Battery Charger - CAT C27 Generator Set DWB00001-UP POWERED BY C27 Engine (SEBP4500 - 40) - Búsqueda Básica

9/4/2021 C27 Generator Set DWB00001-UP POWERED BY C27 Engine(SEBP4500 - 40)/Búsqueda básica
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Bienvenido: p210mcrb
Producto: GENERATOR SET
Modelo: C27 GENERATOR SET DWB00819
Configuración: C27 Generator Set DWB00001-UP POWERED BY C27 Engine
Instrucción Especial
Installation of Improved Battery Charger on Certain C27 Generator Sets{1401, 751B}
Número de medio -REHS5551-00 Fecha de publicación -07/04/2011 Fecha de actualización -06/06/2011
i04224509
Installation of Improved Battery Charger on Certain C27 Generator

Sets{1401, 751B}
SMCS - 1401; 751B
Generator Set:
C27 GEN SET (S/N: DWB1-UP)
Introduction
This Special Instruction provides information to install the new and improved 339-5996 Battery Charger . This
Special Instruction is only for rail-mounted battery chargers.
Important Safety Information

Do not perform any procedure in this special instruction until you have read this special instruction and you
understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools.
Failure to follow these procedures can result in personal injury. The following procedures should also be observed.
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. Ensure
that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is
safe.
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.
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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the
Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury
or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility.
Required Parts
Table 1
Parts List
Item Qty New Part Number Description Former Part Number
1 1 171-4523 Bracket 171-4523
118-4304
2 1 339-5996 Battery Charger 7C-9141
114-6486
281-5567
3 1 371-7079 Wiring Harness
277-4486
4 1 371-8293 Electrical Conduit Gp 323-0233
Note: The 171-4523 Bracket design has been changed to fit-up with the new battery charger. Refer to Illustration 4
to ensure that the correct bracket revision is being used.
References
ReferenceFor additional detailed information reference the following service publications: Operation and
Maintenance Manual, SEBU8088, "C27 and C32 Generator Sets" and 101295"SENS NRG2 24-10 Battery
Charger Installation & Operation Manual".
Note: The 101295"SENS NRG2 24-10 Battery Charger Installation & Operation Manual" is provided with the
new 339-5996 Battery Charger .
Work Procedure
Accidental engine starting can cause injury or death to personnel

working on the equipment.
To avoid accidental engine starting, disconnect the battery cable from

the negative (−) battery terminal. Completely tape all metal surfaces of
the disconnected battery cable end in order to prevent contact with
other metal surfaces which could activate the engine electrical system.
Place a Do Not Operate tag at the Start/Stop switch location to inform

personnel that the equipment is being worked on.
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.
Working with electrical circuits is hazardous. Bodily contact with

electrical potential will cause personal injury or death. Ensure that
personnel are trained in proper operating procedures in order to ensure
safe operation.
1. Isolate the generator set before commencing any work on the unit, open generator set breaker, activate
Emergency Stop, disconnect the battery cables, and either disconnect or open the control circuit breaker for
the AC power supply to the battery charger.
Illustration 1 g02403454
DC harness connections at engine starter
2. At the engine starter, disconnect and remove battery charger DC harness connections as shown in Illustration
1. The harness wire numbers to remove are 229-DC3 (5) and 101-DC4 (6) .
AC harness connections in the generator customer connection box
3. In the generator customer connection box, remove the battery charger AC harness connections from the AC
terminal strip as shown in Illustration 2. The harness wire numbers to remove are 131-BB1 (7), D200-BB3
(8), and 144-BB2 (9) .
DC harness connections in the generator customer connection box
4. If applicable, in the generator customer connection box, remove the battery charger alarm sensor
connections from the DC terminal strip as shown in Illustration 3. The harness wire numbers to remove are
202-DC2 (10) and G448-DC1 (11) .
5. Remove the battery charger with connected harnesses from the existing battery charger mounting bracket
assembly. Save all the mounting hardware.
6. Remove the existing battery charger mounting bracket and save all mounting hardware.
New battery charger mounting bracket
7. Install the appropriate new battery charger mounting bracket (1). Use the mounting hardware that was saved
in Step 6.
8. Install the new battery charger (2) onto the new battery charger mounting bracket (1). Ensure that the battery
charger is mounted on the battery charger mounting bracket holes (12) properly as shown in Illustration 4.
Use the mounting hardware that was saved in Step 5.
NOTICE
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. 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.
Battery charger internal adjustment configuration
9. Remove the battery charger cover and configure the new battery charger Internal Adjustments for operation.
Refer to Illustration 5.
a. Set the AC voltage select switch (SW100) according to the line voltage. Use the 115V position for
nominal mains voltages between 110V and 120V. Use the 230V position for nominal mains voltages
between 208V and 240V.
b. Set the battery range jumper (JP1A) according to nominal battery voltage. Use the 12V position for
12V batteries. Use the 24V position for 24V batteries.
c. Set the boost mode jumper (JP1B) 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.
d. Set the float voltage select jumper (JP1C) according to the battery manufacturer recommended 25 °C
(77 °F) float voltage.
The settings are:
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
*If using the factory as-shipped batteries, use these voltage settings. If not, refer to the battery
specifications on your respective batteries.
e. Set the Display Selector jumper to one of the three available positions on JP800.
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.
**AUTO required for NFPA110.
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.
Reference battery charger wiring terminal locations
(13) 115/230VAC
(14) Neutral
(15) Alarm contacts
(16) Battery+
(17) Battery-
(18) Grounding conductor
(19) Use wiring routing harness clip to hold AC power conductors at least 6.4 mm (0.25 inch) away from DC battery and alarm sensor
conductors.
10. At the battery charger with the battery charger cover still removed connect the new AC and DC harnesses.
Connect the grounding conductor, the DC output supply wiring, the AC power supply wiring, and the
battery charger alarm sensor wiring. Use the following sequence to connect the various conductors. Refer to
Illustration 6 for internal routing and connections.
Connect the Grounding Conductor (wire D200-BB3)
Connect the B+ Conductor (wire 101-DC4)
Connect the B- Conductor (wire 229-DC3)
Connect the AC Neutral Conductor (wire 131-BB1)
Connect the AC Line Conductor (wire 144-BB2)
Connect the Alarm Sensor wiring (wire G488-DC1 on Pin 7) (wire 202-DC2 on Pin 9)
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. Always observe proper polarity of the DC power supply wiring.
Confirm proper conductor termination points using the OEM provided NRG2 24-10 Battery Charger
Installation and Operation Manual.
11. Install and secure the battery charger cover.
120V AC harness connections in the generator customer connection box
240V AC harness connections in the generator customer connection box
12. In the generator customer connection box, connect the battery charger AC harness connections to the AC
terminal strip.
a. For 120V power supply the harness wire numbers to connect are 131-BB1 (7), D200-BB3 (8), and
144-BB2 (9). Wire 131-BB1 should be connected to "N", wire D200-BB3 should be connected to
"GND", and wire 144-BB2 should be connected to "144" on terminal strip. Refer to Illustration 7.
b. For 240V power supply the harness wire to connect are 131-BB1 (7), D200-BB3 (8), and 144-BB2
(9). Wire 131-BB1 should be connected to "140", wire D200-BB3 should be connected to "GND",
wire 144-BB2 should be connected to "142" on the terminal strip. Refer to Illustration 8.
DC harness connections at engine starter
13. At the engine starter, connect the battery charger DC harness connections as shown in Illustration 9. The
harness wire numbers to connect are 229-DC3 (5) and 101-DC4 (6) .
DC harness connections in the generator customer connection box
14. In the generator customer connection box, connect the battery charger DC harness connections to the DC
terminal strip as shown in Illustration 10. The harness wire numbers to connect are 202-DC2 (10) and G448-
DC1 (11). Wire 202 should be connected to "Aux -" and wire G448 should be connected to "DI-06" on the
terminal strip.
15. Reconnect the battery cables and close the control circuit breaker for the AC power supply to the battery
charger.
16. Verify the correct operation of the battery charger.
Copyright 1993 - 2021 Caterpillar Inc. Fri Apr 09 2021 11:03:47 GMT-0600 (hora estándar central)
Todos los derechos reservados.
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Battery Charger - CAT C27 Generator Set DWB00001-UP POWERED BY C27 Engine (SEBP4500 - 40) - Búsqueda Básica

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9/4/2021 C27 Generator Set DWB00001-UP POWERED BY C27 Engine(SEBP4500 - 40)/Búsqueda básica

Installation of Improved Battery Charger on Certain C27 Generator

Important Safety Information

4 1 371-8293 Electrical Conduit Gp 323-0233

Accidental engine starting can cause injury or death to personnel

To avoid accidental engine starting, disconnect the battery cable from

Place a Do Not Operate tag at the Start/Stop switch location to inform

Working with electrical circuits is hazardous. Bodily contact with

The settings are:

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

**AUTO required for NFPA110.

(15) Alarm contacts

(18) Grounding conductor

Connect the Grounding Conductor (wire D200-BB3)

Connect the B+ Conductor (wire 101-DC4)

Connect the B- Conductor (wire 229-DC3)

Connect the AC Neutral Conductor (wire 131-BB1)

Connect the AC Line Conductor (wire 144-BB2)

11. Install and secure the battery charger cover.

16. Verify the correct operation of the battery charger.

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