3100 HEUI TRAINING ENGINE (INSTALLATION GUIDE) MODIFIED 129-3642 EN Installation Guide Caterpillar

General Description

Left Side View
(1) Remote box. (2) Air cleaner. (3) Exhaust muffler. (4) Radiator. (5) Junction box. (6) Air compressor. (7) Battery. (8) Suction fan. (9) Base assembly. (10) Starter. (11) Support (left side). (12) Fuel tank.

Right Side View
(1) Remote box. (2) Air cleaner. (3) Exhaust muffler. (4) Radiator. (7) Battery. (8) Suction fan. (9) Base assembly. (12) Fuel tank. (13) Inlet air elbow assembly. (14) Air cleaner support. (15) Support (right side). (16) Alternator pulley shield.

This publication provides a general description of how to modify a 3100 HEUI Truck Engine (129-3642) for use as a training engine. The modifications are based on the training engine designed by AVSpare for classroom training on the HEUI fuel system. This publication will not describe every detail needed for modification or configuration. This manual will provide the following basic information:

* Supports And Assemblies

* Attachments

* Electrical And Wiring

NOTE: PURCHASE OF A 3100 HEUI TRAINING ENGINE PACKAGE IS POSSIBLE. FOR DETAILS PLEASE CONTACT:

CAPITOL POWER SYSTEMS

#1 CAPITOL DRIVE

P.O. BOX 2550

EAST PEORIA, IL 61611-0550

OR CALL (309) 694-1234.

* There are two packages available.

(1) The complete 3100 HEUI training engine with the 129-3642 engine arrangement.

(2) Electrical options. One is to purchase the complete system which consists of all the needed harnesses and boxes. Another option is to purchase the individual components that suit your specific needs.

Supports And Assemblies

This section provides informative illustrations for additional brackets, shields, supports, angles, etc. The frame assembly and fuel tank is also covered in this section. This section primarily deals with iron that needs to be fabricated for the engine being configured.

NOTE: Dimensioned illustrations have been provided. Refer to Fabrication Drawings in this publication.

Attachments

This section provides informative illustrations for adding a flywheel adapter, air cleaner, fan group, exhaust group, and electrical boxes. This section primarily deals with modifying existing products for the engine being configured.

Electrical Systems, Schematics And Wiring Diagrams

This section provides informative illustrations for the remote electrical box, junction box, wiring harnesses, etc. for the engine loads that are generated and for the modifications that have been made. This section primarily deals with the electrical needs for the engine.

NOTE: Do to the complexity of the wiring it is recommended that only experienced electrical personnel make these modifications. The purchased 3100 HEUI training engine package will include a complete set of electrical schematics. If more information is required please refer to 3100 HEUI Diesel Truck Engine, Schematic, SENR6567.

Supports And Assemblies

Air Cleaner Support

(1) Front Bracket.

(2) Support Plate. Bolt to the air cleaner mounting group (3).

(3) 4P3439 Air Cleaner Mounting Group. Attaches to the right hand side of the inlet air manifold.

(4) Rear Bracket.

Assembly procedure:

1. Fabricate the brackets (1 and 4) and support plate (2).

2. Weld the brackets (1 and 4) to the support plate (2).

3. Attach the support plate to the engine.

4. Attach the air cleaner assembly to the air cleaner support.

NOTE: The air cleaner support is available through General Motors (part number 15679383).

NOTE: A dimensioned illustration has been provided. Refer to Fabrication Drawings in this publication.

Inlet Air Elbow Assembly

(1) Air intake assembly.

(2) 100-8302 gasket.

NOTE: Remove any gasket maker that remains on the inlet air heater.

(3) Air intake plate.

(4) Wrapper end plates.

(5) Angle for the wrapper end plates (4) ... 42 degrees

(6) Vertical length (from bolt hole centerline to the air intake tube (9) centerline) ... 109 mm (4.3 in)

(7) Inlet air heater.

(8) Angle of air intake tube (9) from vertical ... 10 degrees

(9) Air intake tube 8T9472.

(10) Air intake wrapper.

NOTE: The inlet air elbow assembly is similar to 6I4605. The only modification was to shorten the length of the elbow. The modified length is given above as call-out number six.

Alternator Pulley Shield

Right Side View

(1) Alternator Pulley Shield. Assemble to belt guard (3) with two bolts, four washers, and two locknuts.

A. Length (from edge to bolt hole centerline) ... 43 mm (1.692 in)

B. Length (from bolt hole centerline to edge) ... 22 mm (.866 in)

C. Length (from edge to bolt hole centerline) ... 15 mm (.590 in)

D. Length (from bolt hole centerline to bolt hole centerline) ... 156 mm (6.141 in)

E. Length (from bolt hole centerline to edge) ... 15 mm (.590 in)

NOTE: The corner radius is 10 mm (.393 in).

NOTE: Bolt hole diameters are 11 mm (.433 in).

(2) Alternator.

(3) Belt guard.

Base Assembly

(1) Fork lift channels.

(2) Bolt holes for fuel tank assembly. For more information please refer to Fuel Tank Assembly in this publication.

(3) Base assembly.

A. Length (from outside bolt hole centerline to bolt hole centerline) ... 148 mm (5.826 in)

B. Length (between bolt holes centerlines for fuel tank) ... 284 mm (11.181 in)

C. Length (from bolt hole centerline to edge of base assembly) ... 31 mm (1.220 in)

D. Length (from base assembly edge to bolt hole centerline) ... 42 mm (1.653 in)

E. Length (between bolt hole centerlines for fuel tank) ... 50 mm (1.968 in)

NOTE: The base assembly is a 7E1488 base assembly with minor modifications:

* Six bolt holes have been added for attachment of the fuel tank assembly (two on top and two on each side).

* Fork lift pockets have been added for transport.

NOTE: The base assembly was designed using the 122-8936 oil pan. If a larger capacity oil pan is used then it will need to be replaced with the 122-8936 oil pan.

(4) Fork lift pockets.

Battery Support

Rear View

(1) 25.4 mm (1.000 in) by 25.4 mm (1.000 in) angle iron support. For more information please refer to Fuel Tank Assembly in this publication.

A. Length (between bolt hole centerlines) ... 351 mm (13.818 in)

B. Angle of bolt holes in the support ... 45 degrees

(2) Retainer bolt.

(3) Battery. Place battery on 7H8213 rubber mat.

NOTE: Weld angle iron support (1) to the fuel tank assembly. Tighten the wing nuts and washers to the 7E3674 retainer bolts (2) to the angle iron support (1) that is on the top of the battery (3) opposite the welded support.

Engine Supports

Left Side View

Right Side View

(1) Left rear support. Use four bolts for attaching to the engine and use one bolt for attachment to the frame assembly (2).

(2) Frame assembly

(3) Junction box. For more information please refer to Junction Box in this publication.

(4) Right rear support. Use four bolts for attaching to the engine and use one bolt for attachment to the frame assembly (2).

NOTE: Dimensioned illustrations of the engine supports have been provided. Refer to Fabrication Drawings in this publication.

Fuel Tank Assembly

Top View

(1) Bolt. These bolts secure the fuel tank assembly to the Base assembly. For more information please refer to Base Assembly in this publication.

A. Length (from outer edge to bolt hole centerline on the top of fuel tank assembly) ... 94 mm (3.70 in)

B. Length (between bolt hole centerlines on the top of fuel tank assembly) ... 284 mm (11.181 in)

C. Length (from plate edge to bolt hole centerline on the side of fuel tank assembly) ... 36 mm (1.417 in)

D. Length (between bolt hole centerlines on the side of the fuel tank assembly) ... 50 mm (1.968 in)

E. Length (from outer edge to outer edge) ... 472 mm (18.583 in)

(2) 9C7190 Fuel Tank Filler Fitting. Used with 9X2207 Adapter Kit and 7X7700 Fuel Cap Assembly.

(3) Fuel tank plate support assembly (dashed lines).

(4) 5S1057 Fuel Return Fitting.

(5) 5S1057 Fuel Outlet Fitting.

(6) Angle iron support (battery support). For more information please refer to Battery Support in this publication.

(7) Fuel outlet hose.

(8) Fuel return hose.

(9) 6V8724 Elbow (90 degree).

NOTE: The fuel tank assembly requires a fabricated fuel tank with the top plate, bottom plate and the two side plates extending past the enclosed tank. This provides space and support for locating bolts for attachment to the base assembly.

Support Bracket (Exhaust Pipe)

Rear View

(1) Support Bracket. Assemble to lifting eye support (3) with two bolts, four washers, and two nuts. Support the exhaust pipe (2) by bolting the exhaust clamp (4) to the bracket.

B. Length (between bolt hole centerlines) ... 143 mm (5.629 in)

C. Length (between bolt hole centerlines) ... 76 mm (2.992 in)

D. Length between bolt hole centerlines) ... 70 mm (2.755 in)

(2) 110-0358 Exhaust pipe.

(3) 4R9234 Lifting eye support.

(4) 7L8255 Exhaust clamp.

Support Strap (Junction Box)

Left Side View

(1) Support strap. Bolt support strap (1) to the rear support Then secure the junction box (2) to the support strap (1).

A. Length (between support bolt hole centerlines) ... 63.5 mm (2.500 in)

NOTE: The distance to the edge of the strap to the rear support bolt hole centerline is 16 mm (.629 in).

B. Length (between junction box bolt hole centerlines) ... 177.8 mm (7.000 in)

NOTE: The distance to the edge of the strap to the junction box bolt hole centerline is 16.2 mm (.637 in).

C. Length (between support bolt hole centerlines and junction box bolt hole centerlines) ... 62.5 mm (2.460 in)

D. Length (between support bolt hole centerlines and junction box bolt hole centerlines) ... 14 mm (.551 in)

(2) Junction box.

Attachments

Air Cleaner

NOTE: The air cleaner and its parts are supplied by General Motors (air cleaner for medium sized trucks).

The parts that can be used and the quantity needed are the following:

* 15696246 Air Cleaner (1)

* 2358355 Clamps (2)

* 15624757 Duct (1)

* 15673242 Duct (1)

* 14081883 Clamp (1)

* 15550677 Indicator (1)

* 9409931 Elbow (1)

* 2493817 Adapter (1)

* 2043543 Washers (6)

* 11500760 Nut (3)

* 11514766 Bolt (3)

NOTE: 4P2982 Hose and two hose clamps are necessary to attach the 15673242 Duct to the turbocharger. Four 6V4248 bolts and four 6V5839 washers are necessary to attach the 7L8255 exhaust clamp to the support bracket and the support bracket to 4R9234 lifting eye support.

Air Compressor

(1) 001-9440 Connector.

(2) 9Y1116 Hose.

(3) 5P4479 Elbow.

(4) Air compressor.

(5) 4P5388 Governor.

NOTE: The air compressor configuration is to reduce the noise level of the 3100 HEUI Training Engine.

Exhaust Group

Right Side View

(1) 109-6310 Muffler Group

(2) Support Bracket (Exhaust Pipe). For more information please refer to Support Bracket (Exhaust Pipe) in this publication.

(3) 7L8255 Exhaust Clamp.

(4) 110-0358 Exhaust Elbow. Secure to support bracket (2) with strap (3).

NOTE: 7S1784 Rain Cap Assembly is also available for this exhaust group.

Fan And Radiator Group

Fan And Belt Drive

Suction Fan

Right Side View Of Radiator

(1) 7E1479 Fan Belt Drive Group.

(2) 7E1480 Fan Drive Group.

(3) 7E1499 Suction Fan.

(4) 7E1466 Radiator Group.

NOTE: Need to attach an elbow to the water regulator housing for connecting the radiator hose.

(5) 7E1469 Radiator guard and support group. This group also contains 7E5274 Radiator Guard Group.

Flywheel Adapter

(1) Structural steel (207 MPa (30044 psi) minimum yield) flywheel adapter.

(2) Balancing holes. Located opposite side of flange.

(3) Placement of balancing holes from the center of the adapter ... 133 ± 1 mm (5.2 ± .04 in)

(4) Outer dimension of adapter ... 427.48 ± 0.25 mm (16.83 ± .010 in)

(5) Inner dimension of flange ... 414.86 ± 0.03 mm (16.333 ± .001 in)

(6) Distance between balancing holes ... 7 mm (0.28 in)

(7) Bolt hole. Attach flywheel adapter with 0S1590 Bolt and 5M2894 washer. Tighten to a torque of ... 47 ± 9 N·m (35 ± 7 lb ft)

NOTE: The weight of the flywheel adapter is approximately ... 32 Kg (70 lb)

NOTE: A dimensioned illustration has been provided. Refer to Fabrication Drawings in this publication.

Flywheel Cover

(1) Carbon steel (manufacturer's standard) Flywheel cover. The minimum recommended thickness for the flywheel cover is 3.175 mm (0.125 in)

A. Outside diameter ... 489 mm (19.251 in)

B. Diameter of bolt location ... 466.72 mm (18.3748 in)

(2) Bolt hole. The 8T4137 bolts and 8T4121 washer are equally spaced. Tighten to a torque of ... 55 ± 10 N·m (40 ± 7 lb ft)

Electrical Systems

Junction Box

(1) Starter relay.

(2) 7E4886 Junction box.

(3) Plug connector for remote box harness (external).

Remote Box

(1) 2P8292 Box.

(2) Gauges.

(3) Panel plate.

(4) Key switch.

(5) Switches.

(6) Lights

(7) Support for Plate (3).

(8) Plug assembly

Miscellaneous

There are many add on components that are very useful. The following is a list of components that are helpful but this list in no way covers all the components possible:

* Fuel hose clips

* Protector for the inlet air heater and alternator

* Ladder clips for connecting harnesses to the flywheel housing and the radiator support

* Straps for holding the harnesses and remote box while not in use

* Ground studs

* Hose clamps

* Battery terminals

* Battery cables

* 7H8213 Rubber mat for remote box and battery

* Alternator

* Starter

* Damper

NOTE: Purchase the 122-8936 oil pan if a larger capacity oil pan is supplied with the 129-3642 engine arrangement. The 122-8936 oil pan allows the engine to fit the designed base assembly.

Electrical Wiring And Diagram

Remote Box

Rear View Of Panel Plate

Remote Box Wiring (Internal)

Junction Box Diagram

Junction Box Diagram

Main Engine Harness

Main Engine Harness

Remote Box Harness (External)

Remote Box Harness (External)

Fabrication Drawings

Air Cleaner Support

Engine Supports

Left Engine Support

Right Engine Support

Flywheel Adapter