PROBLEM

AFFECTED PRODUCT

PARTS NEEDED

ACTION REQUIRED

OWNER NOTIFICATION

SERVICE CLAIM ALLOWANCES

PARTS DISPOSITION

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach. (1-Owner Notification)

        (2-Rework Procedure)

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

SAFETY - The Exhaust System Needs To Be Inspected And Repaired

MODELS INVOLVED - XQ125, XQ200, XQ225, XQ300 and XQ400 Generator Sets

Dear Caterpillar Product Owner:

The exhaust system needs to be inspected and repaired on certain XQ125, XQ200, XQ225, XQ300 and XQ400 Generator Sets. Exhaust leaks may occur around the silencer connection. The hot exhaust gas could cause damage to the painted surface and the sound foam liner and could lead to fire. Inspection needs to be performed on the products listed below. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. If your unit is readily mobile please make arrangements to transport it to the dealership for service. If it is not readily mobile please call to schedule onsite service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated May 18, 2004 when scheduling this service. If there are any questions regarding this requirement please contact your local dealer.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Attached to May 18, 2004 Service Letter

Rework Procedure

This program consists of four main sections:

1. Sound Foam Removal and Exhaust Inspection
2. Exhaust Leak Repair Procedure
3. Guillotine Clamp Installation (if required)
4. Cleanup and Procedure

A. Sound Foam Removal and Exhaust Inspection

1. Lockout and secure the generator set from inadvertent operation.
2. Using a razor knife with a minimum blade length of 2", make a vertical cut the entire height of the sound foam insulation at the exhaust bracket mounting bolts on the internal upper radiator exhaust panel.
3. Using a putty knife, remove all the foam insulation from the exhaust pipe side of the upper radiator panel. Refer to Illustration 1.

 






Illustration 1 ? Sound Insulation Location




4. Pull back the exhaust pipe insulation blanket where it passes through the upper radiator panel exhaust thimble. Refer to Illustration 2.

 

 



Illustration 2 ? Exhaust Pipe Insulation Blanket

5. Inspect the protective exhaust thimble and the upper radiator panel for any discoloration due to heat or soot. DO NOT operate the machine if discoloration due to heat or soot is found on the thimble, the upper radiator panel or the sound foam insulation previously removed. If a leak is detected, Section B, "Exhaust Leak Repair Procedure", will provide the repair procedure.
6. Locate exhaust screen on top of the roof assembly covering the exhaust plenum opening. Remove the exhaust screen by using a 7/16^th inch wrench to remove the ¼-20NC bolts that secure it to the top of the exhaust plenum opening. Set the screen and hardware aside until the necessary procedures are completed. Refer to Illustration 3.




Illustration 3 ? Exhaust Plenum Opening




7. Inspect the exterior of the upper radiator wall, the exhaust pipe and the exhaust thimble for signs of a leak. DO NOT operate the machine if an exhaust leak is present, Section B, Exhaust Leak Repair Procedure, will provide the repair procedure. Refer to Illustration 4.

Illustration 4 ? Exhaust/Muffler Joint in the Plenum Area

B. Exhaust Leak Repair Procedure (if necessary)

If a leak has been detected, perform the following procedures PRIOR to any further operation of the generator set package.

1. Remove the lower half of the exhaust hanger assembly. Set aside the lower half of the exhaust hanger assembly. Refer to Illustration 5.



Illustration 5 ? Exhaust Hanger Assembly


 
2. Remove the hardware and gasket that connects the exhaust pipe assembly to the turbo outlet elbow. Refer to Illustration 6.




Illustration 6 ? Turbo Outlet

3. Remove the exhaust clamp that is located where the exhaust pipe connects to the exhaust silencer in the plenum compartment. Refer to Illustration 7.

 

 



Illustration 7 ? Exhaust Clamp

4. From inside the engine compartment, remove the exhaust pipe assembly from the generator package. Refer to Illustration 8.




Illustration 8 ? Exhaust Pipe Assembly

5. Visually inspect the following for any damage or wear:
1. Exhaust pipe assembly
2. Exhaust gasket
3. Exhaust clamp
6. Replace any components that are cracked or deformed.
7. Use abrasive cloth to clean all sealer, oxidation, and soot from the silencer end of the exhaust pipe and the inside of the inlet pipe cuff.
8. Apply a 6mm (.25 inch) bead of Permatex MTK-1 Tail Pipe Sealer around the outer perimeter of the exhaust pipe assembly. Refer to Illustration 9.

 






Illustration 9 ? Exhaust Pipe Sealer

9. Reinstall the exhaust pipe assembly into the generator set package. Ensure that the exhaust pipe seats completely into the silencer inlet cuff.
10. If the exhaust clamp that was previously removed is a guillotine style clamp skip ahead to step 12. If it was a band clamp, it must be replaced with a guillotine style clamp. For an XQ125, XQ200 or an XQ225 replace with a 5-inch clamp. For an XQ300, XQ350 or an XQ400 replace with a 6-inch clamp.
11. Install a guillotine clamp where the exhaust pipe and the silencer connect. Tighten the exhaust clamp to 34 N.m (25 lb-ft). Make sure to use two 3/8-inch nuts on each leg of the clamp. Refer to Illustration 10. Note: The exhaust clamp connection should be tightened before connecting the exhaust pipe assembly to the turbo outlet flange. This will eliminate the dislodging of the exhaust pipe from its seating in the silencer cuff during connection to the turbo outlet flange.
12. Use the gasket and 1/2 inch hardware to reconnect the exhaust pipe assembly to the turbo outlet elbow. Replace the exhaust gasket if any defects are observed before installation. Tighten the turbo outlet hardware to 102 N.m (75 lb-ft).
13. Reinstall the lower half of the exhaust hanger assembly. For proper alignment of the exhaust system, some adjustment on the threaded hanger may be required.

C. Band Clamp Replacement

1. In the plenum area locate the exhaust joint connecting the engine exhaust pipe to the muffler. If a guillotine style clamp is installed and has two nuts on each shank, check to make sure they are tightened to 34 N.m (25 lb-ft) and proceed to Section D, Cleanup Procedure. If a band style clamp is installed or the double locking nuts on the guillotine style clamp are missing, proceed to steps 2 or 3 respectfully. Refer to Illustration 10.

 






Illustration 10 ? Guillotine Style Clamp in the Plenum Area

2. If a band clamp is present, replace it with the guillotine style clamp. For an XQ125, XQ200 or an XQ225 replace with a 5-inch clamp (part number 52C190). For an XQ300, XQ350 or an XQ400 replace with a 6-inch clamp (part number 54C176).
3. Double nut the clamp on each side and tighten to 34 N.m (25 lb-ft). If a guillotine style clamp was already installed on the unit, check to make sure that it is tightened down with two nuts on each shank to 34 N.m (25 lb-ft). Refer to Illustration 10.

D. Cleanup Procedure

1. Clean up all fluids and debris in the plenum area and engine compartment. This should always be completed as part of normal preventative maintenance. When flammable liquids are discovered within the enclosure package or plenum area, clean them up immediately.


Note: DO NOT run a unit with flammable liquids exposed.

2. Replace the plenum exhaust screen that was removed. Note: For proper operation, ensure that the silencer rain cap aligns correctly with the opening in the exhaust screen.
3. Test the generator set for proper operation. Inspect for any indication of reoccurring exhaust leaks.
4. If no leaks are detected, operate the generator set according to the Operation and Maintenance Manual.

Special Note on XQ Preventative Maintenance:

The exhaust system should be inspected for leaks prior to each rental and/or startup. If a leak is found, corrective actions must be taken prior to operating the machine.

All fluids and debris in the plenum area and engine compartment should be cleaned up prior to each rental and/or startup. This should always be completed as part of normal preventative maintenance. When flammable liquids are discovered within the enclosure package or plenum area, clean them up immediately.