MOTOR-ELECTRIC 5208338 - Caterpillar

Introduction
The problem that is identified below does not have a permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
Certain engine modules (EIM's) fitted to the following generating sets: C2.2, C3.3, C4.4 and C6.6 fail resulting in the engine not starting. Also, in some cases, an unexpected shutdown can occur and the engine will not start afterwards.Solution
The high voltage that is produced by an operating generator set can cause severe injury or death. Before performing any maintenance or repairs, ensure that the generator will not start.Place the engine control switch in the "OFF" position. Attach "DO NOT OPERATE" tags to all starting controls. Disconnect the batteries or disable the starting system. Lock out all switchgear and automatic transfer switches that are associated with the generator.
Only persons with training in electrical installations must carry connections to the generator.The generator must be wired correctly. A fire or electrocution could result from wiring that is incorrect.The generator is capable of generating high voltages. Ensure that the generator is not on while the connections are being made. Follow these two steps in order to prevent accidental starting:
Isolate the DC breaker.
Disconnect the DC supply battery.
High voltage may be present. The power source must be disconnected before working on the equipment. Failure to disconnect the power source could result in injury or death. Verify that the equipment is not energized before performing any maintenance. This work must be performed by trained personnel with correct tools and procedures.
Bodily contact with electrical potential can cause bodily injury or death.To avoid the possibility of injury or death, ensure that the main power supply has been disconnected before performing any maintenance or removing any modules.
Note: Isolate the generator set before commencing any work on the unit and open the generator set breaker. Next, activate the emergency stop and disconnect the auxiliary power supply for the battery charger and heaters. Disconnect the battery cables. Ensure that 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 before commencing any type of work.
Illustration 1 g02161674
(1) Plastic connectors
Disconnect the engine harnesses by unplugging plastic connectors (1) as shown in Illustration 1.
Illustration 2 g02161675
(1) Plastic connectors (2) Rubber boot
Using a suitable tool, separate rubber boot (2) from each plastic connector (1) as shown in Illustration 2. Ensure that the correct personal protective equipment is worn to prevent any injury.
Illustration 3 g02161676
(1) Plastic connectors (3) Pin connection
Reconnect the engine harness to the EIM by plugging plastic connectors (1) into the EIM as shown in Illustration 3. Ensure that all connections are made by pushing in each pin connection (3) using a pair of needle nose pliers.
Illustration 4 g02161677
Reposition the rubber boots over the connectors and EIM as shown in Illustration 4
Reconnect the auxiliary power supply for the battery charger and heaters, and battery cables. Run the generating set and check for correct operation of the EIM.