PLATE 3590250 - Caterpillar

Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
During various machine operations, the Hazardous Voltage (HV) lamp may turn off intermittently. The problem may cause intermittent fault code 3242-5, "High Voltage System Energized Indicator: Current Below Normal". The HV lamp should always remain on while the machine is in operation and after key-off, until the hazardous voltage has been dissipated from the machine.The HV lamp protection circuitry is triggered by high frequency noise in the HV lamp wiring harness which causes the HV lamp to shut off momentarily.Solution
If after following the troubleshooting guide for code 3242-5, the problem remains, follow the instructions below to install a high frequency filter harness assembly to HV lamp wire 204 at the battery negative terminal.Repair Procedure
Table 1
Required Parts List    
Item     Qty     Part Number     Description    
1     1     453-0940     Harness As (1)    
2     2     7K-1181     Cable Strap    
-     1     9X-3402     Connector Socket    
-     1     155-2270     Connecting Plug Kit    
-     1     8T-8737     Seal Plug    
( 1 ) Refer to Special Instruction REHS8559-00 "Installation Procedure for a High Frequency Filter Harness Assembly on D7E Track-Type Tractors" to create the 435-0940 Harness Assembly .
Illustration 1 g03568288
(1) 453-0940 Harness As
Illustration 2 g03568289
(A) Pin 1 - populated (Wire 204) (B) Pin 2 - empty (White rubber plug)
There is a 16 gauge black wire (labeled "204-CH327") that runs from the negative terminal of the battery to the Auxiliary Power Converter (APC). Remove the 204 wire from the negative battery terminal. Cut off the lug, attach the 9X-3402 Connector Socket and install a 2-pin DT 155-2270 Connecting Plug Kit in pin 1. In pin 2, install a white 8T-8737 Seal Plug .
Illustration 3 g03568290
Illustration 4 g03568291
Electrical Schematic at Battery showing 204-CH327 Wire
Install the lug of the harness assembly (1) onto the battery negative terminal.
Plug in the harness assembly (1) to the modified 204 wire.
Use cable straps (2) to secure harness assembly (1) .