Welding The 3600/C280 Caterpillar Engine And Two Bearing Generator To The Base{1152, 1152} Caterpillar

Welding The 3600/C280 Caterpillar Engine And Two Bearing Generator To The Base{1152, 1152}

Usage:

3616 1FN

Engine: All 3600 All C280

Introduction

Ensure that you read and fully understand the information that follows before performing any of the procedures.

Setting the Weld Plates

The weld plates are fastened to the engine mounting feet. The engine should be set into place utilizing the mounting feet as a template for the location of the weld plates on the base. Follow the procedure below.

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Illustration 1	g03823824

Once the engine has been set, center the engine on the base mounting pads.

Run the jacking screws down until the screws touch the base and then turn an additional 90 degrees.
Note: The weld plates can now be welded to the base.
By using the engine as a template, only three sides of the plate can be welded without first tacking the plates. Then picking up the engine off the plate for welding on all four sides.

If only the three outer sides are welded, care must be taken to keep the temperature of the weld pass as low as possible.
1. Use multiple passes to obtain an 18 mm (0.71 inch) fillet with 2.5 mm (0.10 inch) of penetration.
  Note: Use a 7024 Welding Rod with a diameter of 2.38 mm (0.094 inch). Alternatively, use a flux cored wire with a gas shielding and a diameter of 2.38 mm (0.094 inch).
1. For the root pass, do not exceed 260° C (500° F) and allow the welds to cool after each additional pass.

Note: If too much heat is driven in the plate outside edge without welding the inside, the plate will tip outwards. The tipping will pull the mating surface between the weld plate and base out of parallel. If the weld plate and the base plate surfaces are not parallel, shims can be used. The shims are placed under the weld plate prior to welding to minimize the weld plate from drawing down during the weld process.

Allow the engine welds to cool. Once the welds cool, back off the jacking screws and then torque the engine mounting feet to 900 ± 100 N·m (665 ± 75 lb ft).

Check the engine soft foot and crank deflection.

The weld plates are to be fastened to the generator mounting feet.

Set the generator in place utilizing the mounting feet as a template for location of the weld plates on the base. Run the jacking screws down until the screws touch the base, and then turn an additional 90 degrees.

Measuring Endplay, Setting Split Ring Gap, And Rough Alignment

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Illustration 2	g03824065

Insert a 25.4 mm (1 inch) by 190.5 mm (7.5 inch) long threaded rod through the coupling and generator hub.

Install a nut on each end of the threaded rod. Tighten the two nuts to pull the crank towards the rear to reach full travel of crank endplay.
Note: Rotate the engine if necessary.

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Illustration 3	g03824134

Use a dial indicator and set to zero on the rear of the flywheel. Reposition the nuts to the area between the coupling and the generator hub.

Spread the nuts to push the crankshaft forward.

After the crankshaft is fully forward, release any pressure on the rod and the two nuts.

Read the dial indicator, this reading is the crankshaft endplay. Record the measurement.

Repeat Step 1 to Step 6 except reposition the dial indicator to the generator hub. This measurement is the generator endplay.

Take the measurements and add the measurements together to get the total endplay.

Divide the total endplay by two and record the measurement.

Measure the thickness of the split ring and add that measurement to the total found in Step 9. Record this measurement, this reading is the ring split gap reading needed for this engine and generator set.
Note: The split ring gap reading is used to set the gap between the coupling hub and the generator hub. The gap is with the crankshaft all the way forward and the generator hub all the way to the rear.

Adjust the gap if needed by moving the whole generator forward or towards the rear by the generator push blocks welded on the base.
Note: After this procedure is complete, rough generator alignment can begin.

Loosen the generator weld plates and add shims between the weld plates and generator.
Note: Do not use partial shims.

After adding shims to fill the clearance, torque the weld plate to 900 ± 100 N·m (665 ± 75 lb ft).

Recheck the split ring gap to ensure that the generator has not moved forward or backwards.

Welding The Generator And Final Alignment

Once the rough alignment is complete, tack weld the generator in place.

Recheck the split ring gap prior to the final weld to make sure that the generator has not moved forward or backwards.

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Illustration 4	g03824140

If only the three outer sides are welded, care must be used to keep the temperature of the weld pass as low as possible.
1. Use multiple passes to obtain an 18 mm (0.71 inch) fillet with 2.5 mm (0.10 inch) of penetration.
  Note: Use a 7024 Welding Rod with a diameter of 2.38 mm (0.094 inch). Alternatively, use a flux cored wire with a gas shielding and a diameter of 2.38 mm (0.094 inch).
1. For the root pass, do not exceed 260° C (500° F) and allow the welds to cool after each additional pass.

Allow the generator welds to cool. Once cooled, back off the jacking screws and check for soft foot.

Perform pre-coupled alignment. Torque the generator mounting feet to 900 ± 100 N·m (665 ± 75 lb ft).

Install the split ring and check the final alignment. Check the crank deflection.

160-3655 Isolator Plate Mounting

The weld plates are to be fastened to the isolators and the isolators are to be attached to the base assembly. The entire package should be set into place as a single unit, utilizing the isolators as a template for location the weld plates. Once the engine package has been set, the weld plates can be welded to the deck. The following points are matters that should be considered and observed during the package installation.

By using the engine as a template, only three sides of the plate can be welded without first tacking the plates. Then picking up the engine off the plate for welding on all four sides.

If only the outer three sides are welded, care must be used to keep the temperature of the weld pass as low as possible.
1. Use multiple passes to obtain an 18 mm (0.71 inch) fillet with 2.5 mm (0.10 inch) of penetration.
  Note: Use a 7024 Welding Rod with a diameter of 2.38 mm (0.094 inch). Alternatively, use a flux cored wire with a gas shielding and a diameter of 2.38 mm (0.094 inch).
1. For the root pass, do not exceed 260° C (500° F) and allow the welds to cool after each additional pass.

If too much heat is driven in the plate outside edge without welding the inside as well, the plate will tip outwards. Tipping pulls the mating surface between the isolator and plate out of parallel.
If the mating surfaces are not parallel, binding of the isolator will occur and the package will shake.
If the torque values are not followed, the package will shake.
If the isolator adjustment procedure is not followed, the package will shake.
If the isolators, fiber washers, and isolator pads are not assembled correctly the package will shake.
If the external piping and structural supports interfere with later adjustment of the isolators, the package will shake.
After the welding has been completed, package set, and the isolators properly adjusted check generator alignment and crankshaft deflection to make sure that the engine block is not deflected or bent.