- Electric Power Generation:
- C2.2 GEN SET (S/N: GBE1-UP)
- C3.3 GEN SET (S/N: N3C1-UP; N3X1-UP)
- C4.4 GEN SET (S/N: D4B1-UP; N4D1-UP; GLE1-UP; N4X1-UP)
- C6.6 GEN SET (S/N: N6D1-UP)
- C3.3 GEN SET (S/N: N3C1-UP; N3X1-UP)
Introduction
ReferenceRefer to Parts Manual, SEBP4765, "C2.2 Gen Set 17-20 kW Tier V", Parts Manual, SEBP4335, "C4.4 Generator Set", Parts Manual, SEBP5267, "C4.4 Generator Set", Parts Manual, SEBP5272, "C4.4 Generator Set", and Parts Manual, SEBP4548, "C6.6 Gen Set" for more information for your machine.
This Special Instruction provides information in order to properly fit the diodes in the correct orientation in the alternator charging circuits. This procedure should also be used in order to install a diode that was omitted during production.
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.
Required Tools
The following tools will be required to fit the diode. The list below contains the recommended Caterpillar service tools.
| Necessary Tools | |
|---|---|
| Quantity | Description |
| 1 | Flat head screwdriver |
Required Parts
The following parts will only be required in order to install the diode if a diode was omitted during production.
| Necessary Parts | ||
|---|---|---|
| Quantity | Part Number | Description |
| 1 | 143-5090 | Diode |
Procedure for a diode that is fit in the reverse orientation
 |
When servicing or repairing electric power generation equipment: Make sure the unit is off-line (disconnected from utility and/or other generators power service), and either locked out or tagged DO NOT OPERATE. Remove all fuses. |
 |
- Isolate the generator set prior to starting this procedure.
- Open the breaker for the generator set.
- Activate the emergency stop.
- Disconnect the auxiliary power supply for the battery charger and the heaters.
- Disconnect the cables for the battery.
- Use the appropriate lockout procedure for the generator before starting any work.
- Insert a small flat head screwdriver into the housing for the terminal. Refer to Illustration 1. Repeat this procedure on the other terminal in order to fully release the remaining lead.
Note: Ensure that the proper health and safety requirements are followed during the procedure. Also, ensure that you use the proper lockout and tag out procedures at all times while work is performed on the machine.
 | |
| Illustration 1 | g02085514 |
(1) Terminal 2 (2) Terminal 3 (3) 143-5090 Diode in reverse direction | |
- Inspect the diode leads for any damage that may have occurred during removal. Replace the diode with a 143-5090 Diode if the current diode has been damaged.
- Insert the screwdriver into the third terminal and insert the cathode of the diode into the terminal block. Refer to Illustration 2.
 | |
| Illustration 2 | g02086534 |
(1) Terminal 2 (2) Terminal 3 | |
- Insert the screwdriver into the second terminal and insert the anode of the diode into the terminal block. Refer to Illustration 3.
 | |
| Illustration 3 | g02086544 |
(1) Terminal 2 (2) Terminal 3 (4) 143-5090 Diode in correct direction | |
- Ensure that the diode is secure within the terminal blocks in the correct orientation. Refer to Illustration 4 for the correct orientation of the anode (5) and the cathode (6). Repeat Step 4 through Step 5 if the diode appears to be loose.
 | |
| Illustration 4 | g02087834 |
(5) Anode (6) Cathode | |
- Run the generator set in order to ensure that the battery is receiving a charge from the charging alternator.
Procedure for a diode that was omitted from production
|
When servicing or repairing electric power generation equipment: Make sure the unit is off-line (disconnected from utility and/or other generators power service), and either locked out or tagged DO NOT OPERATE. Remove all fuses. |
|
- Isolate the generator set prior to starting this procedure.
- Open the breaker for the genset.
- Activate the emergency stop.
- Disconnect the auxiliary power supply for the battery charger and the heaters.
- Disconnect the cables for the battery.
- Use the appropriate lockout procedure for the generator before starting any work.
- Remove one of the 143-5090 Diode from the packaging. Cut the leads to approximately 20 mm (0.78 inch). Bend the leads to 90 degrees by using a pair of needle nose pliers in order to make the shape of a "U".
Note: Ensure that the proper health and safety requirements are followed during the procedure. Also, ensure that you use the proper lockout and tag out procedures at all times while work is performed on the machine.
 | |
| Illustration 5 | g02087013 |
The 143-5090 Diode is shown in a "U" shape. | |
- Insert the screwdriver into the third terminal and insert the cathode of the diode into the terminal block. Refer to Illustration 6.
| | |
| Illustration 6 | g02086534 |
(1) Terminal 2 (2) Terminal 3 | |
- Insert the screwdriver into the second terminal and insert the anode of the diode into the terminal block. Refer to Illustration 7.
| | |
| Illustration 7 | g02086544 |
(1) Terminal 2 (2) Terminal 3 (4) 143-5090 Diode in correct direction | |
- Ensure that the diode is secure within the terminal blocks in the correct orientation. Refer to Illustration 8 for the correct orientation of the anode (5) and the cathode (6). Repeat Step 4 through Step 5 if the diode appears to be loose.
| | |
| Illustration 8 | g02087834 |
(5) Anode (6) Cathode | |
- Run the genset in order to ensure that the battery is receiving a charge from the charging alternator.