2007/10/08 A New Main Power Relay and Starter Relay are Now Used {4493, 7499} Caterpillar


A New Main Power Relay and Starter Relay are Now Used {4493, 7499}
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Load Haul Dump:
R1600G (S/N: 9PP1-UP)
Service Magazine, SEPD0909, 08 October 2007, "A New Main Power Relay and Starter Relay are Now Used". Disregard this article. The serial number range has changed. Refer to the article that follows.

Description of Change: A new main power relay and starter relay are now used in the electrical and starting system.

Adaptable To: The new 254-3783 Magnetic Switch is a direct replacement for R1600G (S/N: 9PP1-147).

The new 254-3783 Magnetic Switch is adaptable to R1600G (S/N: 9PP148-254). Refer to the following procedure.

The new 254-3783 Magnetic Switch is effective in production with R1600G (S/N: 9PP255-UP).

Table 1
Former Part Number     Description     New Part Number    
241-8368     Magnetic Switch     254-3783    

Procedure to Install the New Main Power Relay and Starter Relay. R1600G (S/N: 9PP148-254).

Table 2
Required Parts    
Qty     Part Number     Description    
2     254-3783     Magnetic Switch    
2     116-0118     Clip    
1     1DE4128 (316-2969)     Suppressor Harness    
1     1DE4129 (316-2970)     Suppressor Harness    
1     1DE0064 (163-5807)     Cable Strap    
1     5S-7349     Bolt    
2     8T-9367     Bolt    
2     5P-4115     Hard Washer    
1     124-2716     Spacer    

Main Power Relay Installation

  1. Turn the disconnect switch and the key start switch to the OFF position.



    Illustration 1g01414163

  1. Remove cover (1) .



    Illustration 2g01414168

    (2) 241-8368 Magnetic Switch

  1. Remove and discard magnetic switch (2) .



    Illustration 3g01414637

    (3) 254-3783 Magnetic Switch

    (4) 5S-7349 Bolt

    (5) 8T-9367 Bolt

    (6) 5P-4115 Hard Washer

  1. Install magnetic switch (3) .



    Illustration 4g01414639

    (7) 124-2716 Spacer

    (8) 8T-9367 Bolt

    (9) 5P-4115 Hard Washer

    (10) 116-0118 Clip

  1. Install spacer (7) and clip (10) .



    Illustration 5g01414640

    (3) 254-3783 Magnetic Switch

    (10) 116-0118 Clip

    (11) 1DE4129 Suppressor Harness

    (12) 1DE0064 Cable Strap

  1. Connect suppressor harness (11) between magnetic switch (3) and the existing harness.

  1. Install suppressor harness (11) to clip (10) .

  1. Install two cable straps (12) .

Starter Relay Installation

  1. The disconnect switch and the key start switch remain in the OFF position.



    Illustration 6g01414642

    Left side view of engine

    (1) 241-8368 Magnetic Switch

  1. Remove and discard magnetic switch (1) .



    Illustration 7g01414644

    (2) 254-3783 Magnetic Switch

    (3) 116-0118 Clip

    (4) 1DE4128 Suppressor Harness

    (5) 1DE0064 Cable strap

  1. Install magnetic switch (2) and clip (3) .

  1. Connect suppressor harness (4) between magnetic switch (2) and the existing harness.

  1. Install suppressor harness (4) to clip (3) .

  1. Install two cable straps (5) .

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