Replacement Procedure for Power Conductor Braids With New Silicone Cables{1408, 4460} Caterpillar

Generator Set:

3406C GEN SET (S/N: C2G1-UP; C5G1-UP; C8G1-UP; C2Y1-UP)

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

C15 GEN SET (S/N: C5E1-UP; STG1-UP; C5H1-UP; C5L1-UP)

C18 GEN SET (S/N: C6C1-UP; G4C1-UP; STD1-UP; STM1-UP; EKW1-UP)

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

Introduction

The Special Instruction will provide the user with a replacement procedure for power conductor braids with new silicone cables. The replacement procedure gives guidance to replace all four connections of a genset including the three phases and the neutral. The field retrofit procedure is applicable for packages rated 1600 amps and below, with power conductor braids and power take off bus bars.

Do not perform any procedure that is outlined in this publication until you understand the information that is contained in this document.

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 must 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 of a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Avoid using a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar. If used, ensure the safety of the operating personnel and others.

Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures.

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Only persons with training in electrical installations must carry connections to the generator. The generator must be wired correctly. A fire or electrocution could result from wiring that is incorrect. The generator is capable of generating high voltages. Ensure that the generator is not on while the connections are being made. Follow these two steps in order to prevent accidental starting: Isolate the DC breaker. Disconnect the DC supply battery.

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High voltage may be present. The power source must be disconnected before working on the equipment. Failure to disconnect the power source could result in injury or death. Verify that the equipment is not energized before performing any maintenance. This work must be performed by trained personnel with correct tools and procedures.

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Bodily contact with electrical potential can cause bodily injury or death. To avoid the possibility of injury or death, ensure that the main power supply has been disconnected before performing any maintenance or removing any modules.

Required Parts

Below are sets of steps that will provide the required materials for the retrofitting of the genset. Review the TMI As-Shipped data to determine the configuration of the genset. The required materials are grouped into 12 different Kits lettered A through L. Each Genset configuration will lead to a single Kit. The Kit will then list the required parts based on the configuration of the genset. To rework the genset, order all parts in the appropriate Kit.

Kit Selection Procedure

1. Proceed to step 4, if the genset has one of the following serial prefixes. Otherwise proceed to Step 2.
   • US built gensets (Griffin facility) - C3G, ; C5G, ; C4G, ; STD, ; C9E, ; C5H, ; EKW, ; C5E, ; STM.

2. Proceed to Step 3, if the genset has one of the following serial prefixes. If your serial prefix is not listed, this document does not apply to your unit.
   • US built gensets (Newberry facility) - C2Y.

   • UK built gensets (Larne facility) - C2G, ; C1G, ; G4C, ; C5L, ; STG.

   • China built gensets (Tianjin facility) - C2T, ; C6T, ; C8G.

3. The kits are classified based on the type of the circuit breaker.

   1. Select one of the following kits, if the genset has a three pole circuit breaker:
      • Use kit G, if the rated ampacity of the genset package is 630A or 800A.

      • Use kit H, if the rated ampacity of the genset package is 1250A.

      • Use kit I, if the rated ampacity of the genset package is 1600A.

   2. Select one of the following kits, if the genset has a four pole circuit breaker:
      • Use kit J, if the rated ampacity of the genset package is 630A or 800A.

      • Use kit K, if the rated ampacity of the genset package is 1250A.

      • Use kit L, if the rated ampacity of the genset package is 1600A.

   3. Select one of the following kits, if the gensets has power terminal strips:
      • Use kit A, if the rated ampacity of the genset package is 630A or 800A.

      • Use kit B, if the rated ampacity of the genset package is 1250A.

      • Use kit C, if the rated ampacity of the genset package is 1600A.

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Illustration 1	g02160474

4. Select one of the following kits, if the genset is configured for top cable customer entry. Otherwise proceed to Step 5.
   • Use kit D, if the rated ampacity of the genset package is 800A.

   • Use kit E, if the rated ampacity of the genset package is 1250A.

   • Use kit F, if the rated ampacity of the genset package is 1600A.

   Note: Reference the As Shipped consist in TMI for the part number 275-6111. This part number is the top cable entry indicator. Refer to Illustration 1.

5. Select one of the following kits, if the genset is configured for bottom cable customer entry:
   • Use kit A, if the rated ampacity of the genset package is 630A or 800A.

   • Use kit B, if the rated ampacity of the genset package is 1250A.

   • Use kit C, if the rated ampacity of the genset package is 1600A.

Kits

Kit A

Table 1

Parts List
Quantity	Part Number	Description
4x4m (1)	314-6905	Cable
16	3L-7634	Ring Terminal
16	8T-4121	Hard Washer
8	8T-4133	Nut
4	8T-4195	Bolt
4	8T-4196	Bolt
16	7H-8213	Mat
40	7K-1181	Cable Strap

( 1 )

Cables are serviced in 4m segments

Kit B

Table 2

Parts List
Quantity	Part Number	Description
6x4m (2)	314-6905	Cable
24	3L-7634	Ring Terminal
32	8T-4121	Hard Washer
16	8T-4133	Nut
8	8T-4195	Bolt
8	8T-4182	Bolt
2	8T-4196	Bolt
16	7H-8213	Mat
40	7K-1181	Cable Strap

( 2 )

Cables are serviced in 4m segments

Kit C

Table 3

Parts List
Quantity	Part Number	Description
8x4m (3)	314-6905	Cable
32	3L-7634	Ring Terminal
32	8T-4121	Hard Washer
16	8T-4133	Nut
8	8T-4195	Bolt
8	8T-4182	Bolt
16	7H-8213	Mat
40	7K-1181	Cable Strap

( 3 )

Cables are serviced in 4m segments

Kit D

Table 4

Parts List
Quantity	Part Number	Description
8x4m (4)	314-6905	Cable
16	3L-7634	Ring Terminal
16	8T-4121	Hard Washer
8	8T-4133	Nut
4	8T-4195	Bolt
4	8T-4196	Bolt
16	7H-8213	Mat
40	7K-1181	Cable Strap

( 4 )

Cables are serviced in 4m segments

Kit E

Table 5

Parts List
Quantity	Part Number	Description
12x4m (5)	314-6905	Cable
24	3L-7634	Ring Terminal
32	8T-4121	Hard Washer
16	8T-4133	Nut
8	8T-4195	Bolt
8	8T-4182	Bolt
2	8T-4196	Bolt
16	7H-8213	Mat
40	7K-1181	Cable Strap

( 5 )

Cables are serviced in 4m segments

Kit F

Table 6

Parts List
Quantity	Part Number	Description
16x4m (6)	314-6905	Cable
32	3L-7634	Ring Terminal
32	8T-4121	Hard Washer
16	8T-4133	Nut
8	8T-4195	Bolt
8	8T-4182	Bolt
16	7H-8213	Mat
40	7K-1181	Cable Strap

( 6 )

Cables are serviced in 4m segments

Kit G

Table 7

Parts List
Quantity	Part Number	Description
4x4m (7)	314-6905	Cable
16	3L-7634	Ring Terminal
16	8T-4121	Hard Washer
8	8T-4133	Nut
4	8T-4195	Bolt
4	8T-4196	Bolt
3	349-9391	Terminal
16	7H-8213	Mat
40	7K-1181	Cable Strap

( 7 )

Cables are serviced in 4m segments

Kit H

Table 8

Parts List
Quantity	Part Number	Description
6x4m (8)	314-6905	Cable
24	3L-7634	Ring Terminal
32	8T-4121	Hard Washer
16	8T-4133	Nut
8	8T-4195	Bolt
8	8T-4186	Bolt
3	222-0476	Terminal
3	222-0478	Terminal
16	7H-8213	Mat
40	7K-1181	Cable Strap

( 8 )

Cables are serviced in 4m segments

Kit I

Table 9

Parts List
Quantity	Part Number	Description
8x4m (9)	314-6905	Cable
32	3L-7634	Ring Terminal
32	8T-4121	Hard Washer
16	8T-4133	Nut
8	8T-4195	Bolt
8	8T-4182	Bolt
3	222-0476	Terminal
3	222-0478	Terminal
16	7H-8213	Mat
40	7K-1181	Cable Strap

( 9 )

Cables are serviced in 4m segments

Kit J

Table 10

Parts List
Quantity	Part Number	Description
4x4m (10)	314-6905	Cable
16	3L-7634	Ring Terminal
16	8T-4121	Hard Washer
8	8T-4133	Nut
4	8T-4195	Bolt
4	8T-4196	Bolt
4	349-9391	Terminal
16	7H-8213	Mat
40	7K-1181	Cable Strap

( 10 )

Cables are serviced in 4m segments

Kit K

Table 11

Parts List
Quantity	Part Number	Description
6x4m (11)	314-6905	Cable
24	3L-7634	Ring Terminal
32	8T-4121	Hard Washer
16	8T-4133	Nut
8	8T-4195	Bolt
8	8T-4196	Bolt
4	222-0476	Terminal
4	222-0478	Terminal
16	7H-8213	Mat
40	7K-1181	Cable Strap

( 11 )

Cables are serviced in 4m segments

Kit L

Table 12

Parts List
Quantity	Part Number	Description
8x4m (12)	314-6905	Cable
32	3L-7634	Ring Terminal
32	8T-4121	Hard Washer
16	8T-4133	Nut
8	8T-4195	Bolt
8	8T-4196	Bolt
4	222-0476	Terminal
4	222-0478	Terminal
16	7H-8213	Mat
40	7K-1181	Cable Strap

( 12 )

Cables are serviced in 4m segments

Special Tools Required

Table 13

Quantity	Part Number	Description
1	6V-3021	Crimping tool
1	6V-3022	Cable cutter

Field Retrofit Procedure

1. Observe all safety procedures in Caterpillar manuals. Disconnect all power and lock out the genset.

2. Remove the power terminal box covers (PTS or CB box) at the rear of the genset.

3. Remove the plastic top of the generator terminal box cover by removing the eight screws including the front two.

4. Disconnect all power braids from the generator bus bars. Start by removing all hardware that is used to attach the braids to the power terminals on the generator.

5. Remove all cable tie straps and rubber mats used to bundle the braids. Remove all mats and cable tie straps from the braids on the entrance to the conduits.

6. Mark "A" on copper terminals on both generator terminals and CB or PTS terminals for the phase A braid. Repeat the same procedure for phases B and C by marking the terminals "B" and "C". The marking is especially important to remember which copper terminal is A, B and C phase in the generator. The marking is also important to make sure that new cables are reinstalled in same location on generator and CB or PTS bus bars.

7. Mark each voltage sensing wire position on the individual phase in order to reinstall in the same location later.

8. Remove all hardware used to attach the braids to the CB or PTS.

9. Cut the cable tie straps supporting the metering current transformers (CTs). Mark each CT position on the correct phase while observing the CT polarity (dot mark). The marking is important while reinstalling in the same location and with the same orientation. The dot should be facing the generator.

10. Cut any cable tie straps that tie the neutral power braid to the green/yellow ground cables. Keep the ground cables in place and connected.

11. Remove all power braids. Gently pull each individual braid through the conduit from the power terminal box end. If necessary guide the braid into the conduit from the generator end. Work one phase at the time until all braids are removed.

12. Refer to the Kit selection procedure above for the required material.

13. If the genset uses kits G, H, I, J, K, or L, install the terminals on the CB before proceeding. Reuse the existing hardware that was used to mount the braids to the breaker terminals. Torque bolts to standard torque.

14. If the genset uses kit A or kit D, determine if drilling of additional holes on CB bus bars or PTS will be required. Otherwise proceed to step 18. On some units of 800 amps or below, the CB bus bars and/or PTS may have only 6.6mm diameter holes. In order to land the new silicone cables at least one 11mm diameter hole is required.

15. Start by removing bus bars and/or PTS from the unit by removing all hardware. Removing the bus bars is essential for preventing metal shavings from contaminating the CB.

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Illustration 2	g02160493

16. Drill an 11mm hole directly perpendicular to the surface of the bar. Refer to Illustration 2 for the location of the hole to be drilled.

17. Reinstall bus bars and/or PTS using original hardware.

18. Refer to Table 14 for required number of cables per phase.
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    Table 14

    Package Amperage	Number of cables per phase
    600	2
    630	2
    800	2
    1250	3
    1600	4

19. Determine the required length of cables. Use a tape measure to determine the approximate cable length. Begin the cut process with the L3 (C) phase cable. Cut one cable to 50 mm (2 inch) longer than the measured approximate length. Use this cable to confirm the measured approximate cable length. Carefully push the cable into the conduit from the generator terminal box side into the power terminal box. Route the cable so that the cable is not too tight. Allow some excess for cable bundling and CT installation, but do not leave the cable excessively long. Mark the other end to the desired exact length allowing for lug installation. Repeat process for remaining phases.

20. Carefully pull out the cable and measure this cable and cut other cables for the same phase to the same length. Repeat this procedure for the other phases.

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Illustration 3	g02156280

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Illustration 4	g02156282
(1) Conductor is flush with or extended slightly beyond wire barrel (2) Second crimp (3) First crimp (4) Brazed seam against seam of die

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Illustration 5	g02156286

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Illustration 6	g02173422
(2) Second crimp (3) First Crimp

21. Install cable lugs. Strip insulation and crimp the lug on the cable end. Refer to Illustrations 3, 4, 5, and 6 for tool setup and insulation stripping.

22. Ensure orientation of the lugs match. Proper orientation will facilitate the installation by minimizing the twisting of the cable during the installation. Repeat process for remaining cable ends.

23. Install the cables onto the generator. Start with attaching the cables onto the generator terminals. Carefully push the cables into the conduit from the generator terminal box side.

    Note: Ensure to install ground/earth fault or CDVR droop CT if present.

24. If there are more than two cables per phase, use one bolt-hole for two cables. Place one cable lug on the front of the bus bar and the other on the back. Do not tighten the cable terminal bolts yet.

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Illustration 7	g02160495

25. Install CT and Cables to the CB and/or PTS. Insert phase cables through CTs while observing the CT polarity and location. The CT polarity dot should be facing the generator. Refer to Illustration 7.

26. Mount the cables on the CB bus bars and/or PTS. If there are more than two cables per phase, use one bolt-hole for two cables. Place one cable lug on the front of the bus bar and the other on the back. Install the sensing wire terminal under the washer of one cable bolt.

27. Bundle and mat cables. Group cables of same phase to provide an even and neat routing.

28. Install a rubber mat around the L2 (B) phase cables and another mat around the neutral and ground cables in the generator terminal box. Secure the rubber mats with cable tie straps.

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Illustration 8	g02160565

29. Install one rubber mat around each cable bundle for each phase including the neutral cable bundle at the entrance and exit from the conduits. Secure all rubber mats with cable tie straps. Refer to Illustration 8.

30. Bundle the three phases together while wrapping each phase bundle with one mat and securing with cable tie straps.

31. Secure the CTs installed in Step 25 with cable tie straps around each phase bundle and to each other. Refer to Illustration 7.

32. Torque all cable hardware to standard torque.

33. Complete one final review and inspection of all connections. Review all connections and inspect for possible chaffing against sharp metal edges or chaffing of cables on each other where the cables cross at angles. Only cables parallel to each other and of the same phase can be secured together.

34. Apply additional rubber matting and secure with cable tie straps, where any chaffing is possible.

35. Reinstall the power terminal box covers and the plastic top of the generator terminal box.