Rework Procedure for Exhaust Rain Cap and Insulation on Certain XQ200 Generator Sets {1072} Caterpillar

Electric Power Generation

C7.1 GEN SET (S/N: MRP1-903)

Introduction

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

This special instruction describes the rework procedure for replacing the insulation and repositioning the exhaust rain cap on certain generator sets.

Safety Section

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

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Climbing equipment may be required to access this service point. Refer to the Operation and Maintenance Manual, "Mounting and Dismounting" topic for safety information.

Required Parts

Soundcoat Company Inc. M Insulation with 5mm High Temperature PSA Adhesive Backing and Matte Film

Note: Dimensions listed at Illustration 2.

Required Tools

Rework Procedure

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Illustration 1	g06390429
(A) U-bolt (B) Nut

1. Remove and retain u-bolt (A) and nut (B).

2. Remove the existing damaged insulation to bare paint surface.

   1. Clean the surface where the new insulation will be applied using an isopropyl alcohol wipe. Clean the surface until the isopropyl wipe comes back clean.
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   Illustration 2	g06386256
   (D1) 1080 mm (42.5 inch) (D2) 650 mm (25.5 inch) (D3) 35 mm (1.4 inch) (D4) 123 mm (4.8 inch) (D5) 173 mm (6.8 inch) (1) Soundcoat Company Inc. 38 mm (1.5 inch) thicknessM Insulation with 5 mm (0.2 inch) High Temperature PSA Adhesive Backing and Matte Film

3. Cut the insulation to dimension (D1) and dimension (D2).

   1. Cut two notches using dimension (D3), dimension (D4), and dimension (D5).
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   Illustration 3	g06390293
   (D1) 1080 mm (42.5 inch) (D2) 650 mm (25.5 inch) (D6) 395 mm (15.5 inch) (D7) 75 mm (3 inch) (D8) 285 mm (11.2 inch) (D9) 240 mm (9.4 inch) (1) Soundcoat Company Inc. M Insulation with High Temperature PSA Adhesive Backing and Matte Film

4. Cut an opening in the insulation using dimension (D6), dimension (D7), dimension (D8), and dimension (D9).
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   Illustration 4	g06390314
   (D1) 1080 mm (42.5 inch) (D2) 650 mm (25.5 inch) (D10) 280 mm (11 inch) (D11) 575 mm (22.6 inch) (1) Soundcoat Company Inc. M Insulation with High Temperature PSA Adhesive Backing and Matte Film

5. Cut the insulation to dimension (D10) and dimension (D11).

6. To apply the insulation, peel off the back cover.

   Note: The insulation and panel temperature must be between 28° C (82 ° F)and 38° C (100 ° F).

   1. Place one edge of the insulation into position on the panel.

   2. Starting at the edge, apply pressure using an extension floor roller to press the insulation onto the panel.

   3. Press and move the roller from one end of the insulation to the other.

   4. Roll the roller over the entire surface of the insulation in the same direction.

   5. Press and move the roller cross sectionally across the entire surface of the insulation.

   6. Inspect the edges of the insulation for gaps.

      Note: Use of a smaller rubber hand roller may be required for the edges of the insulation.

   7. If a gap is found roll that surface again.

      Note: There should be no air pockets between the insulation and the panel.

      Note: Maximum adhesive strength is not achieved until a minimum of 24 to 48 hours.

7. Install 6 of the 144-7183 Retaining Rings to secure the insulation to the panel.
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   Illustration 5	g06374148
   (D12) 277.5 mm (10.9 inch) (D13) 265 mm (10.4 inch) (2) Steel Sheet With A Caster Class Of 5 And A Thickness Of 1.9 mm (0.075 inch)

8. Cut the steel sheet to dimension (D12) and dimension (D13).
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   Illustration 6	g06400843
   (D12) 277.5 mm (10.9 inch) (D13) 265 mm (10.4 inch) (D14) 50.3 mm (2 inch) (D15) 176.9 mm (7 inch)

9. Make two 45 degree bends at dimensions (D14).
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   Illustration 7	g06374120
   (D12) 277.5 mm (10.9 inch) (D13) 265 mm (10.4 inch) (D14) 50.3 mm (2 inch) (D15) 176.9 mm (7 inch) (D16) 12.7 mm (0.5 inch) (D17) 69 mm (2.7 inch) (D18) 138 mm (5.4 inch) (D19) 38.9 mm (1.5 inch)

10. Use dimension (D16), dimension (D17), dimension (D18), and dimension (D19) to drill two 11 mm (0.43 inch) holes in the sheet metal.
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    Illustration 8	g06374149
    (A) U-bolt (B) Nut (C) Rain Cap (D) Support Bracket (E) Exhaust Tube (2) Exhaust Shield

11. Install exhaust shield (2) between support bracket (D) and exhaust tube (E).

12. Install u-bolt (A) and nut (B).
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    Illustration 9	g06400859
    (C) Rain Cap (E) Exhaust Tube (F) Bolt (G) Locknut

13. Loosen bolt (F) and locknut (G).

14. Reposition rain cap (C) so the rain cap opens to the left side of the package.

    Note: Illustration 9 shows the correct position of the rain cap.

15. Torque bolt (F) and locknut (G) to 40 ± 5 N·m (30 ± 3 lb ft).