CONNECTION GP-GENERATOR LEADS 4P5534 - Caterpillar

Installation Instructions For The 122-0803 Junction Box
Table 2
Parts List    
No.    Quantity    Part Number    Part Name    Description    
1     3     121-6159     Relay Module     Control Harness    
2    
480 mm (19 inch)     5P-9073     Electrical Wire     18 AWG Red Wire    
3    
480 mm (19 inch)     5P-3075     Electrical Wire     18 AWG Black Wire    
4     8     112-7497     Wire End     Ferrule For The 14 AWG Wire    
5     2     121-6865     Wire End     Ferrule For Two 18 AWG Wires    
6     2     110-8714     Wire End     Ferrule For 18 AWG Wire    Removal Of The Existing 3E-0456 Relay (SR-2) And 105-7540 Relay Socket
ReferenceConsult the 122-0803 Junction Box Schematic for additional details.
Disconnect all of the wiring from the 105-7540 Relay Socket . If the circuit's identification cannot be clearly seen on the wire, mark each wire with the number from the terminal. The circuit's identification or the number from the terminal will be needed when the wiring is reconnected to the relay modules.
Discard the flyback diode between terminal 2 and terminal 10. The diode will not be needed with the new relay modules because flyback diodes are included with each relay module.
Remove the 3E-0456 Relay and the 105-7540 Relay Socket .Installation Of The Three 121-6159 Relay Modules
Install three 121-6159 Relay Modules on the rail (DIN) in the place of the 105-7540 Relay Socket . The terminals marked "+" and "−" should be on the left.
Reinstall the 9X-9675 End Bracket in order to hold the relay modules in place.Preparations For Terminating The Wiring At The 121-6159 Relay Modules
See Illustration 2 for additional details.Ferrules should be crimped onto all of the wiring that connects to the 121-6159 Relay Modules . Since a single relay is being replaced with three separate relay modules, it will be necessary to add jumper wires for energizing the coils of the second relay and the third relay.
Remove all of the screw terminals from the existing wiring. Cut the wiring close to the terminals.
Add jumper wires to the red wire that provides the positive charge from the battery in order to energize the coils of the three relay modules. Cut two pieces of the 5P-9073 Electrical Wire to a length of 240 mm (9.5 inch). Connect one end of one of the jumper wires to the red wire in the panel that is marked "P509/RD" by first stripping the wires 8 mm (0.3 inch). Then crimp one 112-7497 Wire End to