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R2900G (JLK) Load Haul Dump Retrofitting The Battery Isolation Control{1402, 1408, 1411} Caterpillar


R2900G (JLK) Load Haul Dump Retrofitting The Battery Isolation Control{1402, 1408, 1411}

Usage:

R2900G JLK
Load Haul Dump:
R2900G (S/N: JLK1-828)

Introduction

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Illustration 1g01051135

This publication contains the information to retrofit the battery isolation control on the R2900G (S/N: JLK) Load Haul Dump.

The supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for each standard machine. This supplement is used to determine the difference between the custom modifications and a standard machine.

The Service Manual and the Parts Manual that is available for the standard machine should be used if the service information is not in this supplementary product support literature.

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Table 1
Parts that are Required in Order to Install the Battery Isolation Control Group    
Qty     Part Number     Description    
1     294-9918     Battery Isolator Mounting Block    
1     186-8345     Frame - Battery Hold Down    
4     288-3086     Battery Hold Down Block    
2     288-3087     Battery Alignment Strip    
4     8T-0389     Locknut    
4     8T-4896     Hard Washer    
2     9U-1399     Battery Frame Retaining Rod    
1     197-8820     Alternator    
1     298-2129     Battery Isolator    
2     295-5259     Stud    
2     295-5258     Cover    
1     311-4741     Harness    
1     314-7329     Harness    
1     310-4152     Harness    
2     9X-9730     Batteries    
1     311-4742     Cable    
1     311-4744     Cable    
1     311-4745     Cable    
1     311-4743     Cable    
1     311-4746     Cable    
1     307-0877     Cable    
1     313-3080     Receptacle    
1     307-0799     Fuse Mounting Block    
2     163-5831     Tapping Block    
1     295-5261     Isolation switch    
1     309-2354     Plate    
1     4P-7581     Clip    
1     163-5531     Tie    
2     253-6273     Insulator Clamp    
1     7X-0311     Bolt    
1     1L-5081     Spacer    
3     6D-4246     Clip    
1     5S-7379     Bolt    
2     8T-4896     Hard Washer    
1     033-8248     Clip    
1     5M-3062     Bolt    
1     311-3771     Dash    

Note: Check the alternator fitted to the machine. The machine must be fitted with a 95 amp Alternator.

ReferenceDisassembly and Assembly, RENR8556, "R2900G Load Haul Dump Machine Systems"

ReferenceSpecial Instruction, REHS1841, "General Welding Procedures"

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------ WARNING! ------

Personal injury can result from flame cutting or welding on painted areas.

The effect of gasses from burned paint is a hazard to the person doing the cutting or welding.

Do not flame cut or weld on painted areas.

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Preparation for Battery Compartment Modification

  1. Move the machine to a hard, level location, that is away from operating machines and away from personnel.

  1. Install the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Remove and Install".

  1. Lower the bucket to the ground.

  1. Engage the parking brake.

  1. Stop the engine.

  1. Turn the battery disconnect switch to the OFF position.

  1. Drain the fuel tank into a suitable container for storage or disposal.
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    Illustration 2g01349270

    Standard battery compartment

    (1) Fuse

    (2) Cover

    (3) Batteries

    (4) Battery hold down frame

    (5) Receptacle

    (6) Cable

  1. Remove cover (2) .

  1. Remove the cables from batteries (3) and fuse (1). Discard cables with the exception of cable (6) .

  1. Remove fuse (1) .

    Note: Fuse (1) to be relocated.

  1. Remove receptacle (5) and discard.

  1. Remove battery holding down clamp (4) and discard.

  1. Remove two batteries (3) and discard.
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    Illustration 3g01349640

    View of the battery compartment

    (A) Battery location angle bracket

    (B) Tapping block

    (C) Fuse mounting block

    Note: Before working on the fuel tank refer to Special Instruction, REHS1841, "Welding on Fuel Tanks" .

  1. Remove four battery location angle brackets (A) .

  1. Remove two tapping blocks (B) .

  1. Remove fuse mounting block (C) .

    Note: Leave a flat finish on all surfaces after removal.

Battery Compartment Modifications

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    Illustration 4g01349645

    Battery compartment modification

    (1) Datum line is the internal face of the battery compartment

    (2) Datum line is the internal face of the battery compartment

    (3) 307-0799 Fuse Mounting Block

    (4) 294-9918 Battery Isolator Mounting Block

    (5) 163-5831 Tapping Block

    (6) 288-3086 Battery Hold Down Block

    (7) 288-3087 Battery Alignment Strip

    (8) 163-5831 Tapping Block

    (A) 559 mm (22.00 inch)

    (B) 429 mm (16.89 inch)

    (C) 354 mm (13.93 inch)

    (D) 245 mm (9.64 inch)

    (E) 198 mm (7.79 inch)

    (F) 55 mm (2.16 inch)

    (G) 5 mm (0.20 inch)

    (H) 96 mm (3.78 inch)

    (J) 153 mm (6.02 inch)

    (K) 231 mm (9.09 inch)

    (L) 438 mm (17.24 inch)

    (M) 664 mm (26.14 inch)

    (N) 145 mm (5.71 inch)

    (P) 329 mm (12.95 inch)

  1. Weld items (3) through (8) to the base of the battery compartment. Refer to Illustration 4.

Battery Hold Down Modifications

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    Illustration 5g01350286

    Battery hold down modification

    (1) 186-8345 Frame - Battery Hold Down

    (2) Mounting tab

    (A) 264 mm (10.3937 inch)

    (B) 75 mm (2.9527 inch)

  1. Remove four mounting tabs (2) .

  1. Reattach the four mounting tabs (2) to battery hold down frame (1). Refer to Illustration 5.

Battery Isolator Installation

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    Illustration 6g01352170

    Battery isolator

    (1) 295-5259 Stud

    (2) 295-5258 Cover

    (3) 298-2129 Battery Isolator

  1. Install two studs (1) and two covers (2) to battery isolator (3) .
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    Illustration 7g01524293

    Battery compartment with the new batteries and battery isolator installed

    (3) 298-2129 Battery Isolator

    (4) 9U-1399 Rod

    (5) 8T-4896 Hard Washer

    (6) 8T-0389 Locknut

    (7) 186-8345 Frame - Battery Hold Down

    (8) 9X-9730 Battery Gp

  1. Install 298-2129 Battery Isolator (3) to the mounting block.

  1. Position two 9U-1399 Rods (4) .

  1. Install two 9X-9730 Batteries (8) .

  1. Install 186-8345 Frame - Battery Hold Down (7) .

  1. Install four 8T-4896 Hard Washer (5) and four 8T-0389 Locknut (6) to 9U-1399 Rods (4) .
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    Illustration 8g01352683

    Battery compartment with relocated fuse and new receptacle installed

    (9) 216-9890 Fuse

    (10) 313-3080 Receptacle

    (11) 5M-3062 Bolt

    (12) 8T-4896 Hard Washer

  1. Install 216-9890 Fuse (9) .

  1. Install 313-3080 Receptacle (10) .
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    Illustration 9g01352672

    Battery compartment with new cables installed

    (13) 311-4741 Harness

    (14) 311-4745 Cable

    (15) 311-4743 Cable

    (16) 307-0877 Cable

    (17) 311-4744 Cable

    (18) 4P-7581 Clip

    (19) 163-5531 Tie

    (20) 311-4746 Cable

    (21) 311-4742 Cable

    (22) 7X-0311 Bolt

    (23) 253-6273 Insulator Clamp

    (24) 1L-5081 Spacer

    (25) 6D-4246 Clip

    (26) 8T-4896 Hard Washer

    (27) 5S-7379 Bolt

    (28) 033-8248 Clip

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    Illustration 10g01352692

    Inside view of rear frame

    (15) 311-4743 Cable

    (21) 311-4742 Cable

  1. Install items (14) through (21). Refer to Illustration 9 and Illustration 10.

  1. Install 311-4741 Harness (13). Refer to Illustration 9.
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    Illustration 11g01355033

    Side view of engine

    (13) 311-4741 Harness

    (19) 163-5531 Tie

    (29) 314-7329 Harness

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    Illustration 12g01355035

    Rear view of engine

    (19) 163-5531 Tie

    (29) 314-7329 Harness

  1. Install 314-7329 Harness (29). Refer to Illustration 11 and Illustration 12.

  1. Install seven 163-5531 Ties (19) .
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    Illustration 13g01356492

    Frame side view

    (19) 163-5531 Tie

    (30) 310-4152 Harness

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    Illustration 14g01356498

    Outside view of cab (standard wiring)

    (31) 241-8368 Magnetic Switch

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    Illustration 15g01356495

    Outside view of cab ( 310-4152 Harness installed)

    (30) 310-4152 Harness

    (31) 241-8368 Magnetic Switch

  1. Install 310-4152 Harness (30). Refer to Illustration 13 through Illustration 15.
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    Illustration 16g01356499

    Inside view of cab (behind dash)

    (30) 310-4152 Harness

  1. Install ground (F) .
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    Illustration 17g01353089

    View of dash panel

    (32) 295-5261 Isolation switch

    (33) 309-2354 Plate

    (34) 311-3771 Dash

  1. Install 311-3771 Dash (34) .

  1. Install 295-5261 Isolation switch (32) and 309-2354 Plate (33) .

  1. Install 197-8820 Alternator if not already installed.

Operation of the Battery Isolation Control

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Illustration 18g01365699

Use the battery isolation control in order to isolate the electrical system. The battery isolation control is a push-pull type switch.

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Battery Isolation Control - Pull battery isolation control knob outward to the OFF position in order to isolate the electrical system. Push the battery isolation control knob inward to the ON position in order to connect the electrical system.

Battery Isolation Control

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Illustration 19g01441965

The components of the battery isolation control are the batteries, main fuse, battery disconnect switch, battery electrical isolator, battery isolation switch and main relay magnetic switch.

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Illustration 20g01441966

(1) Main fuse

(2) Battery electrical isolator

(3) Batteries

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Illustration 21g01441968

(4) Battery isolation switch

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Illustration 22g01441969

(5) Main relay magnetic switch

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Illustration 23g01441970

(6) Battery disconnect switch

When battery disconnect switch (6) is in the ON position, the contacts in battery disconnect switch (6) are closed and connect 24 volt ground from batteries (3) to battery electrical isolator (2). When battery isolation switch (4) is in the ON position the contacts of battery electrical isolator (2) are closed, and connect 24 volt power and 24 volt ground from batteries (3) to the machine electrical system and to main relay magnetic switch (5) .

When battery isolation switch (4) or battery disconnect switch (6) are moved to the OFF position, contacts in battery electrical isolator (2) open and disconnect the 24 volt power and 24 volt ground from batteries (3) to the machine electrical system.

If battery disconnect switch (6) is used to isolate the machine electrical system, it will then be necessary to reset battery electrical isolator (2) by cycling battery isolation switch (4) before 24 volt power can be reconnected to the machine electrical system.

Note: Do not move the battery isolation switch to the OFF position while the engine is running. Machine electrical system damage could result.

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