SUBJECT: FT4250 and FT2650. Electrical Harness Replacement and Alternator Circuit Breaker Fix.

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KPI-JCI is requiring the replacement of the engine electrical harness on FT4250 and FT2650 plants with Tier 4 fi nal engines due to the DEF tank lines not purging upon engine shutdown. In addition to this, FT4250 units will need the hardware that attaches the breaker to the plate on the alternator circuit breaker replaced to eliminate possible failure.

Electrical Harness Replacement

Tools/Equipment Needed

• Engine Harness replacement kit• 5/32” Allen wrench• 3/32” Allen wrench• 9/16” wrench and socket• 11/16” deep well and socket• 10 mm deep well and socket • 1/2” socket or wrench• #2 fl athead screwdriver• 11/32” nut driver• Channel lock pliers • Side cutters

Use the following procedure to replace the electrical harness. Access to the the engine will be on the back side of the engine enclosure above the undercrusher conveyor.

NOTE: Please follow all safety procedures when working on the plant.

Existing Harness Removal

Use the following procedure to remove the existing harness from the engine. The picture below is an overall picture of a CAT engine. The areas circled in red indicate areas pertaining to steps in the procedure.

1. Turn battery disconnect to the off position. Lockout/tagout all power to the Fast Trax plant.

Service BulletinSerial Numbers FT4250 414062-415163

FT2650 414405-414999

October 1, 2015SB 055 1510 FT HSI JAW

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2. Unplug C4 connector from inside the elec-trical control panel.

C4 connection

3. In the spot marked C4, use the channel lock pliers to loosen the nut. Once loose, remove the nut and lockwasher from the spot.

C4 connection - nut, lockwasher, and connection removed

4. Remove C4 plug from the mounting hole.

5. Remove the ECM plug with a 5/32” Allen wrench.

ECM plug

6. Cut and remove any zip ties connected to the existing harness.

7. Unplug CR5 fuel pump relay located behind crossover engine brace.

CR5 fuel pump relay

SB 055 1510 FT HSI JAW October 1, 2015

SB 055 1510 FT HSI JAW October 1, 2015

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8. Remove plugs P30, P31, and P32 located on the power relay module(s).

P30 plug

P31 plug

P32 plug

Note: The orientation of the P30 and P32 plug may be switched. Record the location of each plug for re-assembly.

9. Use a 10 mm socket to remove TRM2, TRM4, and TRM6 from the power relay module(s).

Note: You do not need to remove the two 12 gauge wires from the 12-4 conductor cable.

TRM6

TRM4

TRM2

Note: The orientation of the TRM6 and TRM4 may be switched. Record the loca-tion of each terminal for re-assembly.

10. Using a fl at head screwdriver, remove the buss bar cover.

Buss bar cover

11. Using an 11/16” deep well socket, remove the battery negative connectors TRM5 and TRM3.

TRM3

TRM5

Battery negative connectors

12. Remove P8 starter relay plug and TRM8 (blue wire) using a 1/2” socket or wrench.

TRM8 (blue wire)

Starter relay plug (P8)

13. Follow the coolant sensor wire (P5 and P1 connectors) leading up to the top of the radiator from the ECM. Cut and remove all zip ties connected with this section of the harness.

Leave the big zip tie holding the connector to P1 fastened to the coolant line.

Leave this zip tie and connector fastened to coolant line

P1 Connector

14. Unplug the P5 connector from the air inlet temp sensor.

P5 Connector

15. With all the zip ties cut and removed, and all connections disconnected, remove har-ness from engine compartment.

SB 055 1510 FT HSI JAW October 1, 2015

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SB 055 1510 FT HSI JAW October 1, 2015

Installing New Engine Harness

Use the following procedure to install the new engine harness.

1. Using a 5/32” Allen wrench, connect the ECM plug to the engine.

ECM plug

2. Route the harness to the right of the ECM plug and down behind the support bracket towards the PRM connections.

3. With the breakout section (of the harness) close to the bracket, secure the wire har-ness with a large zip tie.

Zip tie harness to bracket

4. Lay the C4 portion of the engine harness behind the accumulator mounting plate and leave it lay to be connected later.

Accumulator mounting plate

Harness

5. Reconnect the CR5 fuel pump relay plug into the relay.

CR5 fuel pump relay

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6. Connect the P8 starter relay plug to the connector from the starter relay coil.

7. Secure the TRM8 (blue wire) to the starter relay using the lockwasher and nut. Tighten with a 1/2” socket or wrench to 140 in.lbs.

Starter relay TRM8 (blue wire)

P8 plug

8. Using an 11/16” deep well socket, install TRM3 and TRM5 (battery negative) onto buss bar and secure with lockwasher and nut. Tighten to 37 ft.lbs.

TRM3 and TRM5 (BAT NEG)

Buss bar

9. Using a fl at head screwdriver, install the buss bar cover.

Buss bar cover

10. Neatly arrange the wires leading towards the PRM’s. Use a large zip tie to secure wires to the supplied bracket.

Secure wires to PRMs with a large zip tie

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SB 055 1510 FT HSI JAW October 1, 2015

SB 055 1510 FT HSI JAW October 1, 2015

11. Using a 10mm socket, connect TRM4 to PRM1 fused only, TRM2 to PRM1 switched, and TRM6 to PRM2 switched. Tigthen to 92 in.lbs.

PRM 1

PRM 2

PRM 3TRM6

TRM4

TRM2

12. Plug P30 into PRM1 (Bottom), P31 into PRM 2 (Middle), and P32 into PRM3 (Top).

PRM 1

PRM 2

PRM 3

13. Following CAT installed wiring, fi nish rout-ing P1 and P5 section of harness towards the radiator with P1 leading to the coolant sensor and P5 to the air inlet temp sensor. Secure wire every 8-10” with medium zip tie.

P1 Connector

14. Plug P5 into the air inlet temp sensor (this is easier to achieve from the platform side of the machine), and secure with medium size zip tie.

P5 Connector

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5. Install purge lamp indicator light to the mount in the hole next to the battery dis-connect. Use channel lock plies to tighten nut and secure light to mount.

Tighten this nut to secure light to mount

6. Plug P9 into the back of the purge indicator lamp. Use zip ties to secure any extra part of the cord.

7. On FT4250 units, complete the Alternator Circuit breaker update on page 9.

For FT2650 units skip, this step and go to step 8.

8. Remove lockout/tagout. Turn battery dis-connect to the “ON” position.

9. Test the functionality of the purge indicator light by starting the engine, letting it run for 5 minutes, and then turning the keyswitch off. At this time the purge indicator light should come on. Do not turn the battery disconnect off until the purge indicator light goes off.

10. Add the purge lamp indicator decal to the plant as shown in the picture below.

Purge indicator light decal

Purge indicator light

15. Reaching between the main frame and back of the electrical control panel, locate the C4 plug and feed it into the C4 mount-ing hole in the back plate of the control panel. Secure with a new lockwasher and nut. Use channel lock pliers to tighten the nut.

C4 connection

16. Plug in the C4 connector.

Purge Light Indicator Installation

The purpose of the purge light indicator is to let the operator know when the engine has fi nished purging the DEF tank lines. The battery disconnect cannot be turned to the OFF position until the purging process is complete.

1. Remove battery disconnect from mount using 3/32” Allen wrench and 11/32” nut driver.

2. Remove existing battery disconnect mount from plant using 9/16” wrench and socket.

3. Install new battery disconnect mount where old mount was located using exist-ing hardware.

4. Install existing battery disconnect to new battery disconnect mount.

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SB 055 1510 FT HSI JAW October 1, 2015

SB 055 1510 FT HSI JAW October 1, 2015

Alternator Circuit Breaker Update (FT4250 plants only)

Along with replacing the harness, KPI-JCI is requiring a hardware update to the alternator circuit breakers. The procedure involves replacing the rivets on the alternator circuit breaker with screws. The hardware for this update is included in the FT4250 harness replacement kit.

Tools Need• 1/2” deep well socket• 1/2” wrench• Drill• 1/8” drill bit• Flathead screwdriver• 3/8” nut driver• 1/4” nut driver• Channel lock pliers

Use the following procedure to update the hardware on the alternator circuit breaker.

1. Make sure all power to the plant is locked out/tagged out. Make sure battery discon-nect is in the OFF position.

2. Use a 1/2” wrench to disconnect the jumper on the battery.

3. Disconnect electrical connections to the alternator circuit breaker.

4. Use a 1/2” deep well socket to remove the black mounting bracket from the engine (two bolts).

5. Remove the alternator circuit breaker from the mounting plate using a fl athead screw-driver and 3/8” nut driver (four screws).

6. Use drill and 1/8” drill bit to drill out the riv-ets (as circled in red in the picture) on the alternator circuit breaker.

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7. Coat new screws with blue Loctite 242. Install in alternator circuit breaker. Secure with washer and nut. Tighten nut with a 1/4” nut driver.

8. Install two washers into each bolt that secures the mounting plate to the breaker. Re-install alternator circuit breaker to mounting plate with existing hardware.

9. Install black mounting bracket to the engine.

10. Go back to step 8 of the harness installa-tion procedure to test the functionality of the purge indicator light.

Alternator Circuit Breaker with Updated Hardware

Please send to:

Name:

Address:

City: State: Zip:

Attn:

Serial Number:

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Check the boxes below and return to KPI-JCI.

Order one kit for each Fast Trax plant.

Send ______ FT2650 T4f Electrical Harness Replacement Kit (P/N 382623)

Send ______ FT4250 T4f Electrical Harness Replacement Kit (P/N 382625)

Parts and 6 hours labor will be covered under KPI-JCI warranty.

KPI-JCI700 W 21st. St.Yankton, SD 570781-800-532-9311Fax: 1-800-514-6115Email: mail@kpijci.com

SB 055 1510 FT HSI JAW October 1, 2015