GRAPPLE GP-HYD 4531296 - Caterpillar

Illustration 10 g03782046
If there is no damage to the lead cables, then add 416-1646 Tape so that the cable is held tight in the cable support. Wrap the tape tightly around the cable lead until the cable fits tight in the cable support hole. See examples of where lead cables can be protected with tape in the Illustration 11.
For High Voltage units as shown in Illustration 7 remove the cable support bolts and lift the cable support up to tape the leads. One can also unbolt from the bus bar and push down to tape from the access hole. Refer to Illustration 9 and 10.
For Medium Voltage units as shown in Illustration 8, remove the cable-ties and remove the cable support bolts to lift the lead board up. Tape the leads then pull the leads up through the cable support one at a time. Access through the access holes to adjust tape thickness if required.
Illustration 11 g03782047
Illustration 12 g03786317
For leads with abrasion damage, the procedure to repair is as follows:Repair Lead Cables as necessary with one of the following procedures.Note: Lead cable repairs may increase the diameter of the lead cable such that a larger hole is required in the cable support, or a clamp support may be required. Refer to Illustration 1.
If the lead cable is damaged, but not beyond repair, make the repair as follows using the materials provided in the 475-0266 Repair Kit : (i) Sand the surface of the wire insulation in the repair area with a fine grit sandpaper, clean the area with denatured alcohol, and allow to dry. (ii) Insulate the wire as follows: - Cover the area with white RTV 162 silicone rubber adhesive sealant. - Cover the RTV with red silicone tapered tape. Use enough layers to build up to the original insulation height, and extend the final layer on to the lead cable insulation at least 1 inch. - Cover the silicone tape with heat shrinkable tubing. Refer to Illustration 13 for LV example and Illustration 14 for HV example.
Re-bundle phase leads as necessary using cable ties.
Reinstall all phase cable leads if they have been removed.
Apply 1/8" thick neoprene rubber mat (from material kit), in areas where multiple lead cables run across a frame opening as shown in Illustration 12.
Torque all terminal mounting bolts and lugs bolts to the proper value.
Perform Insulation Resistance (megger) test at 1000vdc to confirm insulation strength. Refer to the Special Instruction, SEHS9124, "Winding Insulation Maintenance and Cleaning and Drying of the Generators" for more information.
Take pictures of competed cable improvements for future reference.
Install terminal box cover.
Illustration 13 g03782121
Illustration 14 g03782122
Table 1
CAT P/N     ESO LS #     Description     Phase Lead Support (Wide)     CAT P/N     Mounting Hardware     Qty     Clamp Hardware     Qty    
456-0052
Generator Box Support Gp     62519651     ESO 3000 FR LEAD SUPPORT KIT 6-12 LEAD #2 15KV WIRE (HV) 3010-3045FR.     42527601     456-0053
Support     HEXAGONAL HEAD M6 X 40/40 FULLY THREADED and