ENGINE AR-COMPLETE 3098103 - Caterpillar

Illustration 6 g01835233
Controller Panel (14) "Resistor Cover"Refer to the System Schematic, KENR8247. Refer to resistors "Power Resistor 2" and "Power Resistor 1" in the system schematic. The adjustment of the jumper wire (115-WA1-RD) has been adjusted too close to wire (116-A66-RD). This will result in a high generator output voltage. Also, this will result in a generator overload. The adjustment wire must be moved upward in order to decrease the output voltage.Note: There is no electrical shock hazard in this circuit (24 VDC), but the resistors can be very hot. Use care and the proper equipment.
Set the 146-4080 Digital Multimeter on auto setting or set the multimeter on the 400 VDC scale. Connect the positive test lead to Positive Stud "PDB 151" and the negative test lead to the Negative Stud "PDB 152".
Run the engine and the generator at the normal speed. Depress the lift switch on the RH joystick. Observe the voltmeter.
Read the voltage after the boost cycle is completed. This is approximately 3 seconds after the lift switch was depressed.Note: The Positive Stud "PDB 151" must be positive for the Lift cycle.
Move the adjustment wire (115-WA1-RD) in order to adjust the generator output voltage to between 235 5 VDC. Expected Result:The generator output voltage is 235 5 VDC.Results:
YES - The generator output voltage is 235 5 VDC.STOP
NO - The generator output voltage is not 235 5 VDC. Proceed to test step 9.Test Step 9. DETERMINE IF THE GENERATOR IS OVERHEATED DUE TO POOR VENTILATION
Illustration 7 g01833973
Top View of Generator (8) Duct for Outlet Air (9) Inlet Brush Cover
Inspect the area around the generator inlet (9) and the outlet (8) ventilation openings for obstructions to the airflow. Remove any obstructions.
Depress the drop switch on the LH joystick. Turn the engine to the OFF position. Ensure that the generator is not rotating.
Remove the ventilation cover and the inspection cover from the generator. Inspect the area for dirt accumulation that will reduce airflow and cooling. Expected Result:The generator inlet ventilation openings are clean. The generator outlet ventilation openings are clean.Results:
YES - The generator inlet ventilation and the generator outlet ventilation openings are clean and free of obstructions. Proceed to test step 10.
NO - The generator inlet ventilation openings and the generator outlet ventilation openings are dirty and obstructed.Repair: Use low pressure and dry clean compressed air to dislodge the dirt. Collect the dirt with a vacuum cleaner.STOPTest Step 10. REPAIR THE OPEN CIRCUIT TO ECMThe generator is not overheated. ECM circuit to J1-70 (Wire 201-BK) is open. Repair the Controller harness or replace the Controller harness. Refer to the Schematic, KENR8247.
Illustration 8 g01556873
Control Panel door handle
Depress the drop switch on the LH joystick. Turn the engine off before proceeding.
Open the disconnect switch with the external handle on the enclosure door. Then, open the enclosure door with a screwdriver with your left hand. Hold the external handle in the release position with your right hand.
Illustration 9 g01723035
Enclosure for the ECM
Set the 146-4080 Digital Multimeter to the lowest resistance scale. Connect one test