Installation Procedure for the Space Heater On Generator Sets{4450} Caterpillar

Generator Set:

3406C GEN SET (S/N: C2G1-UP; C5G1-UP; C8G1-UP; KPS1-UP; 9ES1-UP; LRX1-UP)

3456 GEN SET (S/N: CCB1-UP; C1G1-UP; C3G1-UP; C4G1-UP; CBX1-UP)

C15 GEN SET (S/N: PEC1-UP; C5H1-UP; CYY1-UP; C5E1-UP; C5L1-UP)

C15 PET GS ENG (S/N: PET1-UP)

C18 GEN SET (S/N: C6C1-UP; G4C1-UP; STD1-UP; PEE1-UP; PEJ1-UP; STM1-UP; EKW1-UP)

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

C18 GEN SET (S/N: DKE1-UP)

Introduction

This Special Instruction provides information in order to install a space heater on the generators and engines that are listed above.

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 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 operating technique that is not specifically recommended by Caterpillar is used, you must ensure that it is safe for you and for other people to use.

You should 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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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.

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Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

Parts List

Installation

1. Enable the emergency stop.

2. Remove the battery cables from the battery.

3. Lock out the load circuit breakers.

4. Remove the cable connections for the load.

5. Isolate the auxiliary voltage from the control panel.

6. Remove the rear air inlet screen.

7. Attach 240-0238 Space Heater As to the generator. Use the two M5 screws that are present on the generator.

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Illustration 1	g01722333

8. Attach the wiring harness to the space heater.

   Note: Polarity of the wires does not matter.

9. Run the wiring along the generator and into the control panel.

10. Ensure that there is adequate wire in order to secure the harness to the generator.

11. Use a tie strap in order to strap the harness to the generator.

12. Cut off the excess wire from the harness before you install the "AH1" and "AH2" connectors into the control panel.

13. Proceed to Test Step 15 if the unit has a jacket water heater or a battery charger that is mounted to the rail. If the unit does not have a jacket water heater or a battery charger that is mounted to the rail, proceed to Test Step 14.

14. Add a control relay. Determine if you have an EMCP2 or an EMCP3 control panel. Refer to Table 2 for the group part number that needs to be added.
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    Table 2

    Control Panel	Configuration	Control Group	Chassis Group	Wire Diagram
    EMCP3	Line to Line	"A" Illustration 2	"E" Illustration 6	"G1"	Illustration 8
    				"G2"	Illustration 9
    				"G3"	Illustration 10
    				"G4"	Illustration 11
    				"G5"	Illustration 12
    EMCP3	Line to Neutral	"B" Illustration 3	"E" Illustration 6	"G1"	Illustration 8
    				"G2"	Illustration 9
    				"G3"	Illustration 10
    				"G4"	Illustration 11
    				"G5"	Illustration 12
    EMCP2	Line to Line	"C" Illustration 4		"F"	Illustration 7
    EMCP2	Line to Neutral	"D" Illustration5		"F"	Illustration 7

15. Hook up the wires from the space heater to the control panel. Refer to Table 3 for the correct configuration for the pins.
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    Table 3

    	Line to Line	Line to Neutral
    EMCP2	Pin 20 and Pin 9	Pin 20 and Pin 24
    EMCP3	Pin 9 and Pin 14	Pin 9 and Pin 13

16. The space heater is properly connected.

17. Connect the battery cables.

18. Disable the emergency stop and allow the unit to return to the Run position.

19. Connect the voltage supply to the control panel.

20. Run a complete functional test on the control circuit for the heater.

21. Make sure that the heater and the battery charger are powered when the unit is in the Auto position and the Stop position.

22. Also, ensure that the power is disconnected when the unit is in the Run position.

Illustration 2	g01746757

Illustration 3	g01746758

Illustration 4	g01746760

Illustration 5	g01748837

Illustration 6	g01746759

Illustration 7	g01746761

Illustration 8	g01746762

Illustration 9	g01746763

Illustration 10	g01746765

Illustration 11	g01746766

Illustration 12	g01746767

Reference Section

Instructions for Locating the Parts

1. Login to "SISWeb".

2. Select the "Advanced Full Text Search" link.

3. Select the "Information Type" list. Then, select "Parts Identification".

4. Enter the appropriate control number in the "Part Number" field. Refer to Table 4 for the control numbers.

5. Click on the "Search" button.

6. Select the appropriate engine model from the list.

Instructions for Locating the Wiring Diagrams

1. Login to "SISWeb".

2. Select the "Engine Technical Marketing Information" link.

3. In the "Reference Number" field, enter the appropriate drawing number. Refer to Table 5 for the drawing numbers.

4. Select "Part Number" from the drop-down menu.

5. Click on "Retrieve Data".

6. Click on "Download Drawing".

   Note: You must have software that can be used to view the drawing.