FLANGE 2P1012 - Caterpillar

Image1
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-1000 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 1.5-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
1. Isolate the generator set before commencing any work on the unit, open generator set breaker, activate Emergency Stop, disconnect the battery cables and either disconnect or open the control circuit breaker for the AC power supply to the battery charger. Ensure all health and safety requirements are adhered to at all times. Also, ensure proper Lock Out-Tag Out procedures are followed at all times while work is being performed on the machine. Lock out generator operation and disconnect/lockout all power sources before commencing any work.
2. Locate the DC terminal strip inside the AC/DC box. Refer to Image 1.1.1.
Image1.1.1
3. Install four 314-9098 Terminal Blocks and 372-6305 Signal Tag. Refer to Image1.1.1 and Image1.2.2.
4. Install 372-6306 Harness, connect wires on terminal blocks and insert harness inside the right hand panduit. Refer to Image1.2.1 and Image1.2.3.
5. Connect 372-6304 Harness on the left side of the terminal blocks. Refer to Image1.2.2 and Image1.2.3.
Image1.2.1
Image1.2.2
Image1.2.3
6. Remove the generator top box cover and side extension top covers. Route 372-6304 Harness from the AC/DC box to the EMCP 4 along the inside of generator box using tie straps to secure harness. Refer to Image1.3.1 and Image1.3.2.
Image1.3.1
Image1.3.2
7. Locate the EMCP 4.2 panel. Inspect EP-C1 8 pin connector on EMCP harness to ensure wire G408-EP (Black) is in pin 1 and wire G407-EP (Red) is in pin 2. Refer to Image1.4.1. If wires are not in the right location on the pins, swap the wires.
8. Inspect EP-C20 70 pin connector on the EMCP to ensure G408-EP (Black) is in pin 49 and wire G407-EP (Red) is in pin 59. Refer to Image1.4.1. If wires are not in the right location on the pins, swap the wires.
Image1.4.1
9. Connect LD-C1 (8 pin) connector on 372-6304 Harness to EP-C1 (8 pin) connector on EMCP 4.2 harness. Refer to Image1.5.1.
Image1.5.1
10. Perform a continuity test on the two RS485 wires coming from the EP-C20 (70 pin) connector located in the back of the EMCP4.2 panel (Image1.4.1) to the AC/DC box terminal block (Image1.2.3) to make sure that wiring is correct.
11. Install top box covers and tighten the bolts.