Installation of the Generator Cable Support Assembly{0635, 4459} Caterpillar

Engine:

3508 (S/N: ZAB1-UP)

3508B (S/N: ZAD1-UP)

3512 (S/N: ZAF1-UP; YAK1-UP)

3512B (S/N: ZAH1-UP; ZAJ1-UP; YAM1-UP; YAN1-UP)

3516 (S/N: ZAL1-UP; YAS1-UP)

3516B (S/N: ZAP1-UP; PBR1-UP; ZAR1-UP; YAT1-UP; YAW1-UP)

3516C (S/N: SBJ1-UP; SBK1-UP)

C175-16 (S/N: WYB1-UP)

3512C (S/N: SBG1-UP)

Generator Set:

C32 GEN SET (S/N: SXC1-UP)

Introduction

This Special Instruction provides information for the installation of new mounting hardware for the output leads of the stator. This Special Instruction only applies to certain C32, 3500 and C175 generator sets with global design generator terminal boxes. There are separate instructions for the SR4B generator and instructions for the SR5 generator.

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.

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Caterpillar dealer for replacement manuals. Proper care is your responsibility.

When you service an electric power generation set or when you repair an electric power generation set, follow the procedure below:

1. Stop the engine.

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Illustration 1	g00104545

2. Attach a "DO NOT OPERATE" or similar warning tag to the engine prime mover starting circuit. Disconnect the engine starting circuit.

3. Disconnect the generator from the distribution system.

4. Lock out the circuit breaker. Attach a "DO NOT OPERATE" or similar warning tag to the circuit breaker. Refer to the electrical diagram. Verify that all points of possible reverse power flow have been locked out.

5. For the following circuitry, remove the transformer's fuses:
   • Power

   • Sensing

   • Control

6. Attach a "DO NOT OPERATE" or similar warning tag to the generator excitation controls.

7. Remove the necessary covers of the generator's terminal box in order to access components.

8. Use an audio/visual proximity tester in order to verify that the generator is de-energized. This tester must be insulated for the proper voltage rating. Follow all guidelines in order to verify that the tester is operational.

9. Determine that the generator is in a de-energized condition. Ensure that any power source is in this condition: removed, disabled, locked state, tagged out and tested out. Add ground straps to the conductors or terminals. Connect the ground straps to the electrical distribution system's common grounding location or to the ground system. During the entire work period, these ground straps must remain connected to the conductors and generator terminals.

Parts

C32 and 3500 SR4B Low Voltage Generators

1. Ensure that the safety section of this publication has been read and understood.

2. Remove the top access panel (1) of the terminal box in order to access the lead cables of the generator. Remove the front access panel (2) of the terminal box. Other access panels may need to be removed in order to improve access to the lead cables.

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Illustration 2	g01955422
(1) Top Access Panel (2) Front Access Panel

3. Use three 235-4451 Bolts (7) and three 5P-4115 Hard Washers (8) in order to assemble the 330-5566 Support Assembly (6) to the 341-5965 Support Assembly (5). Refer to Illustration 3.

   Note: Finger tighten the bolts.

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Illustration 3	g01955429
(5) 341-5965 Support Assembly (6) 330-5566 Support Assembly (7) 235-4451 Bolts (8) 5P-4115 Hard Washers

4. Place the support assembly (11) across top of the terminal box (10). Adjust the support assembly in order to fit into the opening. Refer to Illustration 4.

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Illustration 4	g01955435

5. Use five 235-4451 Bolts (14) and five 5P-4115 Washers (15) in order to secure the support assembly (11) to the terminal box (10). The 235-4451 Bolts are threaded into existing threaded inserts. Refer to Illustration 4 and Illustration 5.

   Note: Finger tighten the bolts.

   Note: If threaded inserts are not available, then it will be necessary to use 5C-2890 Nuts and 5P-4115 Hard Washers .

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Illustration 5	g01955436

6. Ensure that the support assembly is properly seated. Some earlier versions of the support assembly may not mount flush with the terminal box even though the support assembly is fully extended. The earlier versions are listed below.
   • 341-5965-00

   • 330-5566-01

   1. If a gap remains as shown by the arrows that are in Illustration 6, then one or more 5P-4115 Hard Washers (16) and a longer bolt may be needed in order to properly secure the support assembly. Refer to Illustration 7.
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   Illustration 6	g01955517

   2. Ensure that the replacement bolt is of the same type as the original. The bolt must be long enough in order to allow the bolt to make six full revolutions in order to be correctly seated.

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Illustration 7	g01955519
(16) 5P-4115 Hard Washers Used as a Spacer

7. Torque the support assembly 235-4451 Bolts (16). The bolts must be torqued to 12 ± 3 N·m (8.9 ± 2 lb ft).

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Illustration 8	g01955689

8. Torque the remaining support assembly 235-4451 Bolts (17). The bolts must be torqued to 12 ± 3 N·m (8.9 ± 2 lb ft).

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Illustration 9	g01955680

9. Apply a strip of the 244-9631 Seal to both ends of support assembly. Refer to Illustration 10.

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Illustration 10	g01955690
(20) Applied Sealant

10. Apply a strip of the 244-9631 Seal (21) to the top edge and the bottom edge of the 332-5866 Cover Assembly (22). Refer to Illustration 11.

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Illustration 11	g01955713

11. Remove all of the existing cable straps (24) and ladder clips (23) that secure the stator cables to the terminal box.

    Refer to Illustration 12.

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Illustration 12	g01955719
(23) Ladder Clip (24) Cable Strap (25) Terminal Box

12. Once the cable straps (24) and the ladder clips (23) are removed, visual inspection of previously inaccessible areas will now be possible. Visually inspect the following areas for cracking and physical damage.
    • Stator output leads

    • Protective sleeves

    • Insulation

    If needed, then make repairs as per approved practices.

13. Wrap the cables with the 7H-8213 Mat (32) as shown in Illustration 13. Use the 7K-1181 Cable Straps (31) in order to secure the mats to the stator cables.

    Note: The 7H-8213 Mats must be placed where the cable straps make contact with the cable bundles. Do not wrap the mats around the entire cable bundle. Proper installation of the mats will ensure effective cooling.

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Illustration 13	g01955724

14. Use the 329-1293 Cable Straps (30) in order to secure the cable bundles to the support assembly. Use at least four cable straps (30) to support the cable bundles. Refer to Illustration 13.

    Ensure that the stator output leads are installed in a manner that will prevent the leads from rubbing against any metal objects.

15. Assemble the 332-5866 Cover Assembly (33) to the terminal box. Install the 235-4451 Bolts as shown in Illustration 14. The 332-5866 Cover Assembly (33) uses seven mounting bolts (34) .

    Note: The 332-5866 Cover Assembly is for use with only the SR4B generators.

    Note: In some installations, the mounting bolts for the cover assembly may also be used for exterior ladder clips. Some ladder clip designs may require that the washer (35) be removed from the ladder clip in order to allow the mounting bolt to have the proper thread engagement. Refer to Step 17 as an example.

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Illustration 14	g01955737

16. Torque the 235-4451 Bolts (34) to 12 ± 3 N·m (8.9 ± 2 lb ft).

17. Remove the ladder clip washer (35) if needed in order to provided the bolt with the proper thread engagement. Refer to Illustration 15.

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Illustration 15	g01955738
(35) Ladder Clip Washer

18. Install all of the covers and the access panels that have been removed in order to install the new support assembly. Remove any tools, unused components or parts that were removed, from the area around the generator. Connect the batteries. Release the emergency stop push button. Run a functional test on the generator set.

C175 and 3500 SR5 Generators

The information in this section only applies to SR5 generators that are manufactured with the following characteristics.

• Low voltage

• External power connection with a circuit breaker and/or a bus bar

• Bus bar on left and/or right side

1. Complete Step 1 through 9 of the SR4B instructions with the exception of removing the front access panel (2) of the terminal box. Refer to Illustration 2. Removal of the front access panel (2) is not required for the SR5 generator. Installation of the 332-5866 Cover Assembly (33) is not required.

2. Visually inspect the following areas for cracking and physical damage.
   • Stator output leads

   • Protective sleeves

   • Insulation

   If needed, repair as per approved practices.

3. Wrap the cables with the 7H-8213 Mat (40) as shown in Illustration 16. Use the 7K-1181 Cable Straps (39) in order to secure the mats to the stator cables.

   Note: The 7H-8213 Mats must be placed where the cable straps make contact with the cable bundles. Do not wrap the mats around the entire cable bundle. Proper installation of the mats will ensure effective cooling.

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Illustration 16	g01955740

4. Perform the following steps.

   Ensure that the stator output leads are installed in a manner that will prevent the leads from rubbing against any metal objects.

   1. Use the 329-1293 Cable Straps (38) in order to secure the cable bundles to the support assembly.

   2. Use one or more cable straps (38) in order to support each of the cable bundles.

   3. Install the cable straps in order to ensure that the cable bundles are parallel to each another.

   4. Use the cable straps in order to support each bundle separately as to prevent contact with the other bundle.

5. Install all of the covers and the access panels that have been removed in order to install the new support assembly. Remove any tools, unused components or parts that were removed, from the area around the generator. Connect the batteries. Release the emergency stop push button. Run a functional test on the generator set.