PRODUCT SUPPORT PROGRAM FOR REPLACING THE LIGHTING AND/OR HORN RELAY BLADE TERMINALS ON CERTAIN 120K, 12K, AND 140K MOTOR GRADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE LIGHTING AND/OR HORN RELAY BLADE TERMINALS ON CERTAIN 120K, 12K, AND 140K MOTOR GRADERS

Usage:

TEBE4534-00

Show/hide table

28Apr2016

U-202

A-155

D-186

O-178

Show/hide table

After Failure Only	PRODUCT SUPPORT PROGRAM FOR REPLACING THE LIGHTING AND/OR HORN RELAY BLADE TERMINALS ON CERTAIN 120K, 12K, AND 140K MOTOR GRADERS
4334		PS53203

Show/hide table

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 can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS53203" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

Show/hide table

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.

Show/hide table

TERMINATION DATE

30Apr2018

PROBLEM

Show/hide table

The blade terminals that are installed in the relay mounting block for the headlamp, flood lamp, tail panel lamp, and horn relays can cause an electrical connection issue on certain 120K, 12K, and 140K Motor Graders. If the blade terminals fail it can damage the associated relay causing loss of functionality in that respective circuit.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
120K	JAP04797-06799
12K	JJA03046-03194
140K	JPA03283-03870

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
4	3E6477	RELAY AS
20	6V0491	TERMINAL-BLADE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% 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

Show/hide table

Remove the headlamp, flood lamp, tail panel lamp, and horn relays from the mounting block located in the steering column. Refer to (A) in Image 1 for the location of the relays.

Inspect the relays for damage. Replace any failed or damaged relays with the same part number 3E-6477 Relay As.

Remove the blade terminals from the relay mounting block to inspect for any damage to the terminals. Remove any damaged portion of the harness.

Replace all of the terminals contained within the relay mounting block with the new 6V-0491 blade terminals.

Reinstall the blade terminals into the relay mounting block.

Install the relays to the mounting block and ensure that the terminals are properly seated in the relay mounting block.

Do not use excessive force to install the relays to the mounting block as this may cause the terminals to be driven out of the mounting block. Failure to seat the relay properly could cause additional relay or terminal failures. Refer to Image 2 and Image3 for examples of correctly and incorrectly installed blade terminals.

Reinstall all harness mounting hardware within the steering column to ensure there is no excessive harness movement.

Show/hide table

Image1

Image2

Image3

SERVICE CLAIM ALLOWANCES

Show/hide table

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%
0-7000 hrs, 0-72 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%