Troubleshooting Guide for the Battery Charger{751B} Caterpillar

Engine:

3306B (S/N: 8NS1-UP; LRW1-UP)

3412 (S/N: 2WJ1-UP; 4BZ1-UP)

3412C (S/N: DJN1-UP; 9EP1-UP; LRY1-UP)

3412E (S/N: TGC1-UP)

3508 (S/N: CNF1-UP; 5PW1-UP)

3508B (S/N: CNB1-UP; 4GM1-UP; 5KW1-UP)

3512 (S/N: YAF1-UP; ZAF1-UP; CMJ1-UP; 6WW1-UP; 67Z1-UP)

3512B (S/N: FDE1-UP; YAH1-UP; YAJ1-UP; 8RM1-UP; 6GW1-UP)

3516 (S/N: CMD1-UP; YAL1-UP; 8TW1-UP)

3516B (S/N: FDN1-UP; 6HN1-UP; YAP1-UP; YAR1-UP; YBR1-UP; 8NW1-UP; FDX1-UP)

C-15 (S/N: 6NZ1-UP)

C15 (S/N: C5E1-UP; C5L1-UP)

C18 (S/N: DKE1-UP)

C2.2 (S/N: NCB1-UP; N4C1-UP; XYE1-UP)

C3.3 (S/N: X3B1-UP; NCC1-UP; N3C1-UP; N3X1-UP)

C4.4 (S/N: XYC1-UP; NCD1-UP; N4D1-UP; XYD1-UP; NCE1-UP; N4E1-UP; N4X1-UP)

C6.6 (S/N: SDA1-UP; N6D1-UP)

G3406 (S/N: 4FD1-UP)

G3412 (S/N: KAP1-UP)

G3516 (S/N: CSZ1-UP)

C9 (S/N: X3R1-UP)

G3406 SI (S/N: KAR1-UP)

Generator Set:

3406 GEN SET (S/N: 4ZR1-UP)

3406C GEN SET (S/N: C2G1-UP; C5G1-UP; 1LS1-UP; 9ES1-UP; LRX1-UP)

3406E GEN SET (S/N: 8AZ1-UP)

3456 GEN SET (S/N: C1G1-UP; C3G1-UP; C4G1-UP; CAH1-UP; C2T1-UP; CBX1-UP)

C1.5 (S/N: NCA1-UP; N3B1-UP)

C15 GEN SET (S/N: CYY1-UP; X4R1-UP)

C18 GEN SET (S/N: G4C1-UP)

C2.2 GEN SET (S/N: N4B1-UP)

C32 GEN SET (S/N: WDR1-UP)

C9 GEN SET (S/N: C9E1-UP)

Introduction

This Special Instruction provides information in order to troubleshoot the replacement of battery chargers that can be placed on the machines that are listed above.

Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method or operating technique that is not specifically recommended by Caterpillar is used, you must ensure that it is safe for you and for other people to use.

You should ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance or the repair procedures that are used.

Show/hide table

Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

Show/hide table

Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

Show/hide table

Once the system is placed in automatic mode, blade movement may occur. Ensure that all personnel are clear of the blade before you place the system in automatic mode. Personal injury or death from crushing could occur.

Show/hide table

Do not operate this system unless you are fully trained on this equipment. To avoid injury, the machines park brake must be engaged prior to starting the calibration. Maintain adequate clearance from people and objects as the blade may move abruptly during automatic hydraulic valve calibration.

Parts List

Troubleshooting

24 Volt Open Chargers Can Overheat

Open chargers that are contained within a small, enclosed control panel may overheat. This is especially true for 24 volt chargers. Overheating can cause the potentiometer within the charger to fail. Open chargers that have improved components with fitted assemblies are stamped with a date from 13September 2007. These chargers are not approved by the Underwriters Laboratories Inc.. Also, open chargers that have a serial number break from 0709-1531 are fitted assemblies with the printed circuit board that have a version of 6.3. These chargers are not approved by UL. The new circuit boards allow the temperature compensation to be disabled by moving the jumper that is on the printed circuit board from "INT" to "NON". The new circuit boards can be placed in either vertical orientation regardless of the direction that is shown on the label.

Digital Warnings on the Control Panel

Battery chargers are equipped with circuitry for temperature compensation. Occasionally, the battery chargers will intermittently initiate an erroneous alarm for either a Low Battery Voltage or a High Battery Voltage. The erroneous alarms are attributed to the thresholds that are set for the alarms in the digital controller. The thresholds that have been set may be improper for battery chargers that have compensation for temperature.

Incorrect Supply Voltage

Battery chargers can fail to operate correctly if a charger is used with the incorrect rating for the supply voltage. Cross-reference the supply voltage that is listed on the label for the ratings of the charger against the auxiliary supply voltage which is connected to the charger.

Loose Connections at the Terminals

Wires that are connected to the charger or wires that are connected within the charger may become loose. Check the wires. Reconnect the wires to the terminals. Use the correct size of tool to clamp the wires. A flat screwdriver that has a maximum width of 3.5 mm (0.1378 inch) that does not have a flared tip should be used. Use a tool to push down on the terminal in order to open the jaws. Use special care in order to ensure that the wires are correctly inserted into the terminals. Also, check the crimped terminals to the internal ammeter on chargers that are the type of box. The crimped terminals may be faulty.

Incorrect Battery Type

The chargers are designed to be used with only batteries that are vented and lead acid. The chargers may not operate correctly if the chargers are used with a NiCd battery.

Output Voltages may be Incorrect

The output voltage of the charger may be different from the voltage that is specified in Table 1 due to the following reasons:

• The charger will not operate normally if a battery that is not in good condition is connected or if no battery is connected. The output will only be up to half of the rated output voltage.

• If the batteries are not charged, the output voltage will be lower than the voltage that is specified in Table 1. Charge the battery. Retest the battery. The battery should then output the full floating voltage.

• The internal temperature compensation on the chargers adjusts the output voltage in order to provide the correct charging voltage to the battery for the ambient temperature. Check the ambient temperature. Allow the nominal output voltage that is shown in Table 1 to change to the value that is shown in Table 2.

Short Circuit to Chassis

Due to a defect in the manufacturing of the component, the positive output of the charger may be connected to the chassis of the charger. Replace the charger if replacement is necessary.

Other Factors

Other factors can lead to battery chargers that are diagnosed incorrectly. The following reasons can lead to a faulty diagnosis:

• The main auxiliary supply is disconnected. The battery charger will stop operating when the main supply is disconnected. The battery will drain. No battery voltage will be present when the main supply is reconnected. The charger will not produce the rated output that is expected. This event may be incorrectly interpreted as a failure of the charger.

• A loss of voltage may be the result of an internal failure of a battery. This event may be incorrectly interpreted as a failure of the charger.