- Electric Power Generation
- C2.2 GEN SET (S/N: JK71-339; JK81-128)
- Generator Set
- XQ60 (S/N: CF61-275; CF91-141)
Introduction
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.
This Special Instruction describes the rework procedure for new voltage selector switch cable routing and cable repair.
Safety Section
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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility. |
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Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage. |
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Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below. |
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Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed. |
Required Parts
| Quantity | New Part Number | Part Name |
|---|---|---|
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Abrasion Sleeve | |
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Abrasion Sleeve | |
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Seal | |
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N/A | THOMAS & BETTS CO TBFT201-36 Self Fusing Insulation Tape |
| 1 | Panel Harness As | |
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N/A | Scotch®Super 33+™ Vinyl Electrical Tape |
| 6 | Cable Strap |
Rework Procedure
- Remove the terminal box cover and inspect the cable insulation for damage. If the copper conductor is not damaged, the cable insulation must be repaired.
Note: If the copper conductor is damaged on 478-7864 Panel Harness As, the copper conductor must be replaced.
Note: If the bolt threads are facing towards the cables, remove the bolts and install with the threads facing outward.
- If the bolt threads are facing towards the cables, remove the bolts and install with the threads facing outward.
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| Illustration 1 | g06328867 |
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(A) Bolt
(B) Nut (C) Terminal Box Cover | |
Cable Repair
- Wrap the area of the damaged insulation with the THOMAS & BETTS CO TBFT201-36 Self Fusing Insulation Tape. Follow the instructions below for applying the tape.
- Cut an easy to handle length of tape and stretch the tape over the damaged cable until the width of the tape is reduced by half.
- Wrap along the center-line with as much tension as possible. When the tape touches the previous layer, the tape will stick and hold.
- Extend the tape a minimum of
32 mm (1.25 inch) over the damaged insulation. For additional layers, use less tension and, stretch the tape until the width of the tape is reduced by one quarter inch.
- Wrap the Scotch®Super 33+™ Vinyl Electrical Tape over the THOMAS & BETTS CO TBFT201-36 Self Fusing Insulation Tape.
- Install the 356-0195 Abrasion Sleeve over the repair area. Secure the abrasion sleeve with the 7K-1181 Cable Strap.
Note: The 356-0195 Abrasion Sleeve is a split sleeve with velcro ends.
Cable Routing
- Ensure that the 3E-6600 Seal is present on the top of the voltage selector switch bracket.
- If missing or damaged, add the 3E-6600 Seal to the bottom of the voltage selector switch bracket.
- Reroute the cables to avoid contact with all panels and all sharp edges.
- Route and bundle the cables parallel to one another.
Note: If required, loosen the cable connections, reposition cables to avoid contact with the panels or sharp objects, and retighten the cable connections.
- Add the 7K-1181 Cable Strap as necessary to maintain a clearance of
9.5 mm (0.37 inch) between the cables and all panels. - Add the 356-0195 Abrasion Sleeve over any individual cables that are contacting, or have the potential to contact the panels, wire tie ends, or sharp objects.
Note: If required, 160-2249 Abrasion Sleeve can be used to protect the larger cable bundles. This sleeve is not split. The cable ends will need to be disconnected to install.
Note: If needed, optimize cable length to improve routing.
Examples of Correct Cable Routing and Placement of Cable Straps
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| Illustration 2 | g06311231 |
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Illustration 2 shows an example of the proper cable routing for XQ35 Generator Set. (1) (2) Cables routed over the edge guard on the switch bracket | |
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| Illustration 3 | g06311234 |
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Illustration 3shows an example of the proper cable routing for XQ60 Generator Set. (1) (2) Cables routed over the edge guard on the switch bracket | |