ENGINE AR 7C8807 - Caterpillar

This is a 0.5-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
1. Locate the fuse assembly.
- For 226D, 232D, 239D, and 249D Machines: The 50A glow plug fuse is located on the right hand side of the engine bay when looking in the rear door. A mirror and light is helpful since the fuse panel is more difficult to see and access on these machines. You may also raise the cab and inspect from that side of the machine. Refer to Image1.1.1.
- For 242D, 257D, and 259D Machines: The 50A glow plug fuse is located on the left hand side of the engine bay just past the fuel/water separator when looking in the rear door. Refer to Image1.1.2.
Image1.1.1
Image1.1.2
2. Uncover the 50A fuse and look for the nut on the bottom post.
- For 226D, 232D, 239D, and 249D Machines, refer to Image1.2.1.
- For 242D, 257D, and 259D Machines, refer to Image1.2.2.
Image1.2.1
Image1.2.2
3. If no nut is found, turn the battery disconnect switch in the rear of the machine to the OFF position to disable battery power to the machine. If the machine is not equipped with a battery disconnect, remove the battery cable from the negative battery post. Refer to Image1.3.1.
Image1.3.1
4. Look for evidence of arcing (brown discoloration) at the 50A fuse connections. Replace the fuse if there is discoloration. If there is discoloration on any other connection on the 100A fuse or power post, replace the entire fuse holder assembly.
Note: For 226D, 232D, 239D, and 249D Machines, it will be easier to raise the cab and perform the rework from that side of the machine.
5. If no evidence of arcing is found, install one 8T-0328 Washer and one 5C-2874 Nut to the 50A fuse bottom post. Tighten the nut to a specified torque of 4.5 - 0.5/+ 0.5 N.m.
6. If the 50A fuse requires replacement:
a. Remove the M5 nuts from the top and bottom posts and remove the fuse.
b. Replace the 396-8366 Fuse.
c. Re-install the platform harness terminal onto the top post. Refer to Image1.5.1.
d. Install one 8T-0328 Washer and one 5C-2874 Nut onto each post.?Tighten the nuts to a specified torque of 4.5 - 0.5/+ 0.5 N.m.
Image1.5.1
7. If the entire fuse holder assembly requires replacement:
a. Remove three M5 and one M8 nuts that have harness terminals connected to them and free all harnesses. Refer to Image1.6.1.
(1) M5 nut. Top left 50A post. Platform harness terminal.
(2) M5 nut. Top right 100A post. Platform harness terminal.
(3) M8 nut. Bottom center post. Power cable.
(4) M5 nut. Bottom right 100A post. Platform harness terminal.
Image1.6.1
b. Use a 3mm hex driver to remove all four bolts and washers from the frame wall or mounting plate as shown. Keep hardware to install the new assembly.
c. Install a new 378-1011 Fuse Holder Assembly and existing hardware. Tighten the bolts to a specified torque of 2.5 +/- 0.5 N.m.
- For 226D, 232D, 239D, and 249D Machines, refer to Image1.7.1.
- For 242D, 257D, and 259D Machines, refer to Image1.7.2.
Image1.7.1
Image1.7.2
d. Reinstall all