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APPLICATION AND INSTALLATION GUIDE

MOUNTING
Contents
Mounting..............................................................................1
General Considerations ...................................................... 2
Thermal Growth ........................................................... 2
Mounting Bolt Location.............................................. 3
Mounting Engines with Poured Resin Chocks................ 3
Collision Blocks ........................................................ 4
Linear Vibration ............................................................ 5
Out-Of-Balance Driven Equipment ................................... 5
Misalignment................................................................ 5
Specific Equipment Considerations...................................... 6
Engines and Driven Equipment with Mounting Feet ........... 6
Engines and Packaged Units with Mounting Rails.............. 7
Three Point Mounting ................................................ 7
Four Point Mounting.................................................. 7
Mobile and Service Rigs................................................. 9
Engine-Transmission Mounting ................................... 9
Overhung Power Transmission Equipment...................12
Clutches, Belt and Chain Drives .................................13
Substructure Suitability ............................................14
Isolation .........................................................................15
Isolation Location.........................................................15
Installation of Flexible Mounts .......................................17
Isolation Methods ........................................................17
Spring Isolators........................................................18
Rubber Isolators.......................................................20
Gravel or Sand (Bulk Isolation) ...................................21
Other Isolation Methods ...............................................21
External Piping.........................................................22
Mobile Equipment ....................................................22
Seismic...................................................................23
Foundations ....................................................................24
Responsibility ..............................................................24
Ground Loading ...........................................................24
Concrete.....................................................................25
Bases .............................................................................28
Purpose and Function ...................................................28
Caterpillar Base Design .................................................28
Single Bearing Loads ................................................29
Two Bearing Loads ..................................................29
Bases for Engines with Close-Coupled Loads ...............29
Bases for Engines with Remote-Mounted Loads ...........32
Cat® Special Duty Bases ...........................................32
Reference Material ...........................................................36
Foreword
This section of the Application and Installation Guide generally describes
wide-ranging requirements and options for the Mounting Systems on the
Cat® engines listed on the cover of this section. Additional engine
components, systems and dynamics are addressed in other sections of this
Application and Installation Guide.
Engine-specific information and data are available from a variety of
sources. Refer to the Introduction section of this guide for additional
references.
Systems and components described in this guide may not be available
or applicable for every engine.

Information contained in this publication may be considered confidential.


Discretion is recommended when distributing. Materials and specifications
are subject to change without notice.

CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow,” the “Power


Edge” trade dress as well as corporate and product identity used herein, are
trademarks of Caterpillar and may not be used without permission.
Mounting Application and Installation Guide

Mounting
Correct mounting and coupling to driven equipment are essential to the
success of any engine installation.
Cat engine installations may incorporate many types of mounting methods.
Consequently, no single system will be universally successful.
It is just as possible to encounter problems from a rigid constrained mounting
system if improperly applied as it is with a flexible mounting if improperly
applied.
Cat marine propulsion engine mounting is covered in a separate Application
and Installation Guide.

SECTION CONTENTS

General Considerations ......... 2 Isolation ............................15


• Thermal Growth • Isolation Location
• Linear Vibration • Installation of Flexible
• Out-of-Balance Driven Mounts
Equipment • Isolation Methods
• Misalignment • Other Isolation Methods
• Torsional Vibration Torsional Vibration..............24
• Engine Construction • Torsional Vibration Analysis
Specific Equipment • Cat Torsional Vibration
Considerations..................... 6 Analysis Request Form
• Engines and Driven Foundations .......................29
Equipment with Mounting • Responsibility
Feet • Ground Loading
• Engines and Packaged Units • Concrete
with Mounting Rails
Bases ................................33
• Mobile and Service Rigs • Purpose and Function
• Caterpillar Base Design

© 2012 Caterpillar
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Application and Installation Guide Mounting

General Considerations
Cat engines are rigid, self- C for Cast Iron
contained structures that will 6.7 x 10-6/oF
operate and maintain inherent
12.1 x 10-6/oC
alignment unless subjected to
extreme external stresses.
Due to the diversity of installation Example 1:
types, no one mounting system or Find the thermal growth of the
method is universally acceptable. engine block (cast iron) 250 cm in
The engine must be mounted in a length, with the starting temperature
manner suited to the specific being 10 oC and increasing to 100 oC.
application, taking into account the TG = (100 oC-10 oC) x (250 cm)
characteristics of the engine, the x (12.1 x 10-6/ oC)
driven loads, and the operating cycle
of the machine. One or more of the TG = 0.27225 cm
following results will occur if the
mounting method is inadequate. Example 2:
Thermal Growth Find the thermal growth of a steel
The change in distance between plate 100 inches in length, with the
mounting holes due to thermal starting temperature being 50 oF and
growth of the engine must be increasing to 200 oF.
considered when designing the TG = (200 oF-50 oF) x (100 inches)
mounting system. x (6.5 x 10-6/oF)
TG = 0.0975 inches
Thermal growth is calculated by:
TG = ∆T x L x C The small difference in growth
between the block and the
lubricating oil pan is compensated
TG = Thermal Growth
for in the design of the engine by
∆T = Change in the material’s making the holes in the flange of the
temperature attached component (rails) larger
L = Length of the material than the attaching bolts.
C = Material’s coefficient of linear Due to the growth resulting from
expansion thermal expansion, the engine must
not be fixed in more than one
location. This causes unnecessary
C for Steel stresses in the engine and base
6.5 x 10-6/oF as the engine expands due to
11.7 x 10-6/oC temperature changes. It is
recommended that a ground body
bolt be used on one engine mounting

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Mounting Application and Installation Guide

rail located at the end with the the mounting bolts and the mounting
driven equipment. This will force brackets on the base will allow slip
all thermal growth away from the to compensate for thermal growth.
engine coupling. Clearance between Refer to Figure 1.

Figure 1

Mounting Bolt Location engine mounting rails and the


Each anchor bolt between the engine bed. Refer to Figure 3.
mounting rail and the base must be When using poured resin chocks,
bolted into or through a mounting always follow the manufacturer's
block. Distortion of the mounting installation recommendations and
rails will result if these bolts are these guidelines:
fastened from the rails into the
• Use foam rubber strips of
base; see Figure 2.
the appropriate thickness to
form the dams for pouring
Mounting Bolt Location
the resin chocks.
• Do not pour resin chocks
inboard of the machined pad
on the bottom of the
mounting rail.
Resin chocks can be poured the
full length of the mounting rail
(a continuous pour) or it can be
poured only at the mounting pad
locations (an interrupted pour). If
Figure 2 an interrupted pour is used, the
minimum area of resin chock
Mounting Engines with Poured material must be 29,000 mm2
Resin Chocks (45 in2) per mounting bolt. If the
After the engine and driven mounting rails have mounting pads
equipment have been aligned, only at the bolt hole locations,
poured resin chocks can be used foam rubber strips must be
between the mounting pads of the installed on both sides of each pad

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Application and Installation Guide Mounting

on all pads forward of the flywheel the engine can be raised to install
housing to provide for expansion. the foam rubber strips.
These expansion strips permit Do not pour the resin chocks
thermal expansion of the mounting thicker or thinner than the
rails at operating temperature. No manufacturer's recommendation.
expansion strips are necessary on Use steel spacers if the clearance
engines whose mounting rails have between the bottom of the
full length mounting pads. mounting pad and the top of the
Note: When realigning an existing engine bed is more than the
installation, full-length foam rubber maximum allowable thickness of
strips for a continuous pour can the resin chock. The spacers must
often be difficult because of limited be a minimum of 29,000 mm2
access. It is recommended that a (45 in2) in area per mounting bolt.
full-length continuous pour be used Before pouring the resin chocks,
only for new installations where install all anchor bolts finger tight.

Figure 3

Put sealing material around the bolt mounting bolt torque specification.
at the bottom of the mounting pad Use two nuts on each bolt.
to prevent the resin chock from Collision Blocks
filling the bolt holes in the mounting All spring-mounted and rubber
rails. If resin chock material is allowed isolator mounted equipment should
to enter the bolt holes in the mounting have stops to restrict vertical and
rails, thermal expansion of the rails side movement within reasonable
will be prevented.
limits. Collision blocks may be
After the resin chocks have provided for all auxiliary engine
sufficiently hardened according to installations if they do not restrict
the manufacturer's specification, thermal growth.
the anchor bolts can be tightened
to the resin manufacturer’s

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Mounting Application and Installation Guide

Linear Vibration Even if the engine and driven load


Transmission of undesirable are in balance, it is possible to
vibration to driven equipment or the encounter undesirable and damaging
support structure may occur. In vibration as a result of misaligned or
certain types of plunger installations unbalanced driving or connecting
such as pumps, the engine vibration equipment. Long shafts, drives, gear
is insignificant compared to the assemblies, clutches, or any
driven equipment vibration. In this coupling where misalignment, out-
case, the machine vibration could be of-balance, or mass shifting may
detrimental to the engine and its occur are probable sources of
mounting, and could possibly result vibration.
in cracking or fatigue of a structural
member. Misalignment
An unsatisfactory engine mounting
The same amplitude and frequency nearly always results in alignment
of vibration generated by the engine problems between the engine and
could result in structural damage if the driven machinery. If the failure
a fixed installation were housed in of the driven equipment does not
a building, or close to sensitive occur first, the forces or loads
instruments or equipment, such as transmitted to the engine in the
computers. form of pounding, twisting, flexing,
Additional information is contained or thrust could result in engine
in the Vibration Application and crankshaft and bearing failure.
Installation Guide. Costly failures of this nature can be
avoided if, at the design and
Out-Of-Balance Driven installation stage, the importance
Equipment of proper alignment between the
Engines are designed and built to engine and driven load and adequate
run very smoothly. Objectionable mounting to maintain alignment is
vibration generally arises from either considered.
a poor driveline component match to If this is impossible, a suitable
the engine or unbalanced driven flexible coupling must be
equipment. Reciprocating equipment incorporated into the drive train to
with large imbalances, for example, compensate for misalignment.
can cause premature failure of the
mounting structure or undesirable Additional information is available
vibration even though the unit is in the Alignment section of the
properly mounted and isolated from Application and Installation Guide.
the engine.

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Application and Installation Guide Mounting

Specific Equipment Considerations


The proper engine and driven flat and lie in the same plane. Shims,
equipment mounting system will which are discussed in more detail in
ensure dependable performance and the alignment section of this guide,
long life if the equipment is properly are used as necessary between feet
aligned. and base or support beams so all
The engine and driven equipment mounting feet are in solid contact at
should be mounted on a pair of all locations. If the mounting feet are
longitudinal beams, the tops of not in equal contact with the base or
which are in the same plane. Bolting beams before the anchor bolts are
the engines to an uneven surface installed, the engine and/or
can cause harmful distortions in generator can be stressed when the
the engine block, springing of the anchor bolts are tightened. Radiator
mounting beams, and high stress packages mounted to the front
in welds or base metal. engine support must also be
supported, and not left cantilevered.
If the engine or driven equipment
is subjected to external forces, or
restrained from its natural thermal
growth, tolerances are greatly
affected and could easily result in
bearing or crankshaft damage. This
is of primary concern for mobile and
service rig applications in the
petroleum and industrial markets.
These applications must use
mounting arrangements and Figure 4
techniques that permit their
transportation and installation at
sites with varying degrees of site
preparation and conditions.

Engines and Driven Equipment


with Mounting Feet
Cat engines and driven equipment
with mounting feet can either be
mounted on a base or mounted
directly on a pair of beams without
a base, as shown in Figure 4 and
Figure 5. The mounting feet must be Figure 5
bolted in place. Do not weld the feet
to the base or beams. If support
beams are used, the beams must be

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Mounting Application and Installation Guide

If the mounting beams will be rails are extended for the mounting
subjected to external bending forces, of these units.
such as frame flexing of the chassis Objectionable vibration can occur
in mobile applications, the engine if the power unit is not mounted on
and driven equipment must be well-supported structures or is not
mounted to the beams using a three anchored securely. In addition to
point mounting system. This type the three-point mounting, vibration
of mounting system, similar to isolators may be required to isolate
Figure 6, supports the engine at a objectionable vibrations.
single point at the front and at two
points, one on each side at the rear
of the engine or driven unit. This
mounting system is capable of
efficiently allowing large amounts of
frame deflection without imparting
stresses to the mounting or engine
and driven unit.

Engines and Packaged Units


with Mounting Rails
Mounting rails may be required for
some engine models and packages.
Two types of mounting rails system
Figure 6
are described here.
Three Point Mounting
Three-point mounting rails are used
Four Point Mounting
if the rails are to be secured to a Four-point mounting rails are used
base or foundation that may subject if the rails are to be secured to a
the mounting rails to distorting
base or foundation that will not
forces, such as in mobile subject the rails to distorting forces.
applications. Refer to Figure 7. These rails can be
Suspending the power unit on used for either remote-mounted or
three points isolates the unit from close-coupled driven units. For close-
deflection of the substructure, thus coupled driven units, extended
maintaining proper relationship and mounting rails can be used so the
alignment of all equipment and driven equipment can be fastened
preventing distortion of the engine directly to the rails.
block.
More than three mounting points
can cause base distortion as shown
in Figure 6. The three point
mounting rails can only be used for
close-coupled driven units where the

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Application and Installation Guide Mounting

Mounting of Four Point Mounting the blocks to the base. If necessary,


Rails to the Base remove the engine to complete the
welding. Refer to Figure 8.
Use shims as necessary to make
sure the mounting rails are in solid
contact with the mounting blocks or
base at all four mounting locations.
If the mounting rails are not in solid
contact, distortions of the mounting
rails will result when the anchor
bolts are tightened.

Figure 7

Mounting of Close-Coupled and


Remote Mounted Driven Equipment
to Mounting Rails
Mounting rails which are extended
to mount close-coupled driven units
must not be notched nor should the
cross braces be removed to provide Figure 8
clearance for the driven unit. Shims
are used as necessary between the If the driven equipment is close-
mounting feet of the driven unit and coupled to the engine, use clearance
the mounting rails to align correctly type bolts at all locations to fasten
with the engine. Bolts must be used the mounting rails to the mounting
to fasten the driven unit to the blocks or base. These bolts must
engine mounting rails. have a diameter 1.5 mm (0.06 in)
Four drilled and tapped mounting less than the diameter of the holes
blocks with shims, or shims alone, in the mounting rails.
can be used between the engine rails If the driven equipment is remote-
and the base at the four corner mounted and thermal growth in the
locations as shown in Figure 7. If horizontal direction must be
mounting blocks are used, they must controlled, then a ground body bolt or
be welded to the base. Fasten the spot weld should be used at one
blocks to the bottom of the rails at location on the right mounting rail. If a
the four corners and remove bolt ground body bolt is to be used, install
clearance with the rails by driving the this bolt in the right rail at the end of
blocks toward the end of each rail. the rail next to the coupling, or at the
This will provide clearance for rear of the rail if remote mounted
thermal growth at operating equipment is driven from both ends of
temperature. Put the engine in the engine. If a spot weld is to be
position on the base and tack-weld used, spot-weld the right rail to the

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Mounting Application and Installation Guide

mounting block and/or shims on the Mobile and Service Rigs


side of the rail next to the coupling.
Engine-Transmission Mounting
Install clearance type bolts at all The chassis of mobile rigs have
other mounting locations in both two long stringers. Frame flexing
the right and left mounting rails. All can occur due to off-highway usage.
clearance type bolts must have a Additionally, well site preparations
diameter 1.5 mm (0.06 in) less than may not result in a flat operating
the diameter of the mounting rail surface. Service units can also have
holes. extreme frame flexing due to
For engines driving remote- feedback from the plunger pump.
mounted equipment, the mounting These considerations require that
rails must be cradled between guide some type of three-point mounting
strips that keep the expansion of the of the engine-transmission package
rails always parallel to the output be used. It supports the engine with
shaft centerline. The guide strips are a minimal torsional restraint at a
welded to the top of the mounting single point at the front and at two
blocks at the opposite end of the points, one on each side, on the
rails from the ground body bolt or flywheel housing. This system
spot-weld. Refer to Figure 9. allows large amounts of rig frame
deflection without undue stresses
to the mounting pieces or engine.

Figure 9
Because horizontal thermal growth
of the engine and mounting rails will
always be away from the ground Figure 10
body bolt or spot weld, never weld
stops or chocks against the opposite Front Support
end of the mounting rails from the Most mobile rig engines use the
ground body bolt or spot weld. If mobile equipment engine
chocks or stops are to be used, configurations with a trunnion-type
there must be a sufficient clearance support as shown in Figure 10. This
between them and the ends of the is not a true trunnion support in that
rails to allow for thermal growth. it cannot rotate. For this reason, the

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Application and Installation Guide Mounting

frame connection to the trunnion Power Transmission Equipment,


must allow an engine rocking motion and Figure 15 for the method to
to occur (minimal torsional restraint). calculate bending moment.
The radiator must be mounted Some transmissions provide
separately on the rig chassis. mounting pads to support the rear of
the engine and cause no appreciable
bending moment at the flywheel
housing rear face. Using this mount,
instead of the engine rear mounts and
transmission mounts, eliminates the
transmission bending force on the
flywheel housing. It also eliminates
the need for the bases discussed later
in this section (assuming trunnion
front support). Approval from the
transmission supplier should be
received before this mounting is used.
Figure 11 Figures 12 through Figure 14
illustrate various mounting concepts.
They are all equally suitable, subject
Some engine installations require to the limitations discussed below.
the wide front support of the Figure 12 illustrates the use of
standard industrial engines as shown a base to support the engine, trans-
in Figure 11. A single mounting mission, and radiator. This base is
point is not permissible, as a mounted to the chassis at three
cantilevered radiator could lead to points.
block distortions, or excessive
vibration of the radiator. The wide Three-Point Mounting Engine,
front support is used where it is Transmission, Radiator on a Base
inconvenient to separately mount
the radiator, or where the engine
and radiator weight is restricted.
Rear Engine Mounts
Rear mounts support the rear
of the engine and most of the
transmission weight. Rear mounts
also supply resistance to longitudinal
and torsional forces.
The transmission must also be
supported so that it causes no
appreciable bending moment at the
flywheel housing rear face. Refer
to the following section, Overhung Figure 12

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Mounting Application and Installation Guide

Figure 13 illustrates tying together


the transmission and rear engine Three-Point Mounting
supports with a short base. This Transmission Supported on Springs
base has two mounting points to the
chassis. The front of the engine has
a trunnion mount plus the radiator is
not engine-mounted.

Three-Point Mounting Transmission


and Rear Engine Mount Common,
Trunnion Front Support

Figure 14

Forces and deflections of all


components of the mounting system
must be resolved. If the third mount
is a spring, with a vertical rate
considerably lower than the vertical
rate of the rear engine support, the
Figure 13 effect of the mount is in a proper
direction to reduce the bending
Figure 14 illustrates the overhang- forces on the flywheel housing due
ing weight of the transmission being to downward gravity forces.
supported on springs. Calculations However, the overall effect may be
are required to determine spring minor at high gravity force levels.
sizing. The use of springs is limited Supports with a vertical rate higher
to trailer rigs or service rigs. The than the engine rear mount are not
trailer fifth wheel gives, essentially, recommended since frame
a three-point mount during transit to deflections can subject the engine
minimize deflection forces on the power transmission equipment
flywheel housing. structure to high forces.
Another precaution is to design
the support so it provides as little
resistance as possible to engine roll.
This also helps to isolate the
engine/transmission structure from
mounting frame or base deflection.

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Application and Installation Guide Mounting

Overhung Power Transmission The dynamic load limits and the


Equipment maximum bending moment that can
Power transmission equipment, be tolerated by the flywheel housing
which is directly mounted to the can be obtained from Caterpillar
engine flywheel housing, must be Technical Marketing Information
evaluated to ensure the overhung (TMI).
weight is within tolerable limits of For determination of the bending
the engine. If not, adequate moment of overhung power
additional support must be provided transmission equipment installations,
to avoid damage. refer to Figure 15.
CAUTION: Mobile applications To compensate for power
require consideration of dynamic transmission systems that create a
bending movement imposed during high bending moment due to
normal machine movement or abrupt overhung load, a mount, as shown
starting and stopping. in Figures 12, Figure 13, or
Figure 14, is required.

Identification of Static Bending Moment

Figure 15

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Mounting Application and Installation Guide

Clutches, Belt and Chain Drives two support bearings. As with plate-
type clutches, these bearings and
Clutches
supports must be mounted on the
Both plate-type clutches and air
same skid as the engine.
clutches are used on mobile and
service rig applications. Plate-type Air pressure to operate the clutch
clutches are primarily used to drive is supplied by an air connection
small pumps and compressors. through the drilled passage in the
Engines driving mud pumps, draw output shaft. Clutch alignment
works, or rotary tables normally use tolerances are reduced as air
air clutches. pressure to the clutch increases.
Plate-type clutches can operate Belt and Chain Drives
with a limited amount of side load, Belt and chain drives may cause
but clutch supports or pillow block an engine or driven machine to shift
bearings allow greater side load under heavy load due to torque
capability. Such supports or bearings reaction plus belt and chain preload
must be mounted on the same skid tension. Belts or chains may also
as the engine. Refer to Figure 18. cause the Power Take-Off (PTO)
shaft or crankshaft to deflect
causing bearing and shaft bending
failures. The driven sprocket or
pulley should always be mounted
as close to the supporting bearing
as possible.
Side load limits shown in the
Caterpillar Technical Marketing
Information (TMI) must not be
exceeded. Sometimes, due to the
heavy side load, it is necessary to
provide additional support for the
driving pulley or sprocket. This can
be done by providing a separate
shaft supported by a pillow block
Figure 16 bearing on each side of the pulley or
sprocket as shown in Figure 17.
This shaft can then be driven by
Air clutches use an expanding air the engine or clutch through an
bladder for the clutch element, as appropriate coupling.
shown in Figure 17. However, the
output shaft must be supported by

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Application and Installation Guide Mounting

Figure 17
The pin joints should be tight. On
Substructure Suitability
older rigs, it is sometimes necessary
Substructures must have sufficient
to repair worn pin joints.
strength and rigidity to support the
weight of engines and compounds Figure 18 illustrates that there
and to withstand imposed vibrations should be no appreciable
and torque from mud pumps and unsupported span of the compound
engines. skid. Unsupported spans tend to
allow the skid to sag, causing
Lateral bracing provides resistance
harmful vibrations.
to sway as illustrated in Figure 18.

Mat or Concrete Operating Surface

Figure 18

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Mounting Application and Installation Guide

Isolation
Cat engines and packaged units front support. If additional support is
are capable of withstanding all self- desired, place an isolator midway
induced vibrations and no isolation between front and rear mounts and
is required merely to prolong their under the radiator.
service life. However, isolation is
required if engine or packaged unit References for Distances
vibration must be separated from
building or vessel structures, or if
vibrations from nearby equipment
are transmitted to inoperative
engines or packages. Cat generator
sets with isolation mounts between
the generator set and base already
satisfy these requirements.
Exterior vibrations rarely affect
units that are running. Methods of
isolation are the same for external or Figure 19
self-generated vibrations. Caterpillar
recommends the use of flexible
mounts on all auxiliary engine To apply isolators, the wet weight
installations. and center of gravity of the
assembled unit must be established.
Some new Caterpillar packages
Assuming the engine and generator
have factory installed vibration
are assembled to a base, the wet
isolators. Refer to the Price List to
weight (WT) and assembled center
determine if they are standard or
of gravity can be calculated.
optional.
To begin, a common reference is
Isolation Location needed. Refer to Figure 19. In this
Several types of commercial case, use the rear face of the
isolators provide various degrees of flywheel housing for reference.
isolation. In general, the lower the Because measurements are to both
natural frequency of the isolator, the sides of the reference, one direction
greater the deflection (soft) and can be considered negative.
more effective the isolation.
Weight of generator sets can be
unequally balanced within the limits
of the isolators. However,
overloading eliminates isolator
benefits. Isolators are most effective
when located under driven
equipment mounting and engine

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Application and Installation Guide Mounting

WT (D) = WE (D2) - WG (D1) + WR (D3) Determination of Isolator Location

WE (D2) - WG (D1) + WR (D3)


D=
WT

Where:
WT = wet weight
WE = engine weight
WG = generator weight
WR = radiator weight
D1,2,3 = distances
If additional equipment is added, Figure 20
the process is repeated to determine
Isolators are sized to have natural
a new center of gravity.
frequencies far removed from
Having established the center of engine exciting frequencies. If these
gravity for the total unit, refer to frequencies were similar, the entire
Figure 20, the loading on each pair unit would resonate. The trans-
of isolators can be determined by missibility chart in Figure 21 depicts
using the following formulas: this condition. It also shows the
S1 = WT(B ÷ C) S2 = WT(A ÷ C) significant improvement caused by
decreasing the mounting natural
frequency to allow a ratio increase
above √2, or 1.414.

Figure 21

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Mounting Application and Installation Guide

Installation of Flexible Mounts


Flexible mounts must be placed
between the structural base of the
auxiliary unit and the foundation
structure. It is important that the
base be of substantial design. When
the foundation structure is not
sufficiently rigid, reinforcing
supports should be added. When Figure 23
placing flexible mounts, the
directions of the supplier should
be followed. For three-point mounting of the
The location of isolation mounts is engine base, arrange the isolators to
important. On larger engines which obtain three-point contact with the
require three pairs of mounts, install load equally distributed; as shown in
one pair of isolators under the Figure 24.
center of gravity and the other two
sets equidistant from them at each
end of structural base. Refer to
Figure 22.

Figure 22

Figure 24
On smaller engines which require
only two pairs of mounts, locate one
pair under the front engine supports Isolation Methods
and the other pair under the load Commercially available fabricated
supports; as shown in Figure 23. isolators or bulk isolators can reduce
vibration. Both techniques use static
deflection, with increased deflection
resulting in greater isolation.
Although internal damping of various
materials cause performance
differences, the vibration chart in
Figure 25 describes the general

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Application and Installation Guide Mounting

effect deflection has on isolation. Spring Isolators


By using engine rpm as the nominal The most effective isolators of
vibration frequency, magnitude of low frequency vibration are of steel
compression on isolating materials spring design. They can isolate over
can be estimated. 96 percent of all vibrations and
Several commercial isolators are noise transmitted from rotating
available which provide varying machinery to the foundation or
degrees of isolation. Care must be mounting surface. Conversely,
taken to select the best isolator for isolators can absorb disturbances
the application. In general, the lower generated by adjacent machinery
the natural frequency of the isolator and prevent damage from being
(softer), the greater the deflection transmitted to idle equipment.
and the more effective the isolation. Spring-type linear vibration
However, the loading limit of the isolators are available as
isolator must not be exceeded. attachments (not installed) for
The unit can be separated from all generator sets to be used in
supporting surfaces by these soft stationary applications. These
commercial devices, i.e., those that isolators permit mounting the
deflect under the static weight. generator set on a surface capable
Mounting rails or fabricated bases of supporting only the static load.
withstand torque reactions without In Figure 26, a detail of a spring-
uniform support from the isolators. type isolator shows the addition
Basic Vibration Chart of thrust blocks to restrict lateral
movement without interfering with
the spring function.

Spring Type Isolator

Figure 26

Figure 25 No allowance for torque or


vibratory loads is required. As with

© 2012 Caterpillar
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Mounting Application and Installation Guide

direct mountings, no anchor bolting mounting. This type of isolator, as


is usually required. However, when shown in Figure 27, is equipped with
operating in parallel, vertical all directional limit stops designed to
restraints are recommended and the restrict excessive movement of the
isolator must be firmly fastened to engine and to withstand forces due
the foundation. Spring isolators are to roll, pitch and slamming of sea-
available with snubber for use with going vessels.
side-loaded engines or engines Many spring type isolators are
located on moving surfaces. equipped with horizontal limit stops
Anchor bolting is not always (snubbers) but do not include built in
required, but if the mounts are to be vertical limit stops. If this type of
bolted to the foundation, the typical isolator is used, external vertical
method is to pre-cast multiple limit stops should be added between
anchor bolts into the concrete the engine rail, or support, and the
foundation, necessitating close engine bed of the ship. Refer to
control of bolt placement location. Figure 28.
A preferred method is to drill anchor Isolator snubbers and limit stops
bolt holes after the generator set is should be adjusted to permit only
on site, using the isolators for drilling the amount of motion necessary for
templates. The anchor bolts are then isolation purposes.
installed and secured with epoxy
No matter what type of isolation
resin. If necessary, the foundation
is used, it should be sized to have
must be shimmed or grouted (for full
a natural frequency as far removed
surface area of isolator foot) at the
from the exciting frequencies of the
isolator locations to provide a
engine as possible. If these two
surface flat and level within
frequencies are similar, the entire
6.34 mm (0.25 in) for all three
unit would be in resonance.
isolator contact areas. Elevation
differences between isolators should When anchor bolting is necessary,
be minimized for the isolators to they should be installed according to
share the weight evenly when the the appropriate isolator installation
generator set is horizontal to the guidelines. The installation and
foundation. adjustment of the vibration isolators
supplied by Caterpillar are covered in
Steel spring-type isolators are
the Special Instructions listed under
effective in the vibration frequency
Reference Material at the end of this
range from 5 to 1000 Hz.
section.
Marine-type spring isolators should
be used for auxiliary engine

© 2012 Caterpillar
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Application and Installation Guide Mounting

Marine-Type Isolator

Figure 27

Spring Isolator with External Limit Stop

Figure 28

Rubber Isolators engine exciting frequencies in both


Rubber isolators are adequate for vertical and horizontal planes.
applications where vibration control By the addition of a rubber pad
is not severe. By careful selection, beneath the spring isolator, the high
isolation of 90 percent is possible. frequency vibrations, which are
They isolate noise created by transmitted through the spring, are
transmission of vibratory forces. also blocked. These high frequency
Care must be exercised to avoid vibrations are not harmful but result
using rubber isolators that have the in annoying noise. Refer to Figure 27
same natural frequency as the and Figure 28.

© 2012 Caterpillar
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Mounting Application and Installation Guide

Gravel or Sand (Bulk Isolation) Bulk Isolation


Bulk isolating materials are
sometimes used between the
foundation and supporting surface,
but are not as effective or
predictable as spring or rubber
types.
Isolation of block foundations may
be accomplished by 200 to 250 mm
(8 to 10 in) of wet gravel or sand in
the bed of the foundation pit. Refer
to Figure 29. Wet sand and gravel
can reduce engine vibration one-third
to one-half. The isolating value of
gravel is somewhat greater than Figure 29
sand. To minimize settling of the
foundation, gravel or sand must be Other Isolation Methods
thoroughly tamped before pouring Fiberglass, felt, composition, and
the concrete block. Make the flat rubber of a waffle design do
foundation pit slightly longer and little to isolate major vibration
wider than the foundation block forces, but do isolate much of the
base. A wooden form the size and high frequency noise. The fabric
shape of the foundation is placed on materials tend to compress with age
the gravel or sand bed for pouring and become ineffective. Because
the concrete. After the form is deflection of these types of isolators
removed, the isolating material is is small, their natural frequency is
placed around the foundation sides, relatively high compared to the
completely isolating the foundation engines. Attempting to stack
from the surrounding earth. these isolators or apply them
Where construction practices indiscriminately could force the total
allow, the floor, if at the unit's system into resonance. Pad type
foundation level, should be isolated isolators can be effective for
completely with a soft expansion frequencies above 2000 Hz.
joint sealing material. Rubber, Cork is not effective with
asphalt impregnated felt, fiberglass, disturbing frequencies below
and cork are typical isolating 1800 cps and, if not kept dry, will
materials, but they may not provide rot. It is seldom used with modern
the maximum low frequency generator sets, but is used to
isolation. Cork is seldom used under separate engine foundations and
the foundation of modern generator surrounding floor because of
sets because it will rot if not kept resistance to oil, acid, or
dry. temperature changes between
-18° and 93°C (0° and 200°F).

© 2012 Caterpillar
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Application and Installation Guide Mounting

Stationary equipment isolators are • Prevent torque loading on


used when the package will not be generator sets caused by
transported, (with isolators platforms or trailer beds.
attached), or will not experience
seismic shock. The isolators contain Isolator for Mobile Equipment
thrust blocks to control lateral
movement.
External Piping
Piping connected to engines or
packaged units requires isolation,
particularly when resilient mounts
are used. Fuel and water lines,
exhaust pipes, and electrical conduit
can otherwise transmit vibrations
long distances.
If isolator pipe hangers are used,
they should have springs to
attenuate low frequencies, and
rubber or cork to minimize high
frequency transmissions. To prevent
Figure 31
buildup of resonant vibrations, long
runs of piping should be supported Mobile equipment isolators have
at unequal intervals as shown in the same features as the stationary
Figure 30. equipment isolators. They also have
built in restraints capable of
External Pipe Supports withstanding a +2 G vertical load
and +3 G horizontal load under low
cyclic conditions An example is
shown in Figure 31. They are
suitable for use with mobile
platforms, but are not generally
intended to handle seismic shock.
Vibration carried throughout an
enclosure causes early failureFigure
of 30
auxiliary equipment. Relays,
Mobile Equipment switches, gauges, and piping are
Isolation from a movable platform adversely affected.
is desirable to: Noise, while normally only
• Reduce vibration annoying, can attain levels objection-
able to owners and operators. If
• Reduce noise operating near property lines, noise
could exceed local ordinances.

© 2012 Caterpillar
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Mounting Application and Installation Guide

Perhaps the most important reason lateral movement without interfering


to isolate mobile equipment is to with spring function.
avoid bending of the generator set Seismic
by movement of the sub base. Seismic shocks are insufficient to
Unless the platform or trailer bed is harm generator sets resting on the
extremely rigid, the generator set floor. However, isolation devices,
must not be bolted to it. Deflection particularly spring isolators, amplify
of the bed would be transmitted to small movement generated by
the engine, causing block bending earthquakes to levels that can
and possible crankshaft and bearing damage equipment. Special isolators
failures.
incorporating seismic restraining or
Lateral movement of the generator damping devices are available, but
set must be minimized as the trailer the isolator supplier must review the
is transported. This can be achieved exact requirements. Isolators
simply by blocking the unit off the anticipating seismic shock are bolted
isolators during the move. If not to the equipment base and the floor.
practical, snubbers can confine Positive stops are added to limit
vertical and horizontal movement. motion in all directions. Attached
A spring-type isolator with the piping and auxiliary equipment
addition of thrust blocks restricts supports must also tolerate relative
movement.

© 2012 Caterpillar
All rights reserved. Page 23
Application and Installation Guide Mounting

Foundations
The major functions of a
foundation are to: lb/U.S. Specific
Liquid kg/m3 lb/ft3
• Support total weight of gal Gravity
equipment, accessory Water,
994.6 8.31 62.1 1.001
Fresh
equipment and fluids (coolant,
Water,
oil and fuel) Sea 1018.3 8.51 63.6 1.021

• Maintain alignment between Water/


Glycol 1024.4 8.55 64.0 1.031
engine, driven equipment, and
accessory equipment Diesel Fuel 850.7 7.11 53.1 0.855
• Isolate equipment vibration
Lube Oil 909.7 7.61 56.8 0.916
from surrounding structures.
Kerosene 802.7 6.71 50.1 0.807
Responsibility
The equipment foundation and the
Material supporting the foundation
driven equipment attachment to the
must carry the total weight. The
foundation are not the responsibility
table below shows the bearing load
of Caterpillar. The customer or
capabilities of common materials.
customer's agent, familiar with local
site conditions and application
requirements, bears foundation Safe Bearing
design responsibility. Foundation Material Load
kPa (psi)
comments published herein are
intended only as general guidelines Rock, Hardpan 482.6 (70)
for consideration. Further engine Hard Clay, Gravel and Coarse
386 (56)
foundation general guidelines can be Sand

found in the appropriate Engine Data Loose Medium Sand and


193 (28)
Medium Clay
Sheet.
Loose Fine Sand 96.5 (14)
Ground Loading Soft Clay 0-96.5 (0-14)
Initial considerations include
equipment weight and material
supporting this weight. The wet Firm level soil, gravel, or rock
weight of the total package must be provides satisfactory support for
calculated. This includes accessory single-bearing generator sets used in
equipment and weight of all liquids stationary or portable service. This
(coolant, oil, and fuel) supported support can be used where the
by the foundation. Dry weights weight-bearing capacity of the
of engine and attachments can supporting material exceeds pressure
be found in the price list. Liquid exerted by the equipment package,
densities are given in the and where alignment with external
following table. machinery is unimportant.

© 2012 Caterpillar
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Mounting Application and Installation Guide

Soil, such as fine clay, loose Pressure imposed by the weight of


sand, or sand near the ground water the equipment must be less than the
level, is particularly unstable under load-carrying capacity of supporting
dynamic loads and requires material.
substantially larger foundations. Where support rails or mounting
Information concerning bearing feet have insufficient bearing area,
capacity of soils at the site may flotation pads can distribute the
be available from local sources and weight. The underside area and
must comply with local building stiffness of the pad must be
codes. sufficient to support the equipment.
The area of load-bearing support is Seasonal and weather changes
adjusted to accommodate surface adversely affect mounting surfaces.
material. To determine pressure (P) Soil changes considerably while
exerted by the generator set, divide freezing and thawing. To avoid
total weight (W) by total surface movement from seasonal change,
area (A) of the rails, pads, or extend foundations below the frost
vibration mounts. Refer to Figure 34. line.

Concrete
Several basic foundations are
applicable for Cat equipment. The
foundation chosen will depend on
factors previously outlined as well as
limitations imposed by the specific
location and application.
Massive concrete foundations are
normally unnecessary for modern
multi-cylinder medium speed engines
and packaged units. Avoid
excessively thick, heavy bases to
minimize sub floor or soil loading.
Figure 34 Bases should be only thick enough
to prevent deflection and torque
reaction, while retaining sufficient
P=W÷A
surface area for support. Non-parallel
Where: units require no foundation
P = pressure in (psi) anchoring.
W= weight in (lb)
A= area in (in2)

© 2012 Caterpillar
All rights reserved. Page 25
Application and Installation Guide Mounting

If a concrete foundation is foundation must withstand


required, minimum design guidelines twice the wet weight of the
include: generator set. Bolting the set
• Strength must support wet to the foundation is
weight of units plus dynamic recommended.
loads. The dynamic load can Estimate foundation depth that will
be calculated using the accommodate equipment weight
allowable centerline vibration using the formula:
limits and the equipment FD = W ÷ (D x B x L)
mass.
• Depth sufficient to attain a
Where:
minimum weight equal to
equipment wet weight (only if FD = Foundation depth in m (ft)
large mass, i.e. inertia block, W = Total wet weight of
is specified for vibration equipment in kg (lb)
control). D = Density of concrete in kg/m2
• The mass of the foundation (lb/ft2)
should be no less than the Note: Use 2402.8 for metric units
mass of the equipment. and 150 for English units.
• Outside dimensions exceed B= Foundation width in m (ft)
that of the equipment, a
L= Foundation length in m (ft)
minimum of 305 mm (12 in)
on all sides. Suggested concrete mixture by
volume is 1:2:3 of cement, sand,
• When effective vibration
aggregate, with maximum 102 mm
isolation equipment is used,
(4 in) slump and 28-day compressive
figure depth of floor concrete
strength of 21 mPa (3000 psi).
needed for structural support
of the static load. If isolators Reinforce concrete with No. 8
are not used, dynamic loads gauge steel wire mesh, or
transmit to the facility floor equivalent, horizontally placed on
and require the floor to 152 mm (6 in) centers. An
support 125 percent of the alternative method places No. 6
generator set weight. reinforcing bars on 305 mm (12 in)
centers horizontally. Bars must clear
• If generator sets are
foundation surfaces 76 mm (3 in)
paralleled, possible out-of-
minimum. Refer to Figure 35.
phase paralleling and resulting
torque reactions demand
stronger foundations. The

© 2012 Caterpillar
Page 26 All rights reserved.
Mounting Application and Installation Guide

Concrete Foundation Example

Figure 35

© 2012 Caterpillar
All rights reserved. Page 27
Application and Installation Guide Mounting

Bases
such that resonance does not
Purpose and Function occur during the machinery's
The most important function of normal work.
an engine base is rigidity. It must
• Make proper alignment easy,
maintain alignment between the
and maintain this alignment
engine and its driven equipment.
under all operational and
The major cause of misalignment is
environmental conditions,
flexing of the base due to lack of
thus eliminating the need for
torsional rigidity. Other causes are
frequent, periodic realignment
poor installation methods and
of the engine and driven
incorrect alignment procedures.
equipment. Allow sufficient
The base must offer rigidity space for shimming in the
adequate to oppose the twist due alignment process.
to torque reaction on drives where
• Provide proper mounting holes
the driven equipment is mounted on
for the engine and all other
the base assembly, but not bolted
base mounted components.
directly to the engine flywheel
housing. Note: Bases designed and fabricated
by dealers, or others, must meet the
In general, Cat engine bases will:
design requirements of Caterpillar
• Protect the engine block, supplied bases to assure strength
drive train couplings, and and vibration resistance.
driven equipment (generator
gear reducer, or pump) from Caterpillar Base Design
bending forces during ship- Ease of initial installation, vibration
ment. The entire package isolation, and need for isolation from
must be able to withstand flexing mounting surfaces are major
normal handling during reasons for using fabricated bases.
transportation without No base of any type should be
permanently distorting the rigidly connected to a flexing
base or causing misalignment mounting surface.
of the driven equipment. The type of load will also
• Limit torsional and bending determine specific design features
moment forces caused by required in an engine base.
torque reaction and flexing of Caterpillar offers different bases for
the foundation or substructure close-coupled units (such as single
under the base. bearing generators) and for remote
• Be free of torsional or linear mounted units (such as two bearing
vibration in the operating generators).
speed range of the engine,
and have a natural frequency

© 2012 Caterpillar
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Mounting Application and Installation Guide

Single Bearing Loads Figure 37. If the base were not rigid
When single-bearing generators or enough, engine torque would cause
close-coupled loads are used, the the base to flex excessively. The
base does not have to withstand result is misalignment, proportional
torque reaction. Bolting the to the amount of load, which will
generator housing to the flywheel not show up during a conventional
housing eliminates the need for the static alignment check.
base to absorb the driving torque of Severe cases of this problem result
the engine. Refer to Figure 36. in bearing and coupling failures.

Single Bearing Loads Two Bearing Loads

Figure 36

Figure 37
Two Bearing Loads
With the load remote-mounted, Bases for Engines with Close-
a more rigid structural base is Coupled Loads
required. The full load torque Caterpillar does not recommend
between the engine and load has a specific section modulus for
to be absorbed by the base without the longitudinal girders or cross
causing excessive deflection in the members. Usually I-beams or
coupling. channel section steel beams in
a ladder-type arrangement are
The stationary frame of the
acceptable.
remote-mounted driven equipment
torques in the same direction as
the engine crankshaft. Refer to

© 2012 Caterpillar
All rights reserved. Page 29
Application and Installation Guide Mounting

Base for Foot Mounted Engine with Close Coupled Load

Figure 38

Foot-Mounted Engines equipment first and then weld to


Bases for foot-mounted engines the base providing a flat surface for
should have cross members as shimming and mounting. Mounting
substantial as the longitudinal holes drilled into the structural
beams. Place these cross members members of the base are not
beneath each engine and driven unit recommended.
support location. There should be sufficient space
Do not fasten the engine and for shimming between the mounting
driven unit mounting feet to the blocks and the engine/driven
base by welding. equipment mounting surfaces.
Use drilled and tapped steel Flexible mounts are not allowed
mounting blocks between the between the mounting blocks and
engine/driven equipment and the the engine/load mounting foot
base. Refer to Figure 38. Bolt these surfaces.
blocks to the engine/driven

© 2012 Caterpillar
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Mounting Application and Installation Guide

Base for Rail Mounted Engine with Close Coupled Load

Figure 39

Rail-Mounted Engines available for shimming. Bolt


Refer to Figure 39. In addition to these blocks to the
the requirements for foot-mounted engine/driven equipment first
engines, the following applies for and then weld to the base to
rail-mounted engines: provide a flat surface for
shimming and mounting.
• The standard engine-mounted
support rails (engine length) • Do not weld the engine-
must be used between the mounted rail to the structural
engine and the structural base.
base. • Bolt the engine-mounted rails
• Locate cross members directly to the threaded mounting
beneath the front and rear blocks through clearance
engine-to-rail mounting holes to allow for thermal
locations. growth.
• Place drilled and tapped
mounting blocks at the front
and rear of the engine-
mounted rails with space

© 2012 Caterpillar
All rights reserved. Page 31
Application and Installation Guide Mounting

Base for Engines with Remote Mounted Driven Equipment

Figure 40

Bases for Engines with Remote- distortion during welding. Boxing is


Mounted Loads done to make the base structure
The design requirements for bases stiffer.
used on engines with close-coupled The additional stiffness is
units also apply to bases used for necessary to resist torque loads
engines with remote-mounted units. between the engine and remote-
Bases for use with remote-mounted mounted driven equipment and to
units must be more rigid. The base resist possible vibration loads.
must absorb the full-load torque Vibration-induced base loads are
between the engine and driven unit difficult to predict.
without causing excessive deflection Experience has shown boxing is
in the coupling.
effective in preventing base cracking
The base shown in Figure 40 is a and misalignment.
boxed beam design that provides a
Cat Special Duty Bases
torsionally rigid base.
Boxing consists of welding steel Offshore Power Modules
plates on top and bottom surfaces of The Cat petroleum offshore base
machinery base girders. Skip-weld consists of a base-within-a-base.
the plates to prevent excessive base The inner base is three-point
mounted, with integral spring

© 2012 Caterpillar
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Mounting Application and Installation Guide

isolators and limit stops, to the outer base design as shown in Figure 42
base. The outer base can be welded and Figure 43.
to the rig support structure. The The 12.42 m (40 ft 9 in) base has
inner base structure is not the same no decking provided from the rear of
as engine rails used in other the generator to the rear of the
applications. Refer to Figure 41. base. Customer-supplied auxiliary
The outer base must be supported equipment is to be mounted here,
by large girders, and can either be necessitating customer-supplied
welded or bolted to the rig structure. decking and reinforcement.
Inadequate support may result in Site preparation is generally
power module vibrations. required for land rig power modules
in order to provide level, firm soil. In
Offshore Power Module some cases, planking or concrete
surfacing may be necessary. Certain
types of soil, such as fine clay, loose
sand, sand near the ground water
level, or soil that is freezing or
thawing, are particularly unstable
under dynamic loads. Loose planking
under the power modules may also
cause power module vibration.
Because ground conditions may
Figure 41 vary from well location to well
location, vibrations may result which
Land Rig Power Modules are not due to misalignment or
The Cat petroleum land rig base unbalanced parts. Unstable ground,
uses 460 mm (18 in) wide flange as previously mentioned, may be
beams, available in lengths of 7.85 reacting to normal forces within
m, 9.37 m and 12.42 m (25 ft 9 in, the engine/generator combination,
30 ft 9 in and 40 ft 9 in), to allow whereas at another well location no
matching base length to equipment such reaction may occur.
needs. As with the offshore power In addition, rough handling may
modules, alignment integrity is occur during rig moves, so alignment
provided by using a base-within-a- should be checked after every move.

© 2012 Caterpillar
All rights reserved. Page 33
Application and Installation Guide Mounting

Land Rig Power Module

Figure 42

Land Rig Power Module

Figure 43

© 2012 Caterpillar
Page 34 All rights reserved.
Mounting Application and Installation Guide

Roof and Walkway


The customer can add roofs and
walkway wings for servicing and
weather protection, as shown in
Figure 44. The width of the wings
should suit the customer, but should
be at least as wide as the radiator.
All connections of the bracing to
the base should avoid stressing or
flexing the I-beam's flange or
vertical member. Guard rails, cable
runs, lighting, exhaust piping, etc.,
can be added according to customer
preference.
Figure 44

© 2012 Caterpillar
All rights reserved. Page 35
Application and Installation Guide Mounting

Reference Material
The following information is
provided as an additional reference
to subjects discussed in this guide.
SEHS8700
Special Instruction - Installation of
Flexible Mounting Groups
SEHS9162
Special Instruction - Spring Isolator
Group Installation and Adjustment
Procedure

© 2012 Caterpillar
Page 36 All rights reserved.
© 2008 Caterpillar®
Page 38 All rights reserved.
LEBW4974-05 ©2012 Caterpillar Printed in U.S.A.
All rights reserved.

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