Base Rail Assembly with a continuous weld on each side from the corner notch of the drip pan to the torque tube brace assembly.

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Illustration 16	g01216425
(2) Face Plate (5) Drip Pan (40) Continuous Weld Around Torque Tube Assembly

3. Weld the entire top circumference (40) of the torque tube assembly to the inner rail base, drip pan, and face plate.

   Note: Welds should start and stop in the middle of straight runs.

Generator Mount Reinforcement

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Illustration 17	g01218302
(41) Generator Mounting Block (42) Original 1W-6393 Plate that is part of the 7C-7123 Mounting Grp (43) Top of Base Rail (44) Weldments (45) 281-5593 Plate in Place (46) Torque Tube Assembly

1. Weld (44) the inside seams of the existing 7C-7123 Generator Mounting GP components (41) and (42). That is, add the weld where the block (41) makes contact with the inner base rail (43) and the 1W-6393 Plates (42). Refer to illustration 17.

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Illustration 18	g01218574
(41) Generator Mounting Block (42) Original 1W-6393 Plate that is part of the 7C-7123 Mounting Grp (43) Top of Base Rail (45) 281-5593 Plate in Place (46) Torque Tube Assembly (50) 281-5592 Plate

2. Assemble one 281-5592 Plate (50) to each generator mount (41) on the side of the generator mounting block that is toward the engine. Refer to illustration 18.

3. Assemble one 281-5593 Plate (45) to each generator mount (41) on the side of the generator mounting block that is away from the engine. Refer to illustration 18.

   Note: Each of the new plates (45) and (50) must fit against the current generator mounting plates (42). The beveled edges (51) and (52) of each of the new plates must be toward the existing generator mounting blocks. It may be necessary to grind the existing generator mounting block welds in order to allow the new plates to fit against the existing generator mounting blocks. Refer to illustration 18 and illustration 19.

Illustration 19	g01218580
(41) Generator Mounting Block (45) 281-5593 Plate in Place (50) 281-5592 Plate in Place (51) Beveled Edge on 281-5593 Plate (52) Beveled Edge on 281-5592 Plate

Base Isolator Modification

The changes that are made to the inner base increases the amount of weight that must be supported by the rear isolator. In order to maintain the proper vibration isolation, the rear isolator must be stiffened. In order to accomplish this task, the end of the inner base that is under the generator, must be lifted up in order to provide the clearance that is necessary to effect the isolator modification.

Note: A minimum clearance of 241 mm (9.5 inches) above the generator end isolator will be required in order to safely modify the isolator.

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Illustration 20	g01218703
(55) Isolator Springs (56) Limit Shaft Hardware to be removed

1. Remove all isolator mounting bolts. Remove the isolator travel limiting nuts and hardware (56). The "limiting nuts" must be removed in order to lift the inner base.

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Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

2. Use lifting and blocking devices that are properly rated in order to lift the inner base to a minimum height of 241 mm (9.5 inches).

   Note: The weight of the modified inner base and engine is 8934.74 kg (19700 lb).

3. Use blocking devices that are properly rated in order to safely support the inner base once the inner base is raised to the necessary height.

4. Loosen the shipping bolts on either side of the isolator.

5. Remove the upper piece of the isolator in order to expose the spring pack (60) .

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Illustration 21	g01218745
(60) Spring Pack (61) Location for Added Spring

6. Insert a 282-3741 Spring in the center row of the spring pack (61). Refer to illustration 21.

7. Install isolator upper part that was removed in step 5.

8. Tighten bolts.

9. While the inner base is still raised, weld the bottom of the torque tube assembly to the inner base rails. The torque tube assembly must be welded on each side where the bottom of the hanger plates of the assembly contact the inner base rails.

10. Remove blocking, if used.

11. Lower the inner base back into position.

12. Assemble inner base to the isolator.

13. Replace the travel limiting hardware.

Reassembly and Testing

1. Install the generator. If needed, refer to Service Manual, SENR5359, "SR4B Generators".

2. Install all peripheral components or plumbing that was removed.

3. Aligned the genset. If needed, refer to Special Instruction, SEHS7073, "Alignment Of Two Bearing Generators".

4. Perform genset tests on the unit before returning to service.

   Note: A "Completed Generator Start-up" checklist is required after generator is installed.

Drawings

Illustration 22	g01219493

Illustration 23	g01215952

Illustration 24	g01216363

Illustration 25	g01219450

Illustration 26	g01219455

Illustration 27	g01219456