- Electric Power Generation:
- C4.4 GEN SET (S/N: GLD1-UP; N4D1-UP)
Introduction
The rework procedure within this special instruction details the steps necessary to connect the speed adjust wiring from the electronic governor to the control panel.
Required Parts
The following parts are required in order to connect the speed adjust wiring from the electronic governor to the control panel.
| Required Parts for Connection of Speed Adjust Circuit | ||
| Qty | Part Number | Description |
| 2 | 136-4877 | Wire Splice |
| 2 | 240-1405 | Blade Terminal |
| 260 | 8T-7875 | Electrical Wire |
Connecting the Speed Adjust Wiring from the Electronic Governor to the Control Panel
 |
The high voltage that is produced by an operating generator set can cause severe injury or death. Before performing any maintenance or repairs, ensure that the generator will not start. Place the engine control switch in the "OFF" position. Attach "DO NOT OPERATE" tags to all starting controls. Disconnect the batteries or disable the starting system. Lock out all switchgear and automatic transfer switches that are associated with the generator. |
 |
|
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:
|
|
|
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. |
|
|
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. |
|
Note: Isolate the generator set before commencing any work on the unit and open the generator set breaker. Next, activate the emergency stop and disconnect the auxiliary power supply for the battery charger and heaters. Disconnect the battery cables. Ensure that health and safety requirements are adhered to at all times. Also, ensure proper Lock Out-Tag Out procedures are followed at all times while work is being performed on the machine. Lock out generator before commencing any type of work.
- The wires required to be connected to enable speed adjust are "ST1" and "ST2". These wires are located in DC harness (1) shown in Illustration 1.
 | |
| Illustration 1 | g02161341 |
(1) DC harness | |
- To gain access to the wiring in the DC harness, open T-junction (2) shown in Illustration 2 for ease of work. The ST1 & ST2 wire can be found in smaller conduit (3) .
 | |
| Illustration 2 | g02161345 |
(2) T-junction (3) Conduit | |
- Strip back 6 mm (0.24 inch) of the insulation on the ST1 & ST2 wires as shown in Illustration 3.
 | |
| Illustration 3 | g02161347 |
- Install 136-4877 Wire Splice (4) to "ST1" and "ST2" as shown in Illustration 4.
 | |
| Illustration 4 | g02161350 |
(4) 136-4877 Wire Splice | |
- Fabricate 2 120 mm (4.72 inch) lengths of 8T-7875 Electrical Wire , 16 AWG, and strip back 6 mm (0.24 inch) of insulation. Label one end of the wires "ST1" and "ST2" as shown in Illustration 5.
 | |
| Illustration 5 | g02161351 |
- Fit and crimp the newly made "ST1" and "ST2" wires into the respective splice wires as shown in Illustration 6.
 | |
| Illustration 6 | g02161352 |
- Place the "ST1" & "ST2" wires back into conduit (3) as shown in Illustration 7.
 | |
| Illustration 7 | g02161353 |
(3) Conduit | |
- Feed the wires through grommet (5) fitted to the bottom of the control panel as shown in Illustration 8.
 | |
| Illustration 8 | g02161354 |
(5) Grommet | |
- Route wires (6) along the panel as shown in Illustration 9 and cut to length.
 | |
| Illustration 9 | g02161355 |
(6) Wire routing | |
- Label the wires accordingly as "ST1" and "ST2" and strip back 6 mm (0.24 inch) of insulation. Fit and crimp 1 240-1405 Blade Terminal (7) to each wire as shown in Illustration 10.
 | |
| Illustration 10 | g02161357 |
(7) 240-1405 Blade Terminal | |
- Locate terminals (8) for "ST1" and "ST2" and fit the wires into terminals (8) as shown in Illustration 11.
 | |
| Illustration 11 | g02161358 |
(8) Terminals | |
- Reconnect the auxiliary power supply for the battery charger and heaters, and battery cables. Run the generating set and check for correct operation of the speed adjust switch on the control panel.