819024 Force GASKET-EXHAUST PLATE

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 Caterpillar 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 PURCHASE OF A 3100 HEUI TRAINING ENGINE PACKAGE IS POSSIBLE. FOR DETAILS PLEASE CONTACT: CAPITOL POWER SYSTEMS#1 CAPITOL DRIVEP.O. BOX 2550EAST PEORIA, IL 61611-0550OR 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.
This publication provides information on modifying a 3100 HEUI Truck Engine. The modified engine is intended to be an aid for training and is NOT designed to be used in any commercial application.
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. 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. 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. The air cleaner support is available through General Motors (part number 15679383). 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. 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. 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) The corner radius is 10 mm (.393 in). 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) 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. 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.
Take caution when transporting the 3100 HEUI Training Engine using a forklift or damage to some components (air cleaner, etc.) may occur.
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. Weld angle iron support (1)