- Load Haul Dump:
- R2900G (S/N: JLK1-828)
Introduction
Illustration 1 | g01051135 |
This publication contains the information to retrofit the battery isolation control on the R2900G (S/N: JLK) Load Haul Dump.
The supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for each standard machine. This supplement is used to determine the difference between the custom modifications and a standard machine.
The Service Manual and the Parts Manual that is available for the standard machine should be used if the service information is not in this supplementary product support literature.
Parts that are Required in Order to Install the Battery Isolation Control Group     | ||
---|---|---|
Qty     | Part Number     | Description     |
1     | 294-9918     | Battery Isolator Mounting Block     |
1     | 186-8345     | Frame - Battery Hold Down     |
4     | 288-3086     | Battery Hold Down Block     |
2     | 288-3087     | Battery Alignment Strip     |
4     | 8T-0389     | Locknut     |
4     | 8T-4896     | Hard Washer     |
2     | 9U-1399     | Battery Frame Retaining Rod     |
1     | 197-8820     | Alternator     |
1     | 298-2129     | Battery Isolator     |
2     | 295-5259     | Stud     |
2     | 295-5258     | Cover     |
1     | 311-4741     | Harness     |
1     | 314-7329     | Harness     |
1     | 310-4152     | Harness     |
2     | 9X-9730     | Batteries     |
1     | 311-4742     | Cable     |
1     | 311-4744     | Cable     |
1     | 311-4745     | Cable     |
1     | 311-4743     | Cable     |
1     | 311-4746     | Cable     |
1     | 307-0877     | Cable     |
1     | 313-3080     | Receptacle     |
1     | 307-0799     | Fuse Mounting Block     |
2     | 163-5831     | Tapping Block     |
1     | 295-5261     | Isolation switch     |
1     | 309-2354     | Plate     |
1     | 4P-7581     | Clip     |
1     | 163-5531     | Tie     |
2     | 253-6273     | Insulator Clamp     |
1     | 7X-0311     | Bolt     |
1     | 1L-5081     | Spacer     |
3     | 6D-4246     | Clip     |
1     | 5S-7379     | Bolt     |
2     | 8T-4896     | Hard Washer     |
1     | 033-8248     | Clip     |
1     | 5M-3062     | Bolt     |
1     | 311-3771     | Dash     |
Note: Check the alternator fitted to the machine. The machine must be fitted with a 95 amp Alternator.
ReferenceDisassembly and Assembly, RENR8556, "R2900G Load Haul Dump Machine Systems"
ReferenceSpecial Instruction, REHS1841, "General Welding Procedures"
Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas. |
NOTICE |
---|
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
Preparation for Battery Compartment Modification
- Move the machine to a hard, level location, that is away from operating machines and away from personnel.
- Install the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Remove and Install".
- Lower the bucket to the ground.
- Engage the parking brake.
- Stop the engine.
- Turn the battery disconnect switch to the OFF position.
- Drain the fuel tank into a suitable container for storage or disposal.
- Remove cover (2) .
Illustration 2 | g01349270 |
Standard battery compartment (1) Fuse (2) Cover (3) Batteries (4) Battery hold down frame (5) Receptacle (6) Cable |
- Remove the cables from batteries (3) and fuse (1). Discard cables with the exception of cable (6) .
- Remove fuse (1) .
Note: Fuse (1) to be relocated.
- Remove receptacle (5) and discard.
- Remove battery holding down clamp (4) and discard.
- Remove two batteries (3) and discard.
- Remove four battery location angle brackets (A) .
Illustration 3 | g01349640 |
View of the battery compartment (A) Battery location angle bracket (B) Tapping block (C) Fuse mounting block |
Note: Before working on the fuel tank refer to Special Instruction, REHS1841, "Welding on Fuel Tanks" .
- Remove two tapping blocks (B) .
- Remove fuse mounting block (C) .
Note: Leave a flat finish on all surfaces after removal.
Battery Compartment Modifications
- Weld items (3) through (8) to the base of the battery compartment. Refer to Illustration 4.
Illustration 4 | g01349645 |
Battery compartment modification (1) Datum line is the internal face of the battery compartment (2) Datum line is the internal face of the battery compartment (3) 307-0799 Fuse Mounting Block (4) 294-9918 Battery Isolator Mounting Block (5) 163-5831 Tapping Block (6) 288-3086 Battery Hold Down Block (7) 288-3087 Battery Alignment Strip (8) 163-5831 Tapping Block (A) 559 mm (22.00 inch) (B) 429 mm (16.89 inch) (C) 354 mm (13.93 inch) (D) 245 mm (9.64 inch) (E) 198 mm (7.79 inch) (F) 55 mm (2.16 inch) (G) 5 mm (0.20 inch) (H) 96 mm (3.78 inch) (J) 153 mm (6.02 inch) (K) 231 mm (9.09 inch) (L) 438 mm (17.24 inch) (M) 664 mm (26.14 inch) (N) 145 mm (5.71 inch) (P) 329 mm (12.95 inch) |
Battery Hold Down Modifications
- Remove four mounting tabs (2) .
Illustration 5 | g01350286 |
Battery hold down modification (1) 186-8345 Frame - Battery Hold Down (2) Mounting tab (A) 264 mm (10.3937 inch) (B) 75 mm (2.9527 inch) |
- Reattach the four mounting tabs (2) to battery hold down frame (1). Refer to Illustration 5.
Battery Isolator Installation
- Install two studs (1) and two covers (2) to battery isolator (3) .
Illustration 6 | g01352170 |
Battery isolator (1) 295-5259 Stud (2) 295-5258 Cover (3) 298-2129 Battery Isolator |
- Install 298-2129 Battery Isolator (3) to the mounting block.
Illustration 7 | g01524293 |
Battery compartment with the new batteries and battery isolator installed (3) 298-2129 Battery Isolator (4) 9U-1399 Rod (5) 8T-4896 Hard Washer (6) 8T-0389 Locknut (7) 186-8345 Frame - Battery Hold Down (8) 9X-9730 Battery Gp |
- Position two 9U-1399 Rods (4) .
- Install two 9X-9730 Batteries (8) .
- Install 186-8345 Frame - Battery Hold Down (7) .
- Install 216-9890 Fuse (9) .
Illustration 8 | g01352683 |
Battery compartment with relocated fuse and new receptacle installed (9) 216-9890 Fuse (10) 313-3080 Receptacle (11) 5M-3062 Bolt (12) 8T-4896 Hard Washer |
- Install 313-3080 Receptacle (10) .
- Install items (14) through (21). Refer to Illustration 9 and Illustration 10.
Illustration 9 | g01352672 |
Battery compartment with new cables installed (13) 311-4741 Harness (14) 311-4745 Cable (15) 311-4743 Cable (16) 307-0877 Cable (17) 311-4744 Cable (18) 4P-7581 Clip (19) 163-5531 Tie (20) 311-4746 Cable (21) 311-4742 Cable (22) 7X-0311 Bolt (23) 253-6273 Insulator Clamp (24) 1L-5081 Spacer (25) 6D-4246 Clip (26) 8T-4896 Hard Washer (27) 5S-7379 Bolt (28) 033-8248 Clip |
Illustration 10 | g01352692 |
Inside view of rear frame (15) 311-4743 Cable (21) 311-4742 Cable |
- Install 311-4741 Harness (13). Refer to Illustration 9.
- Install 314-7329 Harness (29). Refer to Illustration 11 and Illustration 12.
Illustration 11 | g01355033 |
Side view of engine (13) 311-4741 Harness (19) 163-5531 Tie (29) 314-7329 Harness |
Illustration 12 | g01355035 |
Rear view of engine (19) 163-5531 Tie (29) 314-7329 Harness |
- Install seven 163-5531 Ties (19) .
- Install 310-4152 Harness (30). Refer to Illustration 13 through Illustration 15.
Illustration 13 | g01356492 |
Frame side view (19) 163-5531 Tie (30) 310-4152 Harness |
Illustration 14 | g01356498 |
Outside view of cab (standard wiring) (31) 241-8368 Magnetic Switch |
Illustration 15 | g01356495 |
Outside view of cab ( 310-4152 Harness installed) (30) 310-4152 Harness (31) 241-8368 Magnetic Switch |
- Install ground (F) .
Illustration 16 | g01356499 |
Inside view of cab (behind dash) (30) 310-4152 Harness |
- Install 311-3771 Dash (34) .
Illustration 17 | g01353089 |
View of dash panel (32) 295-5261 Isolation switch (33) 309-2354 Plate (34) 311-3771 Dash |
- Install 197-8820 Alternator if not already installed.
Operation of the Battery Isolation Control
Illustration 18 | g01365699 |
Use the battery isolation control in order to isolate the electrical system. The battery isolation control is a push-pull type switch.
Battery Isolation Control - Pull battery isolation control knob outward to the OFF position in order to isolate the electrical system. Push the battery isolation control knob inward to the ON position in order to connect the electrical system. |
Battery Isolation Control
Illustration 19 | g01441965 |
The components of the battery isolation control are the batteries, main fuse, battery disconnect switch, battery electrical isolator, battery isolation switch and main relay magnetic switch.
Illustration 20 | g01441966 |
(1) Main fuse (2) Battery electrical isolator (3) Batteries |
Illustration 21 | g01441968 |
(4) Battery isolation switch |
Illustration 22 | g01441969 |
(5) Main relay magnetic switch |
Illustration 23 | g01441970 |
(6) Battery disconnect switch |
When battery disconnect switch (6) is in the ON position, the contacts in battery disconnect switch (6) are closed and connect 24 volt ground from batteries (3) to battery electrical isolator (2). When battery isolation switch (4) is in the ON position the contacts of battery electrical isolator (2) are closed, and connect 24 volt power and 24 volt ground from batteries (3) to the machine electrical system and to main relay magnetic switch (5) .
When battery isolation switch (4) or battery disconnect switch (6) are moved to the OFF position, contacts in battery electrical isolator (2) open and disconnect the 24 volt power and 24 volt ground from batteries (3) to the machine electrical system.
If battery disconnect switch (6) is used to isolate the machine electrical system, it will then be necessary to reset battery electrical isolator (2) by cycling battery isolation switch (4) before 24 volt power can be reconnected to the machine electrical system.
Note: Do not move the battery isolation switch to the OFF position while the engine is running. Machine electrical system damage could result.