Procedure to Install Automotive Fuses{1408, 1417, 7278} Caterpillar

Landfill Compactor:

836H (S/N: BXD1-599)

Wheel Dozer:

834H (S/N: BTX1-299)

Wheel Loader:

988H (S/N: BXY1-1899)

Introduction

New automotive fuses for the electrical system are now used on the 836H Landfill Compactor, 834H Wheel Dozer and 988H Wheel loader. The new fuses replace the previous glass fuses. This Special Instruction contains the procedure to install the new fuses on the machine.

Do not perform any procedure in this publication or order any parts until you understand the information that is contained in this publication.

Safety

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Personal injury or death can occur from heavy components falling during removal or installation. Properly support the component with a suitable lifting device during removal or installation.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

Required Parts

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Illustration 1	g01514051

1. Locate the electronic bay. The electronic bay is located on the right side of the machine.

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Illustration 2	g01514062

2. Unlock two latches (1) on the access door (2) .

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Illustration 3	g01514072

3. Remove three bolts (3) from the door.

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Illustration 4	g01514078

4. Remove the access door.

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Illustration 5	g01514085

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Illustration 6	g01514469

5. Remove the remaining nine bolts (4) from the plate (5). Remove the plate. Replace seal (6) if the seal is damaged or worn.

6. Remove the adhesive from the back of the 321-9695 Film or the 321-9697 Film . Place the film to the inside of access door (2) .

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Illustration 7	g01514096

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Illustration 8	g01514470

7. Remove twelve bolts from plate (7). Remove the plate. Replace the seal (8) if the seal is damaged or worn.

8. This is the procedure to assemble the harness.
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   Illustration 9	g01515926

   1. Remove the adhesive from the back of 103-2543 Seal (9). Attach the seal to the center of the bracket (10). Insert the fuse puller 116-7471 Puller (11) into the seal.
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   Illustration 10	g01515929

   2. Insert fuse blocks into the bracket (10) with the posts (12) toward the front of the bracket.

      Note: The unswitched fuse block (14) is located on the left side of the bracket. The unswitched fuse block is identified by having six wires. The switched fuse block (13) is located on the right side of the bracket. The switched fuse block is identified by having fifteen wires.

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   Illustration 11	g01515985

   3. Secure the fuse blocks into the bracket. Use eight 9F-9327 Screws (15) .

      Note: Place the tab of each of the covers under one of the screws.

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   Illustration 12	g01518719

   4. Install the fuses into the fuse block. The film that is mounted on the access door (2) shows the appropriate placement of the fuses.
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   Illustration 13	g01518579

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   Illustration 14	g01515975

   5. Attach 285-3570 Cable Assembly (16) to the right side post of the unswitched fuse block (14). Place the 8C-3398 Lockwasher (17) onto the post. Next, place the cable assembly (16) onto the post. Then place the 8T-4205 Hard Washer (18) and 5C-2890 Nut (19) onto the post.

      Note: Position the cable (16). Refer to Illustration 13.

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   Illustration 15	g01515999

   6. On fuse block (14), place a 8C-3398 Lockwasher (17) onto each post (12). Place the 258-4142 Bus Bar (20) over the posts. On the left post, add a 8T-4205 Hard Washer (18) and a 5C-2890 Nut (19) .

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Illustration 16	g01514485

9. Remove all cable ties. Disconnect the four connectors (21) .

   Note: 834H and 988H will have one connector on the harness that is not on the existing harness for the fuses. Connect all four connectors with the 321-7310 Harness Assembly .

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Illustration 17	g01514493

10. Remove two 9X-2042 Screws (22) from the plate.

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Illustration 18	g01514499

11. Disconnect the PURPLE-4 wire (23) from the fuse panel.

12. Remove the wiring harness from the electronic bay.

13. Install the 321-7310 Harness Assembly . The harness must be routed in order to look like the previous harness.

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Illustration 19	g01514650

14. Connect PURPLE-4 wire (23) onto the post (12) of the fuse block (14). Place the cable onto the post. Then add a 8T-4205 Hard Washer . Next, add a 5C-2890 Nut .

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Illustration 20	g01514556

15. Disconnect the 106-RED-12 wire from post (24) of the main breaker. Remove the existing nut and hard washer. Fold the wire back onto the harness. Secure the wire with a cable tie.

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Illustration 21	g01518601

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Illustration 22	g01514565

16. Route the 285-3570 Cable Assembly (16) along the existing harness. Connect the cable to the post (25) of the main breaker. Replace the hard washer and the nut.

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Illustration 23	g01514580

17. Install the 321-7309 Bracket (10). Use two 9X-2042 Screws . Install the bracket in place of the previous bracket.

18. Connect the 321-7310 Harness Assembly to the four connectors that were disconnected in Step 9.

19. Install 9X-6772 Cable Straps in order to secure the 321-7310 Harness Assembly and 285-3570 Cable Assembly . Ensure that the harness and cable is not fouling on the enclosure or other parts.