The Routing of the Battery and Wiring Group (Electric Start) Must be Changed on Specific Off-Highway Trucks{1402, 1408} Caterpillar

Off-Highway Truck:

793D (S/N: FDB1-UP)

Introduction

ReferenceSpecial Instruction, REHS1841, "General Welding Procedures"

The problem that is identified in the technical information bulletin that follows does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.

Problem

The following off-highway trucks were manufactured with the 4Z-7054 Battery and Wiring Gp (Electric Start) :FDB111-119, FDB121-129, FDB134-141, FDB146-146, FDB150-157, FDB159-159, FDB161-163, FDB174-176, FDB193-198, FDB223-226, FDB281-285, FDB292-292, FDB303-303, FDB305-310, FDB337-339, FDB341-342, FDB344-349, FDB369-371 and FDB383-386

The electric cables of the 4Z-7054 Battery and Wiring Gp (Electric Start) were routed between the 285-0042 Hose As and the frame. The 285-0042 Hose As can rub the electric cables. This can expose wires inside the electric cables. The exterior of the hose assemblies can also wear from the rubbing. The reinforcing wire in the hose assemblies can become exposed. If the reinforcing wire from the hose assemblies contacts the wires inside the electric cables, a short circuit can occur. This can cause sparks and a fire.

Solution

You need to change the routing of the electric cables in the 4Z-7054 Battery and Wiring Gp (Electric Start). In order to change the routing of the electric cables, you will need to install one weld boss to the frame. Use the following procedure in order to change the routing of the electric cables.

Refer to Table 1 for the parts that are needed in order to change the routing of the electric cables in the 4Z-7054 Battery and Wiring Gp (Electric Start) .

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Illustration 1	g01371282

1. Refer to Illustration 1. Locate the 272-9849 Solenoid and Relief Valve Gp (5) that is on the right side of the frame.

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Illustration 2	g01371290
(6) 92 mm (3.6 inch) (7) 56 mm (2.2 inch)

2. Refer to Illustration 2. The 9R-2613 Weld Boss (1) will be located upward from the mounting bracket for the 272-9849 Solenoid and Relief Valve Gp and to the right of the mounting bracket for the valve group. Move any wires and hoses from the area.

3. By using the dimensions in Illustration 2, locate the position of the weld boss (1) .

4. Refer to the procedures and follow the procedures in Special Instruction, REHS1841, "General Welding Procedures". By using a 3 mm (0.12 inch) fillet weld (W1), weld the 9R-2613 Weld Boss (1) to the frame. The welding electrode should meet the following specifications.
   • AWS A5.1

   • AWS A5.18

   • AWS A5.20

   • AWS A5.17

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Illustration 3	g01371300

5. Refer to Illustration 3. Remove the electric cables from the clips at location (8), location (9), location (10) and location (11) .

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Illustration 4	g01371308

6. Refer to Illustration 4. Install the four new 5K-5338 Clips (2) at location (8), location (9), location (10) and location (11). Attach the new clips with the bolts and washers from location (8) and location (11). At the location (9) and the location (10), install one new 8T-4121 Hard Washer (4) to each new 8T-4137 Bolt (3). Install the new bolt and the new washer to clips (2) .

7. Move any wires or hoses to the original positions.