Procedure to Rework the Harness Assembly for the Air Filter Sensors on Certain 797F Off-Highway Trucks {1051, 1054, 1408, 1439} Caterpillar

Procedure to Rework the Harness Assembly for the Air Filter Sensors on Certain 797F Off-Highway Trucks {1051, 1054, 1408, 1439}

Usage:

797F LAJ

Off-Highway Truck/Tractor: 797F (S/N: LAJ1-622; WSP1-129)

Introduction

The following instruction provides the required parts and procedure to rework the air filter sensor connectors on the chassis harness.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

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Before service work is begun, park the machine on a hard level surface. Block the wheels of the machine so unexpected movement will not occur. Unexpected movement of the machine can cause personal injury or death.

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Contact with loose connectors can result in electrical shock and may cause injury or death.

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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.

Caterpillar Channel 1 Videos

For supplemental information on this procedure, refer to the following video.

Note: A CWS login is required to access Caterpillar Channel 1. Scan the QR code below with a QR enabled device or copy the link that follows.

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Illustration 1	g06258324

Reference: For more information, refer to M0082360 , "Procedure to Rework the Harness Assembly for the Air Filter Sensors on Certain 797F Off-Highway Trucks" on Caterpillar Channel 1.

https://channel1.mediaspace.kaltura.com/media/Procedure+to+Rework+the+Harness+Assembly+for+the+Air+Filter+Sensors+for+Certain+797F+Off-Highway+Trucks/1_oqghr1f7

Required Parts

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Table 1
Parts List
Item	Qty	Part
1	2	102-8803 Receptacle Kit
2	2	155-2260 Connecting Plug Kit
3	6	9X-3401 Connector Pin
4	6	9X-3402 Connector Socket

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Table 2
102-8803 Receptacle Kit
Qty	Part
1	3E-3370 Connector Receptacle As
1	3E-3371 Receptacle Lock Wedge

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Table 3
155-2260 Connecting Plug Kit
Qty	Part
1	169-8670 Connector Plug As
1	155-2276 Plug Lock Wedge⁽¹⁾
1	155-2266 Plug Lock Wedge⁽²⁾

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⁽¹⁾	Standard Application
⁽²⁾	Alternate Application

Rework Procedure

Left-Hand Side

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Illustration 2	g06200472

Disconnect intake sensor connector (A) at the left-hand side pedestal.
Remove wires from the chassis harness intake sensor connector (A).
Cut the pins off the wires.
Strip wires to prepare harnesses for new terminals connectors.
Install one 9X-3402 Connector Socket (4) to each wire end.

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Table 4
169-8670 Connector Plug As Pinout
Pin Location	Wire Color
A	Orange
B	Black
C	Yellow

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Illustration 3	g06200250
169-8670 Connector Plug As - Back side view

Install the three wires to 169-8670 Connector Plug As of 155-2260 Connecting Plug Kit (2). Install the wires to the plug assembly according to Table 4.
Install one 9X-3401 Connector Pin (3) to each wire
Disconnect intake sensor connector (B) at the left-hand side pedestal.
Remove wires from the chassis harness intake sensor connector (B).
Cut the sockets off the wires.
Strip wires to prepare harnesses for new terminals connectors.
Install one 9X-3402 Connector Socket (4) to each wire end.

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Table 5
3E-3370 Connector Receptacle As Pinout
Pin Location	Wire Color
A	Orange
B	Black
C	Blue

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Illustration 4	g06200240
3E-3370 Connector Receptacle As - Back side view

Install the three wires to 3E-3370 Connector Receptacle As of 102-8803 Receptacle Kit (1). Install the wires to the receptacle assembly according to Table 5.
Install connectors (A) and (B) to the intake sensors.

Right-Hand Side

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Illustration 5	g06200785

Disconnect intake sensor connector (C) at the right-hand side pedestal.
Remove wires from the chassis harness intake sensor connector (C).
Cut the pins off the wires.
Strip wires to prepare harnesses for new terminals connectors.
Install one 9X-3402 Connector Socket (4) to each wire end.

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Table 6
169-8670 Connector Plug As Pinout
Pin Location	Wire Color
A	Orange
B	Black
C	Yellow

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Illustration 6	g06200250
169-8670 Connector Plug As - Back side view

Install the three wires to 169-8670 Connector Plug As of 155-2260 Connecting Plug Kit (2). Install the wires to the plug assembly according to Table 6.
Install one 9X-3401 Connector Pin (3) to each wire
Disconnect intake sensor connector (D) at the right-hand pedestal.
Remove wires from the chassis harness intake sensor connector (D).
Cut the sockets off the wires.
Strip wires to prepare harnesses for new terminals connectors.
Install one 9X-3402 Connector Socket (4) to each wire end.

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Table 7
3E-3370 Connector Receptacle As Pinout
Pin Location	Wire Color
A	Orange
B	Black
C	Blue

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Illustration 7	g06200240
3E-3370 Connector Receptacle As - Back side view

Install the three wires to 3E-3370 Connector Receptacle As of 102-8803 Receptacle Kit (1). Install the wires to the receptacle assembly according to Table 7.
Install connectors (C) and (D) to the intake sensors.