Installation of Improved Battery Charger for Certain C9, C15, and C18 Gensets{1401, 1406} Caterpillar

Generator Set:

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

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

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

Introduction

Introduction

This Special Instruction provides instructional information on how to install the new improved 339-5996 Battery Charger .

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 an operating technique is used that is not recommended by Caterpillar, be sure that item is safe for you and for other people to use.

Ensure that all 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 operation and the power source for the battery charger before commencing any work.

Only qualified repair personnel should service this equipment.

Ensure that the product will not be damaged or 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 or work tool unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals and Owner's 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.

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The battery cables or the batteries should not be removed with the battery cover in place. The battery cover should be removed before any servicing is attempted. Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury.

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All lead-acid batteries contain sulfuric acid which can burn the skin and clothing. Always wear a face shield and protective clothing when working on or near batteries.

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Personal injury can result from battery fumes or explosion. Batteries give off flammable fumes that can explode. Electrolyte is an acid and can cause personal injury if it contacts the skin or eyes. Prevent sparks near the batteries. They can cause vapors to explode. Do not allow jumper cable ends to contact each other or the engine. Improper jumper cable connections can cause an explosion. Always wear protective glasses when working with batteries. The power switch must be in the OFF position when connecting the 5P-7366 Power Cable .

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Power source must be disconnected before working on equipment. Failure to disconnect power source could result in injury or death.

Required Parts

(*)To identify which base bracket your generator set requires, utilize the Caterpillar TMI data base.

Removal Procedure

Isolate the generator set before performing any work on the unit by performing the following steps.

1. Open the generator set breaker.

2. Activate the Emergency Stop.

3. Disconnect the battery cables.

4. Either disconnect or open the control circuit breaker for the AC power supply to the battery charger.

Perform the following steps to the battery charger.

1. Remove battery charger cover.

2. Disconnect the AC power supply wiring and DC output supply wiring

3. Disconnect all battery charger alarms, or sensor wiring.

4. Disconnect the grounding conductor

5. Separate the conductors from the battery charger.

6. Remove the battery charger from the existing battery charger mounting bracket assembly. Retain all mounting hardware for reuse.

7. Remove the existing battery charger mounting bracket. Retain all mounting hardware for reuse.

Installation Procedure

For additional detailed information reference the following service publications:Operation and Maintenance Manual, SEBU7878, "C9 Generator Set", Operation and Maintenance Manual, SEBU7909, "C15 Generator Set", Operation and Maintenance Manual, SEBU7898, "C18 Generator Set ", and 101295"SENS NRG2 24-10 Battery Charger Installation & Operation Manual." The latter document is provided with the new 339-5996 Battery Charger .

1. Install the appropriate new battery charger mounting bracket. Reuse the mounting hardware saved in the previous steps.

2. Install the new battery charger onto the new battery charger mounting bracket. Reuse the mounting hardware saved in the previous steps.

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Illustration 1	g02393780
(1) "Jump Start" battery initialization mode. Temporary use only, 5 minutes maximum.

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Illustration 2	g02394405

3. Configure the new battery charger Internal Adjustments for operation.

   1. Set the AC voltage select switch (SW100) according to the line voltage (9, 10). Use the 115V position for nominal mains voltages between 110V and 120V. Use the 230V position for nominal mains voltages between 208V and 240V. Refer to Illustration 2.

   2. On (Detail B) set the battery range jumper JP1A (4) according to nominal battery voltage. Use the 12V position for 12V batteries. Use the 24V position for 24V batteries. Refer to Illustration 1.

   3. On (Detail B) set the boost mode jumper JP1B (2) according to whether the battery should have automatic boost charging. If the battery manufacturer recommends boost charging (equalization), use the "NORMAL" position. If not, use the "OFF" position.

      On (Detail B) for the float voltage jumper (3), choose the settings that follow according to the battery supplier specification.

      • 14.30/28.60 for 10 or 20 cell Nickel Cadmium at 1.43V/cell

      • 13.62/27.24 for 6 or 12 cell (VRLA) lead-acid at 2.27V/cell, and for 19 cell Nickel Cadmium at 1.43V/cell

      • 13.50/27.00 for 6 or 12 cell (VRLA or high capacity) lead-acid at 2.25V/cell, and for 19 cell Nickel Cadmium at 1.42V/cell

      • 13.31/26.62 for 6 or 12 cell (flooded) lead-acid at 2.22V/cell, and for 19 cell Nickel Cadmium at 1.40V/cell

      • 13.08/26.16 for 6 or 12 cell lead-acid at 2.18V/cell

      • 12.87/25.74 for 9 or 18 cell Nickel Cadmium at 1.43V/cell

   4. Set the Display Selector jumper (Detail A) to one of the three available positions on JP800. Reference Illustration 1:
      • VOLTS – Place the short jumper in the "upper" position next to the word "VOLTS".The 3-digit LED meter display will show DC Volts only.

      • AUTO – Place the short jumper in the center position next to the word "AUTO". The 3-digit LED meter display will automatically and continuously alternate between DC Amps and DC Volts. The display shows DC Amps for approximately 6 seconds and DC Volts for approximately 3 seconds.

      • AMPS – Place the short jumper in the "lower" position next to the word "AMPS". The 3-digit LED meter display will show DC Amps only.

      Note: USE THE JUMP FEATURE ONLY WITH LIQUID ELECTROLYTE NICKEL-CADMIUM BATTERIES, OR WITH RECENTLY FILLED NEW LEAD ACID BATTERIES SUPPLIED FROM THE MANUFACTURER DRY AND DISCHARGED.

      Note: NEVER LEAVE A JUMPER IN THE "JUMP" POSITION DURING NORMAL OPERATION. THIS DISABLES THE BATTERY VOLTAGE INTERLOCK, WHICH INCREASES THE RISK OF ACCIDENTALLY OVERCHARGING 12V BATTERIES WITH THE 24V SETTINGS.

4. Use the following sequence to connect the various conductors at the battery charger. Reference Illustration 2.
   • Connect the Grounding Conductor.

   • Connect the B+ Conductor (9) .

   • Connect the B- Conductor (10) .

   • Connect the AC Neutral Conductor (6) .

   • Connect the AC Line Conductor (5) .

   • Connect the Alarm and Sensor wiring (7) and (8) as required.

   Note: Do not energize the AC supply circuit until all wiring is connected, the internal controls are properly set, and the battery charger cover is secured

   Note: Always observe proper polarity of the DC power supply wiring.

   Note: Confirm proper conductor termination points using the OEM provided NRG2 24-10 Battery Charger Installation & Operation Manual.

5. Install and secure the battery charger cover.

6. Energize the battery charger, confirm proper operation and functionality of the battery charger.

7. Restore the generator set to the proper operational condition.