PRODUCT SUPPORT PROGRAM FOR REPLACING THE MAIN POWER RELAY(S) ON CERTAIN OFF-HIGHWAY TRUCKS, WHEEL LOADERS, ARTICULATED TRUCKS, TRACK-TYPE TRACTORS, WHEEL SKIDDERS, KNUCKLEBOOM LOADERS, COMPACTORS, WHEEL DOZERS, TRUCK FELLER BUNCHER, AND MOTOR GRADER Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE MAIN POWER RELAY(S) ON CERTAIN OFF-HIGHWAY TRUCKS, WHEEL LOADERS, ARTICULATED TRUCKS, TRACK-TYPE TRACTORS, WHEEL SKIDDERS, KNUCKLEBOOM LOADERS, COMPACTORS, WHEEL DOZERS, TRUCK FELLER BUNCHER, AND MOTOR GRADER

Usage:

TEBE4322-01

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16Mar2016

(Revised 21Mar2016)

U-135

A-105

D-121

O-116

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Before/After	PRODUCT SUPPORT PROGRAM FOR REPLACING THE MAIN POWER RELAY(S) ON CERTAIN OFF-HIGHWAY TRUCKS, WHEEL LOADERS, ARTICULATED TRUCKS, TRACK-TYPE TRACTORS, WHEEL SKIDDERS, KNUCKLEBOOM LOADERS, COMPACTORS, WHEEL DOZERS, TRUCK FELLER BUNCHER, AND MOTOR GRADERS
1423 7499		PS45020

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS45020" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.

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NOTE:	This Revised Service Letter replaces the 16Mar2016 Service Letter. A change has been made to the Title.

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TERMINATION DATE

31Mar2018

PROBLEM

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The existing main power relay can experience internal corrosion on certain machines listed below. This internal corrosion can cause a short to ground, or a short between the coil wires inside of the main power relay. If the existing main power relay fails, it can cause overheating of the relay and the adjacent wiring.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
914G	PDF01839, 1846, 1850, 1852, 1860-1863, 1865-1867, 1870
914G 2	KNP00414, 451, 453
938H	MCC00757
938K	HFW00264

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*****Group 2*****
120K	JAP05152 SZN01145, 1150-1151, 1154-1156, 1158-1162, 1445, 1456, 1587, 1660, 1662, 1745-1746, 1755, 1759-1761, 1778-1779, 1782, 1874, 1899, 1901, 1913, 1924, 1976-1977
120K 2	SZS00106
120K 2 OEM	SZZ00102
120M	B9C01175
12K	SZP00389-00391
12M	B9200130, 230, 239, 250
12M 2	F9B00153
140K	SZL01791, 1927, 2081-2082, 2084, 2306, 2352-2353, 2449, 2453-2454
140M	B9D04511, 4513 D9G01419, 1468, 1471, 1481
140M 2	M9D01144, 1572, 1744, 1791
14M	R9J00531, 533, 535, 559, 567, 571, 880, 1118
16M	R9H00733, 815, 822, 887, 891, 901, 909
24M	B9K00623, 628
525C	52501654, 1702, 1711, 1855, 1944, 1968, 2018, 2032
541B	F7D00200, 222, 226, 237
730C	LFF00261
740B	L4E02399, 2733, 2739, 2758, 2768, 2784-2786, 2816, 2831, 2840, 2843, 41945 T4R02299, 2328, 2330, 32032
740B EJ	L4F00413, 420, 490-491
770G	ECM00221
772G	LTS00317, 328-330
773E	ASK00846, 932, 991-998, 1092-1093 KEG00198, 202-203, 213, 216, 218, 267, 273, 314, 319-324
773G	MWH00186, 249, 253, 282-285, 300-301, 317, 329, 338, 346-352
775G	RFM00392-00395
777D	FKR01626-01633, 1676, 1947-1948, 1953-1955, 2007, 2037-2038, 2041-2042, 2046, 2071-2076, 2078, 2095-2104, 2156-2157
777G	RDR00256, 259-260 TNM00441-00442, 444, 446, 498, 507, 509, 531, 536-537, 539, 544, 546, 548, 551, 553, 555, 569, 604-606, 635-638, 675, 758
777G OEM	T5A00103
785C	APX02352-02354, 2368
785D	MSY00535, 537, 544-545, 561
785D OEM	DMC00135
789D	SPD00265-00267, 277, 309, 317, 423, 425, 430, 496, 513, 517-518, 528-529, 546, 548, 590-591, 593-594
793D	FDB01640
793F XQ	SND00117, 128-131
815F 2	BYN01027, 1052
824H	ASX00486, 502
825H	AZW00361
834H	BTX01247, 1285, 1311
950 GC	M5K00118, 123, 126
950H	MXL00474-00476, 478, 511, 536, 554, 556, 558, 745, 829, 854, 871-876, 878-881, 883-889, 891-892, 895, 970, 1033, 1035
962H	PCW00240, 260-261, 266, 285, 287 SSA00295
966H	BJ600222, 483, 510, 523, 527-528, 785 TAL02143, 2145, 2173, 2176, 2440
972H	GTA00776, 783
980H	KZL00699, 1102, 1269
986H	L8S00262-00263, 270, 272-274
988H	A7A00222 BXY05038
CW34	TLJ00412
D10T	RJG04069, 4147, 4289, 4461, 4467, 4528, 4543, 4590, 4657, 4660-4661, 4788, 4807, 4809, 4815, 4820-4821, 4858-4859, 4862, 4869-4870
D11T	AMA00321 JEL00233, 240-241, 249, 333, 336
D5R XL	D5X00101, 117-118, 122, 137, 161-188
D6T	SMC01636-01637, 1692
D6T XL	GCT02343, 2363-2367
D6T XL PAT	DTD01153
D7E	TAN01202, 1210, 1257-1258, 1336, 1338, 1350-1351
D7R	DSH00236, 242-244, 295, 308, 310-311, 324, 326-327, 329
D7R XR	DJR00110
D8R	9EM07415, 7544, 7793, 7903-7905, 7999, 8006, 8381, 8463, 8475-8478, 8878, 9016, 9056, 9103, 9140, 9152-9158, 9179, 9181-9182, 9184-9187, 9189-9190, 9193, 9232, 9246-9258 T5X00231, 259-260, 277, 283, 285, 303
D8T	FCT00361, 1189, 1313, 1350, 1357, 1359-1360 J8B04699, 4814 MLN00746-00748
D9R	WDM03551, 3698, 3766, 3777, 4067, 4074
D9T	TWG00207
PS-150C	FPS01388
PS-300C	PFS00367-00368

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*****Group 3*****
2670C	B3E01470
559C	KAS00240, 251
573C	RJT00280
579C	KAX00276
950K	FER00001, 153, 428, 639-640, 685, 3756 J5M01063 R4A01073
962K	FLL00163
966K	PBG00607, 1081, 1098, 1107-1108, 1119, 1136, 1138, 1174 TFS00793, 1187, 1226, 1276
966K XE	NGX00254
966M	KJP00464
980K	GTZ00283, 659, 719 W7K01670, 1984, 2194, 2429
980K OEM	NEP00113-00114
988K	TWX00301, 319, 347
992K	88000443-00444
992K 2	ZMX00480
993K	Z9K00517, 552-553, 557

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*****Group 4*****
924K	HJF00259, 265 PWR02285, 2634, 2675, 2720, 2742, 2982, 2986, 2994
930K	EYE00274 RHN01752, 2837, 3031, 3080
938K	HFW00276, 313, 388-389 SWL00602, 829, 1905, 1922, 2177, 2299, 2480, 2495, 2568, 2580, 2594, 2626, 2714 XXT00495

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*****Group 5*****
924H Z	JZZ00594
928H	CXK01988, 2017
930H	DHC04198, 54101

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
2	4B4277	WASHER
1	2418368	SWITCH AS-MAG
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 2*****
2	4B4277	WASHER
1	2418368	SWITCH AS-MAG
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 3*****
4	4B4277	WASHER
2	2418368	SWITCH AS-MAG
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 4*****
4	4B4277	WASHER
2	2418368	SWITCH AS-MAG
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 5*****
6	4B4277	WASHER
3	2418368	SWITCH AS-MAG
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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Install the new Main power relay(s) with the additional 4B-4277 Washers and increased torque as outlined in the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
0-1000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 1.0-hour job for Group 1

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
0-1000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 1.0-hour job for Group 2

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 3*****
0-1000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 1.0-hour job for Group 3

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 4*****
0-1000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 1.0-hour job for Group 4

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 5*****
0-1000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 1.0-hour job for Group 5

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

1. Locate and remove the 241-8368 Main Power Relay(s) on the machines listed above.

2. Mount the new Main Power Relay(s)

3. Clean and Install the appropriate Bus Bars / Ring Terminals.

4. Ensure the additional 4B-4277 Washers are placed between the nut and the Bus Bar/Ring Terminal. Use the hardware stack-up shown in Image 1.1.1 as a reference.

Image1.1.1

4. Tighten the Nuts to 9 +/- 0.5 Nm (80 +/- 4.4 lb in). This torque is critical for a good electrical connection. Over torquing of the nuts will cause damage to the Main Power Relay Cap and studs.

Note: A few degrees of stud rotation is acceptable. If the stud moves with the attached ring terminal, it is not considered to be a loose bolted joint.

Note: For machines that use bus bars, ensure that the vinyl coating on the bus bars is not part of the bolted joint. Cut off any portion that interferes with the electrical connection.

5. Secure the cables and wiring within 5 inches of the relay if possible.

Note: Do not secure the wiring directly to the relay housing. The relay housing gets hot and may deteriorate the insulation.