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}
`
Load Haul Dump:
R2900G (S/N: GLK1-UP; JLK1-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 R2900G (S/N: GLK1-UP; JLK1-818).

The new 254-3783 Magnetic Switch is effective in production with R2900G (S/N: JLK819-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    
1     116-0118     Clip    
1     1DE4128 (316-2969)     Suppressor Harness    
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 1g01416555

  1. Remove cover (1) .



    Illustration 2g01416556

    (2) 241-8368 Magnetic Switch




    Illustration 3g01418195

    (2) 241-8368 Magnetic Switch

  1. Remove and discard magnetic switch (2) .



    Illustration 4g01418197

    (3) 254-3783 Magnetic Switch

  1. Install magnetic switch (3) .

  1. Install cover (1) .

Starter Relay Installation

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



    Illustration 5g01416561

    Left hand view of engine

    (1) 241-8368 Magnetic Switch

  1. Remove and discard magnetic switch (1) .



    Illustration 6g01416562

    (2) 254-3783 Magnetic Switch

    (3) 116-0118 Clip

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



    Illustration 7g01416563

    (2) 254-3783 Magnetic Switch

    (4) 1DE4128 Suppressor Harness

    (5) 1DE0064 Cable Strap

  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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