Excessive Radiant Heat May Cause Melting of Components on Certain DG30 Generator Sets {1067, 1408} Caterpillar

Electric Power Generation

DG30 (S/N: NBW1-134,136-UP)

Introduction

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

Problem

Illustration 1	g06242046
(1) O2 Harness (2) Exhaust Location

Illustration 2	g06242057
(3) Battery Charger Screen (4) Documentation Holder Tube (5) Exhaust Elbow

The O2 sensor wiring, battery charger screen, and the documentation holder tube are susceptible to extreme radiant heat as shown in the illustrations above.

Solution

Parts Required

Table 1 contains the parts required to complete this procedure.

Safety

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Shock/Electrocution Hazard – Do not operate this equipment or work on this equipment unless you have read and understand the instructions and warnings in the Service Manual. Failure to follow the instructions or heed the warnings will result in serious injury or death.

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Personal injury or death can result from high voltage. When power generation equipment must be in operation to make tests and/or adjustments, high voltage and current are present. Improper test equipment can fail and present a high voltage shock hazard to its user. Make sure the testing equipment is designed for and correctly operated for high voltage and current tests being made. When servicing or repairing electric power generation equipment: Make sure the unit is off-line (disconnected from utility and/or other generators power service) , and either locked out or tagged DO NOT OPERATE. Remove all fuses. Make sure the generator engine is stopped. Make sure all batteries are disconnected. Make sure all capacitors are discharged. Make sure residual voltage in the rotor, stator and the generator is discharged. Failure to do so could result in personal injury or death.

Isolate the generator set before performing any work on the unit. Open the alternator set breaker, activate the "Emergency Stop", and disconnect the battery cables.

Ensure that all health and safety requirements are adhered to always. Ensure that proper Lockout/Tagout procedures are followed always while work is being performed. Lock out the generator set before performing any work. Only qualified personnel should service this equipment.

Insulation Tape and Clamp Installation

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Illustration 3	g06242124
(1) 246-0992 Tape (2) 5P-0597 Hose Clamp

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Illustration 4	g06242128

1. Install 2000 mm (78.74 inch) of tape (1) onto the exhaust from the flange of the elbow to the outlet of the elbow.
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   Illustration 5	g06242134

2. Install clamps (2) at each end of the tube as shown in Illustration 5. Torque the clamps to 7.5 ± 1 N·m (66 ± 9 lb in).

Heat Shielding Installation

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Illustration 6	g06242234

1. Cut the tie strap that is highlighted in Illustration 6.
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   Illustration 7	g06242238

2. Pull the excess slack out of the O2 sensor harness connector look and move the connector as far away frm the exhaust manifold as possible as shown in Illustration 7.
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   Illustration 8	g06242229
   Harness Connector with Heat Shielding Installed

3. Install the 493-2772 Sleeve as shown in Illustration 8 and tie strap the harness back together.

4. Restore the generator set back to the operating configuration.