853228 Mercruiser PLUG

Introduction
This instruction contains the basic requirements for the transportation and testing of the 3524B Engine from the 797 Off-Highway Truck. The 3524B Engine can be tested as a single engine. The 3524B Engine can also be tested as two separate 3512B Engines. The configurations for testing the single engine and the separate modules require varying facilities, tooling, and procedures. The two configurations are treated separately in this instruction.The specifications that are listed in this instruction must be met in order to ensure efficient operation of the engine, safe handling of the engine, and accurate testing of the engine.Refer to the Product Bulletin, SEBD0642, "Engine Dynometer Facilities" for additional information on the required sizing, the dimensions of the pipes, and the construction of the test cell.Note: The engine will be referred to as a single engine or as separate modules throughout this instruction. The single engine is the complete 3524B Engine on frame rails. The single engine can be split into two modules.Transportation Of The Engine
3524B Engine
The complete 3524B Engine weighs approximately 18144 kg (40,000 lb) with fluids. The 3524B Engine will require a 20 ton lifting device in order to transport the 3524B Engine on the frame rails without the torque converter. The lifting eyes can be used in order to lift the engine with the use of a spreader bar.Single Module
The transportation of a single module is similar to a typical 3512 Engine that is used in the 785C Off-Highway Truck. Each module weighs approximately 9072 kg (20,000 lb) with accessories and fluids.The alternator, the water pumps, the air compressor, the regulator housing, and the A/C compressor are part of the front module. The coupler is part of the rear module.Both 3512B Engines have two lifting eyes on the top of the engine. The lifting eyes can be used in order to transport the engine.Test Cell Requirements For Testing And Control
3524B Engine
Illustration 1 g00585094
This Illustration shows the top view. All dimensions are in millimeters. (A) Right Hand Edge Of Shipping Stand. (B) Front Trunnion. (C) Rear Edge Of Shipping Stand.
Illustration 2 g00585097
This Illustration shows the left side view. All dimensions are in millimeters. (C) Rear Edge Of Shipping Stand.
Illustration 3 g00585101
This Illustration shows the front view. All dimensions are in millimeters.The 3524B Engine with the coupler is 5026 mm (198 inch) long. The frame rails are 1736 mm (68 inch) wide. The front trunnion is 2400 mm (94 inch) wide. The engine is 2107.4 mm (83 inch) tall from the bottom of the oil pan to the top of the turbochargers. When the engine is tested on a standard dynamometer with a centerline of 820 mm (32 inch), the overall height of the engine is 2218 mm (87 inch). Illustration 1, Illustration 2, and Illustration 3 show the dimensions. The distance from the centerline of the crankshaft to the bottom of the oil pan is 709.4 mm (27.93 inch). The 3524B Engine can be tested on dynamometers with a centerline of 740 mm (29 inch) or higher. An engine stand must be designed and the engine must be supported through the frame rails.The current rating of the 3524B Engine is 2535 kW (3400 hp) at 1,750 rpm. The dynamometer must be capable of producing 16491 N m (12163 lb ft) of torque at 1,300 rpm. In a typical dynamometer, this load will require 1136 L/min (300 US gpm) of water at 448 kPa (65 psi). When you install a new dynamometer or when you upgrade a current facility, future horsepower and torque requirements must be considered.The fuel pump must provide 42 L/min (11 US gpm) of fuel to the engine during the test. The return line and the fuel tank must be able to handle a flow of 38 L/min (10 US gpm). It may be necessary to install a fuel cooler in order to keep the fuel below 66 °C (150 °F). If the temperature exceeds 66 °C (150 °F), the engine's capability to produce horsepower will be reduced. The fuel line to the 3524B Engine must be 1 1/2 inches ID.The Caterpillar Electronic Technician (CAT ET) will allow control and monitoring of the engine through the master ECM without derating the engine. A recording device will need to be set up in order to document the test results. The CAT ET does not record the data. No additional gauges need to be set up in order to monitor the engine. Emergency shutdown systems for low oil pressure and high engine temperature are recommended. This is specified in the Product Bulletin, SEBD0642, "Engine Dynometer Facilities".If you do not use the CAT ET in order to monitor the 3524B Engine, a dual set of gauges will be required. Additional gauges for the oil pressure, the fuel pressure, the aftercooler temperature, and the jacket water coolant temperature must be installed in order to monitor the 3524B Engine. For additional information about the recommended gauges, refer to the Product Bulletin, SEBD0642, "Engine Dynometer Facilities", "Instrument Specifications".The engine air intake system will require 890 m3/min (32,000 cfm). The exhaust system in the test cell requires 1300 m3/min (46,000 cfm) in order to maintain an adequate negative pressure in the test cell. In order to maintain this flow, multiple fans are recommended. For sizing requirements for the fans and pipes, refer to the Product Bulletin, SEBD0642, "Engine Dynometer Facilities", "Ventilation/Exhaust Systems".Note: Air velocity must be kept below 7.6 m/sec (25 ft/sec) in order to minimize the noise level.Two cooling towers will be required. One cooling tower must be capable of providing 982 kW (56,000 Btu/min) of cooling for the jacket water circuit. One cooling tower must be capable of providing 600 kW (34,200 Btu/min) of cooling for the aftercooler circuit. In a PowerTest cooling tower, this is approximately 1052 L/min (278 US gpm) of water.Note: The test cell must be able to provide continuous water flow for the jacket water circuit, the aftercooler circuit, and a dynamometer. With a dynamometer and two cooling towers, this will be a minimum of 2196 L/min (580 US