28624 Mercruiser FITTING

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 Frame3516 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
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°
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.
Illustration 6 g00586438
(1) Check For Level (2) Larger Chamfer (3) Shim As Required
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.
Illustration 7 g00586468
(E) 6.4 mm (0.25 inch) (The "G" signifies "Ground Flush".) (F) 12.7 mm (0.5 inch) (3 sides)
Check for a level plane across the locomotive again. Finish welding the plates. Refer to illustration 7 for details.
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.
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.
Illustration 8 g00586490
(G) 1117.6 mm (44 inch) (H) 63.5 mm (2.5 inch)
Repair the old thread