BAR 0689623 - Caterpillar

Rework Procedure
Reference: Refer to the Disassembly and Assembly manuals for the Track-Type Tractor being serviced.
Illustration 1 g06020878
Turn the battery disconnect switch to the OFF position. Open the battery access door (A).
Illustration 2 g06020889
Remove the ground level service center enclosure cover (B). Retain and reuse all removed hardware.
Illustration 3 g06020908
Remove the fuse block access door assembly (C). Retain and reuse all removed hardware.
Illustration 4 g06020916
Remove the two nuts from the main relay (D). Discard the nuts.
Remove the two nuts, two washers, and two lock washers from the fuse block terminals (E). Discard the nuts, washers, and lock washers.
Disconnect the two cables (F) from the fuse block. Discard the cables.
Illustration 5 g06020926
Remove the nut (G) from the power stud. Discard the nut and washer.
Remove the two screws and washers (H) from the main power relay (7). Discard the screws and washers.
Remove the main power relay (7) and the strap (J) from the power stud. Discard the main power relay. Retain and reuse the strap.
Illustration 6 g06020939
Remove the vinyl coating from the strap (10) if present. Install the strap (10) and main power relay (7) on the power stud.
Install two mounting screws (5) and two Washers (6) to secure the main power relay to the enclosure. Leave the mounting screws finger tight to allow the main power relay to move.
Illustration 7 g06021044
Illustration 8 g06021054
Install cable (purple) (9) and cable (red) (11) assemblies in the correct location.
Install two washers (1) and two nuts on the main power relay terminals. Leave the two nuts finger tight to allow the main power relay to move.
Install one washer (4) and one nut (3) on the power stud. Leave the nut finger tight to allow the main power relay to move.
Install two lock washers (8), two cable terminal ends, two washers (4) and two nuts (2) on the fuse panel terminals in the correct order.
Illustration 9 g06021062
Illustration 10 g06021234
Tighten all nuts finger tight to the sequence of (a), (b), (c), and (d) and then repeat order for final torque values.
Tighten the two nuts on the main power relay terminals to 9 +/- 0.5 Nm. (a) and (e)
Tighten the nut on the power stud to 15 +/- 2 Nm. (b)
Tighten the two mounting screws for the main power relay. (c) and (d)
Tighten the two nuts on the fuse panel terminals to 19 +/- 1 Nm. (e)
Install the fuse block access door assembly.
Install the ground level service center enclosure cover.
Close the battery access door. Turn the battery disconnect switch to the ON position.
Verify that the main power relay is operating properly.