Assembling and Installation of a Selective Catalytic Reduction (SCR) Module for Certain 3516 Locomotive Engines {1089, 1091} Caterpillar

Engine

3516C (S/N: PRC1-UP; SDX1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Caterpillar Channel 1 Videos

For supplemental information on this procedure, refer to the following video. The previous training has been replaced with the video below.

Note: A CWS login is required to access Caterpillar Channel 1. Scan the QR code below with a QR enabled device or copy the link that follows.

Illustration 1	g06306276

https://channel1.mediaspace.kaltura.com/media/Introduction+to+Visualization+Service+Procedures+%28VSP%29/1_92vjr92v

Important Safety Information

Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards, including human factors that can affect safety. This person should also have the necessary training, skills, and tools to perform these functions properly.

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform lubrication, maintenance, or repair on this product, until you verify that you are authorized to perform this work, and have read and understood the operation, lubrication, maintenance, and repair information.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Cat dealers have the most current information available.

In the United States, the maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair establishment or individual of the owner choosing.

Welding on Electronically Controlled Engines

Proper welding procedures are necessary in order to avoid damage to electronic controls. Perform welding on the engine, SCR, or locomotive frame according to the following procedure.

1. Turn the engine OFF.

2. If the unit is equipped with a locking EFCO button, depress and lock the EFCO button.

3. Open the main DC Knife Switch.

4. If the unit is equipped with a battery disconnect switch, open the switch (located by the main battery compartment).

5. Remove all electrical harness or wiring connections to any microprocessor. This includes but is not limited to, the engine ECM, LCM, TCM, PE Box, DVR/Interface Box, and any other electrically sensitive equipment.

6. Disconnect the negative battery cable from the battery (24V and 64V as equipped).

7. DO NOT use electrical components in order to ground the welder.

8. Do not use the ECM or sensors or any other electronic component in order to ground the welder.

General Information

Graphic Color Description

Color-coding of targeted components, or sections of a part, is used to communicate a required action.

The descriptions below illustrate the different colors and what is represented when used in a graphic.

(Blue) The primary component of focus for a particular step. Target or primary component to be installed or removed. Installation implied unless otherwise noted with a symbol.

(CAT® Yellow) Description of parts.

(Cyan) Special tools or other equipment required for use in a particular step.

(Light Gray) Components used for reference.

(Magenta) Any fastener, retainer, or electrical connector used to install or remove the primary component.

Graphic Symbol Description

This section includes all the symbol graphics used throughout the Visual Service Procedure (VSP), along with a brief description of what the symbol represents.

Attach

Compress, Load - To press together, to squeeze. To transfer weight or force to an object. The weight or force carried by an object.

Insert - To place or fit into another object

Route - To install a harness, hose, or wire along a specific course or layout along or through a product, to direct along a predefined path.

Tighten - To make nearer to fully stretched; without slack; to apply tension or torque.

Weld - To join by heating until liquid portions of two or more pieces of metal in contact with each other and allowing the common puddle to solidify.

Torque Specifications

English (SAE) Fasteners

The following table has the recommended standard torque values.

Table 1

Nuts and Bolts
Thread Size Inch	Standard Torque
1/4	12 ± 3 N·m (9 ± 2 lb ft)
5/16	25 ± 5 N·m (18 ± 5 lb ft)
3/8	47 ± 10 N·m (35 ± 5 lb ft)
7/16	70 ± 15 N·m (50 ± 10 lb ft)
1/2	105 ± 20 N·m (75 ± 15 lb ft)
9/16	160 ± 30 N·m (120 ± 20 lb ft)
5/8	215 ± 40 N·m (160 ± 30 lb ft)
3/4	370 ± 50 N·m (275 ± 37 lb ft)
7/8	620 ± 80 N·m (460 ± 60 lb ft)
1	900 ± 100 N·m (660 ± 75 lb ft)
1 1/8	1300 ± 150 N·m (960 ± 110 lb ft)
1 1/4	1800 ± 200 N·m (1320 ± 150 lb ft)
1 3/8	2400 ± 300 N·m (1780 ± 220 lb ft)
1 1/2	3100 ± 350 N·m (2280 ± 260 lb ft)

Metric (ISO) Fasteners

The following table has the recommended standard torque values.

Table 2

Nuts and Bolts
Thread Size Metric	Standard Torque
M6	12 ± 3 N·m (9 ± 2 lb ft)
M8	30 ± 5 N·m (20 ± 5 lb ft)
M10	55 ± 10 N·m (40 ± 5 lb ft)
M12	100 ± 20 N·m (75 ± 15 lb ft)
M14	160 ± 30 N·m (120 ± 20 lb ft)
M16	240 ± 40 N·m (175 ± 30 lb ft)
M20	460 ± 60 N·m (340 ± 45 lb ft)
M24	800 ± 100 N·m (590 ± 75 lb ft)
M30	1600 ± 200 N·m (1180 ± 150 lb ft)
M36	2700 ± 300 N·m (2000 ± 220 lb ft)

Frame Assembly

Parts List

Illustration 2	g06076027

Table 3

Parts List
Item	Qty	Part number	Part Name
1	1	333-2522	Frame Assembly
2	18	7X-0366	Bolts
3	18	8T-4994	Hard Washers

Installation Procedure

Table 4

Required Tools
Tool	Part Number	Part Name	Qty
A	—	Suitable Lifting Device	4

Illustration 3	g06074893

Exhaust Bellows

Parts List

Illustration 4	g06075932

Table 5

Parts List
Item	Qty	Part Number	Part Name
1	2	214-6045	Bellow As.
2	16	0S-1571	Bolts-Hex Head
3	32	3V-3308	Washers-Hard
4	2	245-3512	Gaskets-Exhaust
5	16	9S-8752	Nuts-Full

Installation Procedure

Illustration 5	g06076011

Exhaust Module Arrangement

Parts List

Illustration 6	g06076078

Table 6

Parts List
Item	Qty	Part Number	Part Name
1	1	362-5224	Exhaust Module Arrangement
2	4	333-2562	Plates
3	4	333-2561	Plates
4	2	245-3512	Exhaust Gaskets
5	16	5P-8245	Washers-Hard
6	16	6V-5684	Bolts-Hex Head
7	16	8T-4994	Washers-Hard
8	16	7X-0368	Bolts-Hex Head

Installation Procedure

Table 7

Required Tools
Tool	Part Number	Part Name	Qty
A	—	Suitable Lifting Device	4

Illustration 7	g06076226

Urea Tank Group

Parts List

Illustration 8	g06086560

Table 8

Parts List
Item	Qty	Part Number	Part Name
1	8	OS-1575	Bolts 3/4-16
2	8	8T-4994	Washers-Hard
3	1	333-1039	Tank Gp-Urea
4	1	333-1091	Carrier As.
5	8	180-4803	Locknuts 3/4-16

Installation Procedure

Table 9

Required Tools
Tool	Part Number	Part Name	Qty
A	—	Fork Lift	1

Illustration 9	g06089539

DEF Control Group

Parts List

Illustration 10	g06087003

Table 10

Parts List
Item	Qty	Part Number	Part Name
1	1	360-1777	DEF Control Gp
2	8	4I-6454	Bolts
3	8	8T-4896	Washers

Installation Procedure

Table 11

Required Tools
Tool	Part Number	Part Name	Qty
A	—	Suitable Lifting Device	4

Illustration 11	g06087064

Mounting Group

Parts List

Illustration 12	g06107620

Illustration 13	g06107609

Illustration 14	g06107729

Illustration 15	g06107735

Illustration 16	g06107817

Illustration 17	g06108192

Table 12

Parts List
Item	Qty	Part Number	Part Name
1	1	396-0754	Indicator Gp-F
2	1	394-9091	Dosing Lines As.
3	1	171-3442	Elbow Fitting
4	1	394-8564	Exhaust Control Gp
5	2	472-4144	Grommet As.
6	5	472-3148	Channel - Stud
7	5	472-3146	Pipe Clamp
8	5	7X-0623	Washer - Hard
9	5	6V-8801	Nut 3/8 - 16
10	2	472-4141	Coupling
11	306 cm	437-4007	Conduit - Rigid
12	1	472-2607	Body - Conduit
13	4	7X-2552	Bolt - Hex Head M16x2
14	4	9X-8257	Washer-Hard
15	16	0S-1570	Bolt 1/4-28
16	1	339-9340	Shield As.
17	16	8T-4205	Washer-Hard
18	1	339-9345	Shield As.
19	24	5M-3062	Bolt 3/8-16
20	24	8T-4896	Washer-Hard
21	2	375-0572	Door As.

Installation Procedure

Illustration 18	g06089577

Illustration 19	g06089588

Illustration 20	g06089602

Illustration 21	g06089652

Illustration 22	g06089645

Illustration 23	g06089663

Illustration 24	g06107716

Illustration 25	g06107722

Illustration 26	g06107797

Illustration 27	g06107813

Illustration 28	g06108164

Illustration 29	g06108242

Carbody Enclosure Group

Parts list

Illustration 30	g06108274

Table 13

Parts List
Item	Qty	Part Number	Part Name
1	1	333-2551	Door As.
2	1	333-2552	Door As.
3	2	333-2560	Door As.
4	2	333-2557	Door As.
5	16	343-7711	Latch As.
6	64	292-6947	Rivets

Installation Procedure

Illustration 31	g06108290