Installation Procedure for 366-9748 Injector Wiring Harness Kit {1254, 1290, 1408} Caterpillar

Agricultural Tractor:

MT735 (S/N: AKN1-UP)

MT745 (S/N: ALA1-UP)

MT755 (S/N: ALM1-UP)

MT765 (S/N: AMS1-UP)

MTC735 (S/N: 8121-UP)

MTC745 (S/N: 8131-UP)

MTC755 (S/N: 8141-UP)

MTC765 (S/N: 8151-UP)

Combine:

Lexion 450 (S/N: 5531-UP)

Lexion 460 (S/N: 6541-UP)

Lexion 460 R (S/N: 6651-UP)

Lexion 470 R (S/N: 7651-UP)

Lexion 475 R (S/N: 7671-UP)

Engine:

3126 (S/N: 1ED1-UP; 1WM1-UP; 4ES1-UP)

3126B (S/N: BKD1-UP; DCD1-UP; BEJ1-UP; 1AJ1-UP; 5GL1-UP; 8YL1-UP; 7AS1-UP; BDZ1-UP; 6PZ1-UP; 7JZ1-UP; 8SZ1-UP)

C-9 (S/N: CLJ1-UP)

C11 (S/N: KCA1-UP)

C13 (S/N: KCB1-UP; LEE1-UP)

C15 (S/N: SDP1-UP; BXS1-UP; MXS1-UP)

C7 (S/N: FML1-UP; KAL1-UP; FMM1-UP; C7S1-UP; WAX1-UP)

C9 (S/N: 9DG1-UP; CKP1-UP)

Marine Engine:

C7 MARINE (S/N: C7X1-UP)

C9 MARINE (S/N: CSN1-UP)

Truck Engines:

3126E (S/N: DPF1-UP; LEF1-UP; 6ZG1-UP; CKM1-UP; CRP1-UP; HEP1-UP; 9SZ1-UP)

Excavator:

320C (S/N: BRX1-UP)

322C (S/N: DAA1-UP; FED1-UP; BTE1-UP; KCF1-UP; HBG1-UP; HEK1-UP; BYL1-UP; C3R1-UP; EMR1-UP; LAR1-UP; MAR1-UP; ADX1-UP)

325B (S/N: 2JR1-UP)

325C (S/N: BLA1-UP; CRB1-UP; JLC1-UP; S2C1-UP; JLD1-UP; DTF1-UP; BKH1-UP; CSJ1-UP; M2K1-UP; BMM1-UP; S3M1-UP; Y4P1-UP; BKT1-UP; BKW1-UP; BLX1-UP)

330C (S/N: CYA1-UP; HAA1-UP; MCA1-UP; JAB1-UP; D3C1-UP; JCD1-UP; KDD1-UP; GAG1-UP; RBH1-UP; JNK1-UP; B2L1-UP; BTM1-UP; B3M1-UP; MKM1-UP; B4N1-UP; CAP1-UP; GKX1-UP; DKY1-UP; CGZ1-UP)

M325C (S/N: XJA1-UP; PAN1-UP)

Track Feller Buncher:

TK711 (S/N: 1011-UP)

TK721 (S/N: 1021-UP)

TK722 (S/N: 1031-UP)

TK732 (S/N: 1041-UP)

TK741 (S/N: 2021-UP)

TK751 (S/N: 3011-UP)

TK752 (S/N: 3021-UP)

Integrated Toolcarrier:

IT62G Series II (S/N: AYA1-UP)

Motor Grader:

12H (S/N: CBK1-UP; AMZ1-UP; 1251-UP)

Track-Type Loader:

953C (S/N: BBX1-UP)

963C (S/N: BBD1-UP)

973C (S/N: BCP1-UP)

Track-Type Tractor:

D5N (S/N: AKD1-UP; AGG1-UP)

D6N (S/N: ALH1-UP; CCK1-UP; AKM1-UP; ALR1-UP; ALY1-UP)

D6R Series II (S/N: BNC1-UP; CAD1-UP; ADE1-UP; BLE1-UP; BRE1-UP; DAE1-UP; ACJ1-UP; BMJ1-UP; BRJ1-UP; BMK1-UP; BNL1-UP; AEM1-UP; AFM1-UP; AGM1-UP; BPM1-UP; AEP1-UP; BPP1-UP; BPS1-UP; BLT1-UP; FDT1-UP; AAX1-UP; BMY1-UP; BPZ1-UP)

D6R (S/N: 8XN1-UP; 9MN1-UP)

Wheel Loader:

950G Series II (S/N: AYB1-UP; AXX1-UP)

962G Series II (S/N: AYE1-UP; AXY1-UP)

Wheel Tractor-Scraper:

627G (S/N: CEZ1-UP)

637G (S/N: CEJ1-UP; CEM1-UP)

Introduction

This Special Instruction is intended for the installation of the 366-9748 Injector Wiring Harness Kit . The 366-9748 Injector Wiring Harness Kit can be used to repair TPI connectors. TPI connectors can be found on HEUI injectors, variable valve actuators, and Cat Brakes.

Removal of the Connector From the Wire Harness

The following steps will remove the connector for an injector from the wire harness that is under the valve mechanism cover.

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Illustration 1	g01035448
(1) Side "A" of the connector (2) Side "B" of the connector

Note: Side "A" or side "1" of the connector is the output signal wire from the ECM. Side"B" or side "2" of the connector is the sensor return.

1. Identify side "A" of the connector and identify side "B" of the connector.

2. Mark each wire on the wire harness before the wires are cut. Most connectors will have the label of an "A" and a "B". Some connectors may have a "1" and a "2" that is on the connector. The label with a "1" will be an "A". The label with a "2" will be a "B".

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Illustration 2	g01034438
Connector that is cut from the wire harness (3) Wire on side "A" of the connector (4) Wire on side "B" of the connector

3. Cut wire (3) at a distance of 45 mm (1.8 inch).

4. Cut wire (4) at a distance of 40 mm (1.6 inch).

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Illustration 3	g01034450
(5) Wire from the harness for side "B" on the connector (6) Wire from the harness for side "A" on the connector

Note: The wires on the old connector are cut to length so that the wires on the wire harness to the new connector will match up. The proper length will help in matching the harness wires to the wires on the new connector wires.

5. Discard the connector.

Installation Procedure for the Connector

1. Use Tool (A) to strip the plastic off wires (5) and (6) at a distance of 5 mm (0.19 inch).

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Illustration 4	g01034451
Connecting the connector to the wire harness (5) Wire from the harness for side "B" on the connector (6) Wire from the harness for side "A" on the connector (7) Heat shrink tube (8) Butt splice on wire (4) that is on side "B" of the connector (9) Butt splice on wire (3) that is on side "A" of the connector

2. Use the heat shrink tubes from 366-9748 Injector Wiring Harness Kit . Slide the heat shrink tubes toward the connector in order to expose the butt splices.

3. Take wire (5) and slide wire (5) in the butt splice (8).

4. Take wire (6) and slide wire (6) in the butt splice (9).

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Illustration 5	g01035814

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Illustration 6	g01034452
(8) Butt splice on wire (4) that is on side "B" of the connector (9) Butt splice on wire (3) that is on side "A" of the connector

5. Use Tool (A) to crimp butt splices (8) and (9 ) in order to secure the wires together.

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Illustration 7	g01034453

6. Slide the heat shrink tube over the splices. Evenly cover the splices with the heat shrink tube.

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Illustration 8	g01034456

Note: Do not overheat the heat shrink tube.

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Illustration 9	g01034457

7. Use Tool (B) to heat the heat shrink tube. Heat the tube until the tube shrinks around the wires.