16811

Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA
Telephone: (818) 734-5300 • Fax: (818) 734-5320 • Website: www.capstoneturbine.com
Work Instructions
Powerhead Replacement
Capstone Model C200 MicroTurbine®/C1000 Series
Purpose and Scope

This document describes the procedure to replace the powerhead on all Capstone Model
C200 MicroTurbine® and C1000 Series microturbine engines. Only Certified C200
Powerhead Replacement ASPs are authorized to perform these procedures.
Guidelines
Review entire procedure prior to performing. Ensure you have all material, tools/equipment,
and reference documents on hand.
Conduct maintenance in a clean, well-lighted area using normal shop tooling to avoid
damage to delicate components.
Retain all parts removed for use in re-assembly, unless otherwise specified.
Safety Procedures
Become familiar with general safety precautions in the Capstone Model C200 MicroTurbine®
User’s Manual (400008) and Capstone C1000 Series User’s Manual (400024). Follow all
warnings and cautions in this work instruction.
Symbols
The following symbols are used throughout Capstone documents to alert you to potential
hazards to people or equipment and tips for proper operation of the equipment.
ELECTRICAL WARNING: Identifies an electrical hazard that can result in personal
injury or death.
WARNING: Identifies a hazard that can result in personal injury or death.
CAUTION: Alerts you to a hazard that can result in equipment damage.
NOTE: Clarifies instructions or highlights important information.
440316 Rev A (November 2013) Page 1 of 18

This information is proprietary to Capstone Turbine Corporation. Neither this document nor the information contained herein shall be copied, disclosed to others, or used for any
purposes other than the specific purpose for which this document was delivered. Capstone reserves the right to change or modify without notice, the design, the product
specifications, and/or the contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction.
Copy is uncontrolled; user is responsible for verifying current revision.
C200/C1000 Work Instructions: Powerhead Replacement
Material Information
The part being replaced is one of the powerhead assemblies listed below.
Part # Description Qty

524699-1XX SUB ASSY, POWERHEAD, NG, C200 1
524700-1XX SUB ASSY, POWERHEAD, CARB, NG, C200 1
524701-1XX SUB ASSY, POWERHEAD, MBTU, C200 1
524702-1XX SUB ASSY, POWERHEAD, LBTU, C200 1
514505-XXX GASKET, POWERHEAD 1
516316-001 BOLT, 5/16-24UNFX3/4”,gr8, ZN 40
Required Tools and Equipment

Tools specific to this procedure are listed below. This list does not include tools required
for other procedures referenced in this work instruction. Refer to those other work
instructions and Capstone Recommended Tools (400003) for more detailed requirements
and recommendations.
 Overhead lift hoist/crane (minimum 12-feet lift height; minimum 2500 lb. capacity)
(Dual lifting heads required to un-crate and re-crate powerhead)
 Engine work stand with rotatable cradle
 2 X Hoist rings (McMaster-Carr part 3046T61)
 2 X Coupling nuts, 5/16-18 X 1-1/8 inch (McMaster-Carr part 90977A150)
 Lift sling, 2-leg with hook (McMaster-Carr part 9089T21)
 Capstone tool TL60399 lifting frame assembly with lift hooks and chains (lift tee)
 Capstone tool TL60299 C200 Turbine Build Fixture (powerhead support fixture)
 Engineer’s scraper/Gasket scraper
 Vacuum cleaner
 Nickel-based grease
 Personal Protective Equipment
• Mechanic’s gloves with lining
• Protective coveralls (long sleeves and long pants)
• Safety glasses with side shields
• Steel-toed shoes

Reference Documents
The following Capstone documents are referenced in these Work Instructions:
 440000 Microturbine Standard Maintenance Schedule
 400003 Recommended Tools, Capstone MicroTurbine
 400008 Capstone Model C200 MicroTurbine® User’s Manual
 400024 Capstone C1000 Series User’s Manual
 440193 Capstone Model C200/C1000 Gaseous Fuel Injector Replacement
 440200 C200/C1000 Engine Replacement Work Instructions
 440286 C200 Hazardous Location MicroTurbine Engine Replacement
 440304 C200/C1000 Combustor Liner Replacement512298 Field Service Report

Procedures
NOTE: Only Certified C200 Powerhead Replacement ASPs are authorized to
perform these procedures.
1. If necessary, refer to Work Instruction 440200 through step 2v as required, or Work

Instruction 440286 (Hazloc) through step 2t as required to remove engine from system.
2. Prepare special tools as follows. See Figure 1.
a. Assemble and set aside lift tee assembly.
b. Ensure powerhead support fixture is on flat, level, and stable surface.
NOTE: For additional stability, bolt powerhead support fixture to a flat, heavy,
wood or metal platform. Holes are provided in fixture for this purpose.
c. Slightly loosen powerhead support fixture clamp lug nuts and turn clamp lugs
outward. Leave nuts loose.
Lift Tee Holes for

Assembly Fixture
(shown Stabilizing
attached to Bolts
engine ready to
lift)
Powerhead
Support
Fixture
Figure 1 – C200/1000 Powerhead Replacement Special Tools
NOTE: The term “stabilizing tension” in these procedures means apply enough
tension with hoist to take up slack in the lift hardware and stabilize the load.
3. If a new powerhead is to be installed, proceed to step 4. If old powerhead will be removed
to replace combustor liner and then reinstalled, proceed to step 8.

4. Prepare new powerhead as follows.

a. Open crate and unwrap new powerhead to allow attachment of hoist rings and
coupling nuts.
b. Attach powerhead lift hardware to new powerhead as follows. See Figure 2 and
Figure 3.
Secondary Lift Lug
Hoist Ring (2 places)

Coupling Nut
(2 places)
Figure 2 – Powerhead Lift Hardware Attachment
(1) Fully thread coupling nuts to diagonally opposite generator through bolts, hand
tighten/snug with wrench.
(2) Fully thread hoist rings into coupling nuts, hand tighten/snug with wrench.
(3) Attach sling hooks to powerhead hoist rings.
(4) Attach lift lug to powerhead main cone bolt hole at TDC alignment mark.
TDC Alignment Mark
Attach secondary lift

lug here
Attach hoist rings/lift sling

to diagonally opposite
through bolts
Partially
Unwrapped
Powerhead
Figure 3 – Powerhead Hoist Attachment Points

c. Remove new powerhead assembly from crate as follows. See Figure 4.
Figure 4 – Powerhead Removal from Crate
(1) Attach primary hoist lift hook to powerhead lift sling.

(2) Attach secondary hoist lift hook to secondary lift lug.
(3) Using secondary lift lug, carefully lift new powerhead assembly completely out
and clear of crate. Keep stabilizing tension on primary lift chain/sling and guide
powerhead during lift to avoid contact with crate sides.
(4) Remove any remaining protective wrapping material and all moisture absorption
material (desiccant packs).
(5) Use primary lift hoist to rotate powerhead to vertical position. Adjust secondary lift
tension to maintain safe and convenient load height.
(6) With powerhead in vertical position, lower powerhead assembly to support fixture.
Ensure turbine nozzle is centered over fixture. Guide and lower slowly to seat
powerhead squarely on fixture.
(7) Turn clamp lugs to secure powerhead to fixture. Tighten clamp lug nuts. See
Figure 5.
CAUTION: While powerhead is mounted to support fixture, cover open end of

inlet shroud to reduce the possibility of shop debris or other material entering
powerhead inlet. Failure to observe this caution can result in equipment
damage.
Clamp Lugs
And Nuts
(3 places)
Powerhead
Support
Fixture
Figure 5 – Powerhead Supported on Fixture

(8) Relieve hoist tension and detach lift hook from powerhead lift sling.
(9) Remove lift sling, lift rings and coupling nuts from powerhead; remove secondary
lift lug.
(10) Reposition hoist as necessary.
(11) Temporarily cover open end of inlet shroud with clean protective material to
prevent dirt, dust or other debris from entering inlet area.
5. With engine and sub-frame removed and on stable work surface (shop floor, cart, etc.),
prepare engine for disassembly as follows.
WARNING: Potential irritant! Wear protective equipment to prevent contact with

thermal blanket, penetrating lubricant and anti-seize compound. Failure to
observe this warning can result in personal injury.
NOTE: Position engine and sub-frame assembly directly under hoist lift
hook/chain/cable. Later operations require straight vertical lift.
a. Disconnect fuel tubes from injectors per Work Instruction 440193.
b. Loosen fuel tubes at manifold. Do not disconnect. Move tubes to clear injectors. Do
not bend tubes.
c. Remove manifold and fuel tubes to reduce possible damage.
d. Disconnect igniter lead from exciter.
e. If applicable, loosen, detach and set aside dump valve tube, hose couplings and
clamps. See Figure 6.
Dump
Valve
Tube Hose Couplings
And Clamps
Figure 6 – Dump Valve Tube

f. Detach insulating blanket past exhaust outlet. See Figure 7.
Figure 7 – Insulating Blanket Partially Detached
g. Attach lift tee. See Figure 8.
Figure 8 – Lift Tee Attachment
(1) Attach hoist lift hook to lift tee ring. To balance load, attach to inner lift ring. See
Figure 9.
(2) Attach hooks and chains to engine lift rings.
Attach to this ring to

balance load if powerhead
is installed
Attach to this ring to balance

load if powerhead is not
installed
Figure 9 – Load Balancing Lift Rings

h. Apply stabilizing tension.

i. Loosen engine mount bolts (4). Maintain stabilizing tension, then remove engine
mount bolts and washers. Set bolts and washers aside. See Figure 10.
Engine Mount
Bolt And Washer
(4 Places)
Figure 10 – Engine Mount
j. Lift engine straight up off sub-frame, high enough to mount on engine work stand.
Position engine work stand under engine and adjust/lower engine to engine work
stand cradle. Attach engine to cradle with bolts and washers supplied with engine
work stand. Tighten bolts to secure engine. See Figure 11.
Figure 11 – Engine Mounted to Stand (Typical)
k. Lock engine stand cradle.

l. Relieve hoist tension. Detach lift tee hooks from engine lift points. Detach lift tee from
hoist hook and set lift tee aside.
m. Attach hoist lift hook to rear engine lift point, apply stabilizing tension.

n. Attach powerhead coupling nuts, lift rings and lift sling to powerhead assembly as
instructed in steps 4b(1) and 4b(2) above.
o. Unlock engine stand cradle, relieve hoist tension and rotate engine so powerhead
end is up. Lock engine stand cradle. Detach lift hook from engine lift ring. See Figure
12.
Figure 12 – Engine Stand Rotation
6. If a new powerhead will be installed, proceed to step 7. If old powerhead will be removed
to replace combustor liner and then reinstalled, proceed to step 8.
7. Remove inlet shroud as follows.
NOTE: If wires/cables are not labeled, label or color-code them before

disconnecting.
a. Label or color code generator leads and disconnect from terminal block(s). See
Figure 13.
Figure 13 – Generator Leads

b. Remove and set aside generator lead tube attaching screws, grommet, grommet
plates, lead tube and lead tube seal. See Figure 14.
Lead
Tube
Lead
Tube
Seal
Figure 14 – Lead Tube and Seal Removal
c. Remove and set aside inlet shroud bracket bolts (4). See Figure 15.
Inlet Shroud
Bracket Bolts
(4 places)
Figure 15 – Inlet Shroud Bracket Bolts
d. Carefully lift air inlet shroud from generator assembly, guiding generator leads
through access opening.

8. Remove powerhead as follows.

a. Fully thread coupling nuts to diagonally opposite generator through bolts, hand
tighten/snug with wrench.
b. Fully thread hoist rings into coupling nuts, hand tighten/snug with wrench.
c. Attach sling hooks to powerhead hoist rings.
d. Align hoist and lift hook directly over powerhead. Attach hoist lift hook to powerhead
lift sling. Apply stabilizing tension.
e. Remove and set aside all main cone flange bolts. See Figure 16.
Main Cone
Flange Bolts
Figure 16 – Main Cone Flange Bolts

(Shown with inlet shroud installed)
CAUTION: Do not allow bolts or flange clamp ring segments to fall into
recuperator. Failure to observe this caution can result in equipment damage.
f. Maintain powerhead vertical and slowly lift powerhead out of recuperator. When
powerhead assembly is clear of recuperator flange, remove and set aside main cone
flange clamp ring segments. See Figure 17.
Main Cone
Clamp Ring
Segments (4)
Figure 17 – Main Cone Flange Clamp Ring Segments

g. Lift powerhead completely out of recuperator. If powerhead will be replaced with

new assembly, lower old assembly into shipping crate (procedure is reverse of
step 4 above). If powerhead will be reinstalled after combustor liner replacement,
lower it onto support fixture as follows. See Figure 18.
(1) Lower powerhead assembly to support fixture. Ensure turbine nozzle is centered
over fixture. Guide and lower slowly to seat powerhead squarely on fixture.
(2) Turn clamp lugs to secure powerhead to fixture. Tighten clamp lug nuts.
Clamp Lugs
And Nuts
(3 places)
Powerhead
Support
Fixture
Figure 18 – Support Powerhead Assembly on Fixture
h. Ensure powerhead is stable in fixture, relieve hoist tension and detach hoist lift hook
from sling.
CAUTION: While powerhead is mounted to support fixture, cover open end of

inlet shroud to reduce the possibility of shop debris or other material entering
powerhead inlet. Failure to observe this caution can result in equipment
damage.
i. Temporarily cover open end of inlet shroud with clean protective material to prevent
dirt, dust or other debris from entering inlet area.
j. Remove old powerhead gasket from both recuperator flange and powerhead main
cone flange gasket surfaces with engineer’s scraper/gasket scraper. Thoroughly
clean gasket surfaces. Remove all traces of old gasket material, graphite residue, etc.
Use vacuum cleaner to remove any residual dust and particles from flange surface
and flange bolt holes. See Figure 19.
Main Cone
Flange
Remove
Gasket
Residue
Powerhead
Gasket
Figure 19 – Powerhead Gasket Removal

9. Install powerhead as follows.
CAUTION: Handle new powerhead gasket carefully. Do not crease or bend

gasket (other than normal installation flexing). A bent or creased powerhead
gasket will not seal correctly after assembly. Do not use a bent or creased
gasket. Failure to observe this caution can result in equipment damage.
a. Carefully install new powerhead gasket to recuperator flange. Align bolt holes
correctly. Note bolt hole pattern: three closely spaced holes at 12:00, 3:00, 6:00 and
9:00 positions, each group of three separated by seven wider spaced holes. See
Figure 20.
Closely
Spaced
Holes
(4 Places)
Figure 20 – Powerhead Gasket Installation

b. With powerhead mounted to support fixture, remove temporary protective covering
applied in previous step.
c. Attach hoist lift hook to powerhead lift sling.
d. Apply stabilizing tension.
e. Loosen powerhead support fixture clamp lug nuts and turn clamp lugs to release
powerhead from fixture. Maintain stabilizing tension.
f. Lift powerhead from support fixture and raise to working height.
g. Apply nickel-based grease to outer machined surface of powerhead turbine nozzle
and inner circumference of nozzle. See Figure 21.
Apply
nickel-
based
grease
here
and
here.
Figure 21 – Turbine Nozzle Lubrication

h. Position powerhead assembly directly over engine and lower powerhead assembly
into recuperator. While lowering, rotate assembly to align groove on main cone with
alignment mark on recuperator flange. See Figure 22.
Main Cone
Alignment
Groove
Recuperator
Flange
Alignment
Mark
Figure 22 – Powerhead Alignment Marks
i. Lower powerhead fully into recuperator. Guide and adjust assembly until it seats
squarely and completely. Ensure alignment marks and bolt holes align correctly.
CAUTION: Do not force-align powerhead with pin/parallel punches.

Recuperator flange bolt hole threads can be damaged. If alignment is difficult,
powerhead may not be seated squarely. Apply hoist tension to slightly lift
powerhead and allow easy alignment with pin punches. Failure to observe this
caution can result in equipment damage.
j. Maintain stabilizing tension and use pin punches or similar tools to align main cone
flange ring segments, powerhead gasket and recuperator flange. See Figure 23.
Pin/parallel
Punches
Figure 23 – Powerhead Alignment

(Shown with inlet shroud installed)

k. When bolt holes are aligned, hand start flange bolts. Relieve hoist tension to allow
hand tightening of bolts, adjusting alignment as necessary. Relieve hoist tension
completely as bolts are tightened. See Figure 24.
Figure 24 – Install Powerhead Bolts
l. If new powerhead was installed, reinstall inlet shroud as follows. If old powerhead is
reinstalled, proceed to step 9m.
(1) Carefully lower inlet shroud over generator section.
(2) Carefully pull generator leads through inlet shroud access hole.
(3) Install lead tube seal to generator lead tube with notched side down. Install lead
tube with seal into air inlet shroud, guiding generator leads through tube. Secure
with 2 screws.
(4) Install protective grommet and retaining plate.
(5) Replace any damaged terminal blocks with new. Secure with SEM screws.
(6) Attach generator leads to terminal blocks. Secure with locking hex nuts. Torque
to 61 in/lbs.
(7) Align inlet shroud support bracket bolt holes with main cone flange bolt holes
and hand start/hand tighten bolts.
m. Torque bolts in three stages to correctly seat powerhead gasket. Torque first stage
with cross pattern to 105 in-lbs. Torque second stage with cross pattern to 210 in-
lbs. Torque third stage in circular pattern ensuring 210 in-lbs. Do not over-torque.
n. Detach hoist lift hook from powerhead lift sling. Remove powerhead lift sling, lift rings
and coupling nuts.
10. Reattach engine to sub-frame as follows.
a. Attach hoist lift hook to rear engine lift ring. Apply stabilizing tension, unlock engine
stand cradle, rotate engine to horizontal position. Lock engine stand cradle.
b. Relieve hoist tension and detach hoist lift hook from engine lift ring.
c. Attach lift tee hooks to engine lift rings.
d. Attach hoist lift hook to lift tee lift ring.
e. Apply stabilizing tension.
f. Remove engine mount bolts.

g. Lift engine from engine stand and lower it on to engine sub-frame.

h. Align mounting holes, attach engine to sub-frame with bolts and washers removed in
step 5i. Ensure washers are correctly positioned in mounting holes. Hand tighten
bolts.
i. Relieve hoist tension, torque engine mounting bolts to 150 in-lbs.
j. Remove lift tee assembly.
k. Reattach insulating blanket to engine. Ensure uninsulated flap is outside, and secure
with spring retainers. See Figure 25.
Uninsulated Flaps
(Note double rows
of stitching)
Figure 25 – Insulating Blanket Installed
l. Reattach dump valve coupling hoses and clamps, if detached in step 5e.
m. Install fuel manifold and fuel tubes removed in step 5c.
n. Reattach fuel tubes to injectors per Work Instruction 440193.
o. Tighten fuel tubes at fuel manifold per Work Instruction 440193.
p. Reconnect igniter lead to exciter.
11. Refer to Work Instruction 440200 or Work Instruction 440286 (Hazloc) to install engine.
Responsibility
It is the responsibility of Capstone to:
• Make these procedures available to Certified C200 Powerhead Replacement
Authorized Service Providers so they can successfully complete this task.

It is the responsibility of the Certified C200 Powerhead Replacement Authorized Service

Provider to:
• Read this document, understand its contents, and effectively complete procedures.
• Explain service benefits provided to end user.
• Upon completion of service, submit a Field Service Report (512298) to
service@capstoneturbine.com.
Capstone Technical Support

If you have questions or need assistance, please contact Capstone Customer Service:
E-mail: service@capstoneturbine.com
Toll Free Telephone: (866) 4-CAPSTONE or (866) 422-7786
Direct Telephone: (818) 407-3600 • Fax: (818) 734-5382
Capstone Document Library

The latest revisions of all Capstone product documents are available on our website,
www.capstoneturbine.com . Select Document Library link under Quick Links box on lower left
side of home page.
Capstone values your feedback. Please email comments or suggestions for improving
documentation to techpubs@capstoneturbine.com and enter "Documentation" in the subject
line.
© 2013 Capstone Turbine Corporation. All rights reserved.


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Capstone Turbine Corporation • 21211 Nordhoff Street • Chatsworth • CA 91311 • USA

Telephone: (818) 734-5300 • Fax: (818) 734-5320 • Website: www.capstoneturbine.com

Purpose and Scope

WARNING: Identifies a hazard that can result in personal injury or death.

CAUTION: Alerts you to a hazard that can result in equipment damage.

NOTE: Clarifies instructions or highlights important information.

440316 Rev A (November 2013) Page 1 of 18

Part # Description Qty

Required Tools and Equipment

440316 Rev A (November 2013) Page 2 of 18

440316 Rev A (November 2013) Page 3 of 18

1. If necessary, refer to Work Instruction 440200 through step 2v as required, or Work

Lift Tee Holes for

Figure 1 – C200/1000 Powerhead Replacement Special Tools

440316 Rev A (November 2013) Page 4 of 18

4. Prepare new powerhead as follows.

Secondary Lift Lug

Hoist Ring (2 places)

Figure 2 – Powerhead Lift Hardware Attachment

TDC Alignment Mark

Attach secondary lift

Attach hoist rings/lift sling

Figure 3 – Powerhead Hoist Attachment Points

440316 Rev A (November 2013) Page 5 of 18

c. Remove new powerhead assembly from crate as follows. See Figure 4.

Figure 4 – Powerhead Removal from Crate

(1) Attach primary hoist lift hook to powerhead lift sling.

CAUTION: While powerhead is mounted to support fixture, cover open end of

Figure 5 – Powerhead Supported on Fixture

WARNING: Potential irritant! Wear protective equipment to prevent contact with

Figure 6 – Dump Valve Tube

440316 Rev A (November 2013) Page 7 of 18

f. Detach insulating blanket past exhaust outlet. See Figure 7.

Figure 7 – Insulating Blanket Partially Detached

g. Attach lift tee. See Figure 8.

Figure 8 – Lift Tee Attachment

Attach to this ring to

Attach to this ring to balance

Figure 9 – Load Balancing Lift Rings

440316 Rev A (November 2013) Page 8 of 18

h. Apply stabilizing tension.

Figure 10 – Engine Mount

Figure 11 – Engine Mounted to Stand (Typical)

k. Lock engine stand cradle.

440316 Rev A (November 2013) Page 9 of 18

Figure 12 – Engine Stand Rotation

NOTE: If wires/cables are not labeled, label or color-code them before

Figure 13 – Generator Leads

440316 Rev A (November 2013) Page 10 of 18

Figure 14 – Lead Tube and Seal Removal

Figure 15 – Inlet Shroud Bracket Bolts

440316 Rev A (November 2013) Page 11 of 18

8. Remove powerhead as follows.

Figure 16 – Main Cone Flange Bolts

Figure 17 – Main Cone Flange Clamp Ring Segments

440316 Rev A (November 2013) Page 12 of 18

g. Lift powerhead completely out of recuperator. If powerhead will be replaced with

Figure 18 – Support Powerhead Assembly on Fixture

CAUTION: While powerhead is mounted to support fixture, cover open end of

Figure 19 – Powerhead Gasket Removal

440316 Rev A (November 2013) Page 13 of 18

9. Install powerhead as follows.

CAUTION: Handle new powerhead gasket carefully. Do not crease or bend

Figure 20 – Powerhead Gasket Installation