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The Power Train Electric Drive System and the Accessory Power System will contain hazardous voltage levels during machine operation and for a period of time after machine shutdown. Do not remove any covers that will expose energized electrical components while the engine is operating. Do not remove any covers that will expose the energized electrical components while the components remain energized following an engine shutdown. Do not perform any type of electrical maintenance on the orange hazardous voltage conductors, the power train components or the accessory power system components while the engine is operating. Do not perform any type of electrical maintenance on the orange hazardous voltage conductors, the power train components or the accessory power system components while the components remain energized following an engine shutdown. Always perform the safe shutdown and de-energizing procedure before performing electrical service on the Power Train Electric Drive System or the Accessory Power System. Failure to follow these instructions could result in personal injury or death. |
READ AND FOLLOW THESE PROCEDURES IN ORDER TO ENSURE PERSONNEL THAT PERFORM SERVICE OR MAINTENANCE ON THE MACHINE ELECTRICAL SYSTEMS OR THE MACHINE MECHANICAL SYSTEMS ARE ACTING IN A SAFE MANNER.
When the machine is to be serviced after the Engine has been in operation, perform this Safe Shutdown Procedure in order to ensure that the residual voltage in the electrical power train systems and the accessory power systems are at a safe voltage level before any work is performed.
Note: When a service procedure must be performed after the machine has not been operated for a period of time, the “Hazardous Voltage Lamp Test” that is presented after the Safe Shutdown Procedure should be performed first in order to verify the Hazardous Voltage Lamp is operating correctly.
Note: If you are not sure which components are used in the Power Train Electric Drive System and the Accessory Power System, do not perform maintenance on the machine. Refer to the Systems Operation, "Power Train Electrical System" in order to identify the components that are involved.
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| Illustration 1 | g01861541 |
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The Ground Disconnect Switch and the Hazardous Voltage Present Lamp located under the access cover on the left fender of the machine. | |
Note: The amber Hazardous Voltage Present Lamp (2) monitors the voltage levels of the DC Power Bus voltage and the DC Accessory Power Bus voltage at all times. When hazardous voltage levels are present the lamp is illuminated. When the key start switch is moved to the OFF position the Hazardous Voltage Present Lamp (2) will remain illuminated until the voltage level in the DC system is at a safe level (50.0 VDC or less). The Hazardous Voltage Lamp (2) will turn OFF when the voltage is at a safe level. The Hazardous Voltage Present Lamp circuit operates regardless of the state of the disconnect switch.
- Turn the key start switch to the OFF position.
- Access the disconnect switch (1) and the Hazardous Voltage Present Lamp (2) that are located under the access cover on the left-hand fender of the machine.
- Observe the state of the amber Hazardous Voltage Present Lamp (2). If the lamp IS ILLUMINATED, do not perform any type of service on the machine. Wait until the lamp is NOT ILLUMINATED. Then, perform the Hazardous Voltage Lamp Test in the next step.
- Once operation of the Hazardous Voltage Present Lamp (2) has been checked and the lamp operation is verified, the disconnect switch (1) can be turned to the OFF position. The machine can now be serviced.
Note: When the machine is operating and a problem is detected in the Hazardous Voltage Present Lamp circuit, an error message will be activated on the Monitoring System Display. The Implement Control ECM will activate a CID 3242 diagnostic code in order to indicate the abnormal condition in the lamp circuit. When a diagnostic code is activated for the lamp circuit, refer to the Implement Electronic Control System, KENR5165 Service Manual. Perform the troubleshooting procedure for the active CID 3242 diagnostic code in order to correct the problem. The Caterpillar Electronic Technician (Cat ET) Service Tool or the Monitoring System Display can be used to monitor the voltage levels of the DC Power Bus and the DC Accessory Power Bus. The voltage levels for each bus circuit must be below 50.0 VDC before the machine can be serviced.
Hazardous Voltage Present Lamp Test
Note: When an electrical service procedure must be performed, the “Hazardous Voltage Lamp Test” should be performed in order to verify the Hazardous Voltage Lamp (2) is operating correctly.
In order to check the operation of the Hazardous Voltage Present Lamp (2), perform the following lamp test when the Engine is OFF and the lamp is NOT ILLUMINATED.
- Access the disconnect switch (1) and the Hazardous Voltage Present Lamp (2) located under the access cover on the left-hand fender of the machine.
- While observing the Hazardous Voltage Present Lamp (2), turn the disconnect switch (1) to the OFF position and then turn the disconnect switch (1) to the ON position.
- When the disconnect switch (1) is turned to the ON position the amber Hazardous Voltage Present Lamp (2) will illuminate briefly and then turn OFF. This indicates that the lamp circuit is operating correctly and the voltage in the medium voltage system is at a safe level.
Incorrect operation of the Hazardous Voltage Present Lamp (2) can be indicated by the following lamp conditions:
- When the engine is running, the Hazardous Voltage Present Lamp (2) is NOT ILLUMINATED.
- When the key start switch is in the OFF position, the Hazardous Voltage Present Lamp (2) IS ILLUMINATED and DOES NOT TURN OFF after a period of more than ten seconds, however, this could take as long as five minutes under some circumstances.
- When the key start switch is in the OFF position and the lamp test is performed (disconnect switch (1) is cycled from OFF to ON), the Hazardous Voltage Present Lamp (2) does NOT ILLUMINATE briefly and then turn OFF.
If any of these Hazardous Voltage Present Lamp (2) conditions are present, use the Caterpillar Electronic Technician (Cat ET) Service Tool or use the Monitoring System Display to monitor the voltage levels of the DC Power Bus and the DC Accessory Bus systems. The voltage levels of these systems must be below 50.0 VDC before the machine can be serviced.
For troubleshooting the Hazardous Voltage Present Lamp circuit, refer to the Implement Electronic Control System, KENR5165 Service Manual. Perform the troubleshooting procedures for the CID 3242 diagnostic code.