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:
R1700G (S/N: SBR1-UP)

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 adaptable to R1700G (S/N: SBR1-561).

The new 254-3783 Magnetic Switch is effective in production with R1700G (S/N: SBR562-UP).

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

Procedure to Install the New Main Power Relay and Starter Relay

Table 2
Required Parts    
Qty     Part Number     Description    
2     254-3783     Magnetic Switch    
2     1DE4128 (316-2969)     Suppressor Harness    
1     124-2716     Spacer    
2     116-0118     Clip    
1     130-5300     Clip    
1     5S-7349     Bolt    
1     8T-9367     Bolt    
1     8T-4138     Bolt    
2     5P-4115     Hard Washer    
1     1DE0064 (163-5807)     Cable Strap    

Main Power Relay Installation

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



    Illustration 1g01414645

  1. Remove cover (1) .



    Illustration 2g01414168

    (2) 241-8368 Magnetic Switch




    Illustration 3g01414646

    (2) 241-8368 Magnetic Switch

  1. Remove and discard magnetic switch (2) .

  1. Reposition clip (6) through 180 degrees to the other side of bolt (5) .

  1. Reposition harness connector (4) to clip (3) .

  1. Remove and discard spacer (7), bolt (8) and clip (9) .



    Illustration 4g01414648

    (10) 254-3783 Magnetic Switch

    (11) 5S-7349 Bolt

  1. Install magnetic switch (10) .

  1. Install bolt (11) .



    Illustration 5g01414665

    (10) 254-3783 Magnetic Switch

    (12) 130-5300 Clip

    (13) 124-2716 Spacer

    (14) 8T-9367 Bolt

    (15) 5P-4115 Hard Washer

    (16) 1DE4128 Suppressor Harness

    (17) 1DE0064 Cable Strap

  1. Install two clips (12), spacer (13), bolt (14) and washer (15) .

  1. Connect suppressor harness (16) between magnetic switch (10) and existing harness.

  1. Install two cable straps (17) .

Starter Relay Installation

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



    Illustration 6g01416032

    Rear view of engine

    (1) 241-8368 Magnetic Switch

  1. Remove and discard magnetic switch (1) .



    Illustration 7g01416039

    Part of 9EQ7856 Engine Harness

    (2) Harness Receptacle




    Illustration 8g01416034

    (2) Harness Receptacle

    (3) 254-3783 Magnetic Switch

    (4) 116-0118 Clip

  1. Remove contact 1 wire T946-PU from harness receptacle (2) .

  1. Remove contact 2 wire 306-GR from harness receptacle (2) .

  1. Install wire 306-GR into contact 1 of harness receptacle (2) .

  1. Install wire T946-PU into contact 2 of harness receptacle (2) .

  1. Install 254-3783 Magnetic Switch (3) and 116-0118 Clip (4) .



    Illustration 9g01416056

    (3) 254-3783 Magnetic Switch

    (4) 116-0118 Clip

    (5) 1DE4128 Suppressor Harness

    (6) 1DE0064 Cable Strap

  1. Connect suppressor harness (5) between magnetic switch (3) and the existing harness.

  1. Install suppressor harness (5) to clip (4) .

  1. Install two cable straps (6) .