Assembling and Installing a Selective Catalytic Reduction (SCR) Module for Certain C175-16 Generator Sets{1050, 1091} Caterpillar

Engine:

C175-16 (S/N: WYC1-UP)

Introduction

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

This Special Instruction describes the procedures required in order to install the Selective Catalytic Reduction (SCR) Module on the above generator sets. Wiring harnesses and lines groups connecting to the dosing cabinet have additional length to allow routing to any of the four corners.

Note: The additional length must be bundled in a way that prevents any trip hazards.

Required Parts

Assembly of the 363-2739 Mounting Frame Gp

The frame group is designed to support the SCR, positioning the SCR over the generator set. The mounting surface must conform to the guidelines found in Mounting- Application & Installation Guide, LEBW4974 for strength and flatness. The publication is available at the Electronic Media Center.

Illustration 1	g03324120
(1) 363-2739 Mounting Frame Gp

Attach a suitable lifting device in order to position the frame group in place. The frame group weighs approximately 430 kg (946 lb).

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Illustration 2	g03324492
(2) 8T-4193 Bolt (3) 3E-4356 Hard Washer (4) 363-2769 Support As (5) 363-2740 Support As

1. Tighten bolts (2) to a torque of 100 ± 20 N·m (74 ± 15 lb ft).

2. There are multiple heights of frame (1) which is determined by what package you have.
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   Illustration 3	g03328534

   1. Position one is without isolators.
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   Illustration 4	g03328546

   2. Position two is with rubber isolators.
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   Illustration 5	g03328564

   3. Position three is with spring isolators.
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   Illustration 6	g03328626

   4. Position four is with seismic isolators.

Assembling the 363-2070 Air Cleaner Mounting

Illustration 7	g03329107
(1) 296-1291 Support As (2) 8T-4192 Bolt (3) 8T-4223 Hard Washer

1. Install support assembly (1) with bolt (2) and hard washer (3). Torque bolt (1) to 100 ± 20 N·m (74 ± 15 lb ft).

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Illustration 8	g03329135
(4) 296-1292 Support (5) 8T-4195 Bolt (6) 7X-7729 Washer (7) 8T-4133 Nut

2. Install supports (4) with bolt (5), washer (6), and nut (7). Torque bolt (5) to 55 ± 10 N·m (41± 7 lb ft).

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Illustration 9	g03329144
(8) 162-2177 Hose (9) 5P-3860 Hose Clamp (10) 258-8009 Turbocharger Gp (11) 374-8151 Tube As (12) 8T-4182 Bolt (6) 7X-7729 Washer (13) 4S-5719 Spacer (7) 8T-4133 Nut (14) 374-8152 Tube As (15) 374-8153 Tube As

3. Install hose (8) to turbocharger (10) with hose clamp (9).

4. Install tube assembly (11), (14), and (15) to hose (8) with clamp (9) .

5. Install bolt (12), washer (6), spacer (13), and nut (7) .

6. Torque bolt (12) to 55 ± 10 N·m (41 ± 7 lb ft).

7. Torque clamp (9) to 7.5 ± 1 N·m (66 ± 9 lb in).

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Illustration 10	g03329181
(16) 371-7116 Plate As (17) 8T-4140 Bolt (18) 3E-4356 Hard Washer (19) 371-7114 Support As (20) 371-7118 Support As (21) 8T-4956 Bolt (22) 8T-4223 Hard Washer

8. Install plate assembly (16) with bolt (17) and hard washer (18). Torque bolt (17) to 240 ± 40 N·m (177 ± 30 lb ft).

9. Install support assembly (19) and (20) loosely with bolt (21) and hard washer (22).

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Illustration 11	g03329323
(23) 273-3538 Hose (9) 5P-3860 Hose Clamp (24) 371-7112 Tube

10. Install hose (23) with clamp (9), then install tubes (24) to hose (23) with hose clamp (9). Torque clamp (9 ) to 7.5 ± 1 N·m (66 ± 9 lb in).

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Illustration 12	g03329528
(21) 8T-4956 Bolt (22) 8T-4223 Hard Washer

11. Torque bolts (21) to 100 ± 20 N·m (74 ± 15 lb ft) now that tube (24) has been installed.

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Illustration 13	g03329366
(17) 8T-4140 Bolt (18) 3E-4356 Hard Washer (25) 371-7117 Plate As (26) 8T-0207 Bolt (27) 9X-8257 Washer (28) 8T-4132 Nut (29) 371-8147 Support As

12. Install plates (25) with bolt (17) and washer (18). Then install support assembly (29) with bolt (26), washer (27), and nut (28). Torque bolt (17) and (26) to 240 ± 40 N·m (177 ± 30 lb ft).

Assembling the 288-8380 Air Cleaner Gp

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Illustration 14	g03329396
(1) 287-1530 Air Cleaner Gp (2) 296-1292 Support (3) 8T-4195 Bolt (4) 7X-7729 Washer (5) 8T-4133 Nut (6) 8T-4192 Bolt (7) 8T-4223 Hard Washer (8) 296-1291 Support As (9) 113-1587 Reducer Hose (10) 8T-4196 Bolt (11) 5P-0600 Hose Clamp (12) 5P-3860 Hose Clamp

1. Install support assembly (8) with bolt (6) and hard washer (7). Torque bolt (6) to 100 ± 20 N·m (74 ± 15 lb ft).

2. Install support (2) with bolt (3), washer (4), and nut (5). Torque nut (5) to 55 ± 10 N·m (41 ± 7 lb ft).

3. Install air cleaner (1) with reducer hose (9), clamp (11), clamp (12), bolt (10) and washer (4). Torque clamps (11) and (12) to 7.5 ± 1 N·m (66 ± 9 lb in).

Mounting the 374-2497 Selective Catalytic Reduction Module Ar

Illustration 15	g03324625
(1) 374-2497 Selective Catalytic Reduction Module Ar

1. Attach a suitable lifting device in order to position the catalytic converter into place. The catalytic converter group weighs approximately 2540 kg (5560 lb).

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Illustration 16	g03324566
(2) 8T-4141 Bolt (3) 8T-5439 Hard Washer (4) 8T-4131 Nut (Not Shown)

2. Tighten bolt (2) to nut (4) to a torque of 240 ± 40 N·m (177 ± 30 ft).

Assembling the 356-1583 Control Wiring Gp

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Illustration 17	g02465148
(1) 355-4860 Plate As (2) 8T-4908 Bolt (3) 5P-4115 Hard Washer (4) 5C-7261 Nut

1. Place a hard washer (3) on each side of the plate (1). Tighten the bolts (2) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).

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Illustration 18	g02465302
(5) Control box (6) 356-1578 Engine Harness As (7) 156-6175 Clip (8) 174-9194 Bolt (9) Generator group

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Illustration 19	g02468017
(10) 7K-1181 Cable Strap

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Illustration 20	g02468397
(7) 156-6175 Clip

2. Tighten straps (10) to an approximate tension of 250 - 290 N (56 -65 lb).

   Tighten bolts (8) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).

Assembling the 384-7858 Control Wiring Gp

Illustration 21	g03325881
(1) 7K-1181 Cable Strap (2) 356-1578 Control Harness As (3) 156-6175 Clip (4) 4P-8134 Clip

Illustration 22	g03325926
(5) 8T-4133 Nut (6) 7X-7729 Washer (7) 091-9035 Spacer (8) 8M-2773 Clip (9) 8T-6466 Bolt (10) 5M-2894 Hard Washer

Assembling the 384-7859 Engine Wiring Gp

Illustration 23	g03325953
(1) 7K-1181 Cable Strap (2) 356-1578 Control Harness As (3) 156-6175 Clip

Illustration 24	g03325951
(4) 8T-4133 Nut (5) 7X-7729 Washer (6) 091-9035 Spacer (7) 8M-2773 Clip (8) 8T-6466 Bolt (9) 5M-2894 Hard Washer

Assembling the 373-6531 Exhaust Connection Gp

Illustration 25	g03325757
(1) 6V-8133 Bolt (2) 288-3717 Hard Washer (3) 7X-0851 Nut (4) 155-5996 Gasket (5) 353-8081 Bellows As (6) 319-3917 Exhaust Adapter (7) 3E-2331 Plug (8) 151-2115 Seal Washer (9) 8T-0357 Bolt (10) 9X-8268 Washer (11) 8T-1757 Nut (12) 266-2451 Exhaust Gasket (13) 356-3254 Tube As (14) 356-3255 Tube As

1. Apply Loctite C5A copper anti-seize to (1) and (9) before assembly.

Assembling the 374-1548 Exhaust Shield Gp

Illustration 26	g03325830
(1) 373-1967 Manifold Shield (2) 373-7604 Manifold Shield (3) 373-7604 Manifold Shield (4) 373-1966 Manifold Shield

Assembling the 373-3738 Exhaust Shield Gp

Illustration 27	g03325838
(1) 371-4316 Manifold Shield (2) 371-4313 Manifold Shield (3) 371-4314 Manifold Shield (4) 372-2852 Manifold Shield (5) 371-4315 Manifold Shield (6) 371-4311 Manifold Shield