0335158 JOHNSON NEEDLE

Introduction
This Special Instruction describes the installing a starter motor relay on the engines listed above.Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.Safety Section
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.A person must be alert to potential hazards. This person must also have the necessary training, skills, and tools to perform these functions properly.Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance of a potential hazard.Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Avoid using a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar. If used, ensure the safety of the operating personnel and others.Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures.Operation and maintenance of the machine must not occur unless the instructions and warnings in the machines Operation and Maintenance Manual have been read and are understood.
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Personal injury can result from improper handling of chemicals.Make sure you use all the necessary protective equipment required to do the job.Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used.Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.
Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.
Required Parts
Table 1
Required Parts
Qty Part Number Part Name
2 1H-3338 Lockwasher
1 286-4745 Circuit Breaker
1 286-4774 Bus Bar
2 2L-8077 Ring Terminal
2 5C-2890 Nut
1 9X-8124 Magnetic Switch As
2 9X-8256 Washer Installation Procedure
Illustration 1 g06350576
Schematic
Illustration 2 g06350580
Panel Board
Obtain parts
Run EPR wires behind (left side of) Starter Motor Relay (SMR).
Remove wire 101-A288 from old SMR. 101-A288 needs carefully terminated in conduit. This is particularly important as it is an unfused battery (+)ve. This should be snipped, inline crimped (with nothing on the other end) and taped over for maximum confidence that a short will not occur.
Move wires A774-A187 and R564-A214 from the coil of the old SMR to the coil of the new SMR ( 9X-8124 Magnetic Switch As).
Cut the spade connector off X861-A205 as close as possible to the spade connector and re-crimp with red ring crimp. Wire X861-A205 may be a little tight so it’s important not to cut off any extra wire when re-crimping. Connect to lower contact of SMR relay.
Add new MCB, link left-hand side of MCBs to include new MCB (for instances on EMCP 4.4 Link 4 / 4B / 5 / 6 with new MCB link copper).
Run a new wire 101A from right-hand side of new MCB - red blade crimp at MCB, to upper contact of SMR 9X-8124 Magnetic Switch As - red ring crimp at SMR.
Attach ring crimps to SMR using plain washer, lock washer and nut (all M6). Crimps should run out towards the door to relieve stress on crimp and avoid bending of the crimp.
SMR mounts to panel using upper "wing", and previous mounting hardware for old SMR relay. Mount relay as shown such that harness does not conflict with other wires. Wire X861 might be a little tight in which case it’s preferable to run it above the grey conduit rather than have it under tension.