C2.2 Generator Set Enclosures{7263, 7274} Caterpillar

Generator Set:

C2.2 (S/N: GBE933-934,937-939,951-951,955-955,958-961,966-966,970-976,986-987,989-989,993-994,1003-1003,1005-1006,1008-1015,1018-1019,1066-UP)

Introduction

The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.

Problem

There have been a number of isolated instances of issues with water ingress in certain C2.2 Generator Sets. When the generator set is not operating, water is collecting inside the canopy.

The water appears to be coming in through the top mesh of the generator set. The water then gets inside the canopy through the radiator opening and the silencer outlet.

Required Parts

Solution

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Illustration 1	g02813756
Typical example

1. Produce two "L-shaped" flanges made from 1.6 mm (0.063 inch) plate and a specification of BS EN 10111:HR4P. Refer to illustration 1 and table 2 for the dimensions.
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   Table 2

   Letter	Dimension
   A	10 mm (0.39 inch)
   B	50 mm (1.97 inch)
   C	200 mm (7.87inch)
   D	200 mm (7.87inch)
   E	21.4 mm (0.84 inch)
   F	4 mm (0.16 inch)
   G	50 mm (1.97 inch)
   H	230 mm (9.06 inch)
   J	52 mm (2.05 inch)
   K	31.8 mm (1.25 inch)
   L	Five holes with a diameter of 7 mm (0.28 inch)
   M	834 mm (32.83 inch)
   N	335.6 mm (13.21 inch)
   P	357 mm (14.06 inch)
   Q	12 mm (0.47 inch)
   R	501.6 mm (19.75 inch)
   S	63 mm (2.48 inch)
   T	65 mm (2.56 inch)
   U	523 mm (20.59 inch)

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Illustration 2	g02815636
Typical example

2. Drill ten holes with a diameter of 5.25 mm (0.21 inch) is the radiator outlet plate. Refer to illustration 2 and table 3 for the correct positions.
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   Table 3

   Number	Dimension
   1	13 mm (0.512 inch)
   2	52 mm (2.05 inch)
   3	334 mm (13.15 inch)
   4	230 mm (9.06 inch)
   5	52 mm (2.05 inch)
   6	13 mm (0.512 inch)
   7	500 mm (19.69 inch)
   8	13 mm (0.512 inch)
   9	Ten holes with a diameter of 5.25 mm (0.21 inch)
   10	200 mm (7.87 inch)
   11	200 mm (7.87 inch)

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Illustration 3	g02815741
Typical example

3. Position the two "L-shaped" flanges (12) on the metal surface. The two "L-shaped" flanges should be positioned on the radiator side, with the edges facing towards the radiator, over the transition foam. Make temporary marks on the metal surface in the locations where the mounting holes should be drilled.

4. Drill 5 mm (0.19685 inch) holes in the metal surface as indicated by the temporary marks.

5. Mount support "L-shaped" flanges to the inside face of the metal surface. Install ten rivets (13) in the correct locations.

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Illustration 4	g02815758
Typical example

6. Install 241-3091 Seal (14) onto the "L-shaped" flanges. Ensure that the transition foam is covered.

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Illustration 5	g02815759
Typical example

7. Wrap approximately 4 m (13.12 ft) of 246-0992 Tape tightly around the exhaust pipe (15) inside the enclosure. Ensure that the tape is located past the outlet hole to prevent water ingress. Ensure that the tape is pushed up tight to the metal surface. Secure with 3E-7419 Hose Clamp (16) .

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Illustration 6	g02815761
Typical example

8. Fill area (Y) with strips of 5P-5931 Seal and 119-0781 Adhesive if necessary.

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Illustration 7	g02815763
Typical example

9. Fill area (Z) with 119-0781 Adhesive .

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Illustration 8	g02815765
Typical example

10. Drill holes (17) in the end of base to allow for water drainage. Caterpillar recommends that six 19 mm (0.74803 inch) are drilled.

11. Paint the bare metal once the six holes are drilled. Refer to the Original Equipment Manufacturer (OEM) for more information.