- Generator Set Engines:
- 3406E (S/N: 9NN1-UP)
- 3456 (S/N: EPE1-UP; 3PG1-UP; 9BZ1-UP; 7WG1-UP)
- C-12 (S/N: BCY1-UP)
- 3456 (S/N: EPE1-UP; 3PG1-UP; 9BZ1-UP; 7WG1-UP)
- Industrial Engines:
- 3176B (S/N: 3NL1-UP)
- 3176C (S/N: 2AW1-UP)
- 3196 (S/N: 1DW1-UP)
- 3406E (S/N: 6BR1-UP)
- 3408E (S/N: 7PR1-UP)
- 3412 (S/N: BDT1-UP)
- 3412C (S/N: 8AR1-UP)
- 3412E (S/N: BFT1-UP; 4CR1-UP)
- 3456 (S/N: 3LW1-UP; BGA1-UP)
- C-10 (S/N: BCX1-UP)
- C11 (S/N: GLS1-UP)
- C-12 (S/N: BDL1-UP)
- C13 (S/N: LGK1-UP)
- C15 (S/N: JRE1-UP)
- C-15 (S/N: BEM1-UP; Z2C1-UP)
- C-16 (S/N: BFM1-UP)
- C18 (S/N: WJH1-UP)
- 3176C (S/N: 2AW1-UP)
- Marine Engine:
- 3176B (S/N: 9WK1-UP)
- 3176C (S/N: 6BW1-UP)
- 3196 (S/N: 2XR1-UP)
- 3406E (S/N: 9WR1-UP)
- 3412E (S/N: 9PW1-UP; 9KS1-UP)
- C-12 (S/N: 9HP1-UP)
- C12 (S/N: C1Z1-UP)
- C18 (S/N: C1J1-UP; CKH1-UP; CYN1-UP)
- C30 (S/N: CLX1-UP)
- C32 (S/N: RXB1-UP)
- C18 MARINE (S/N: NAX1-UP; NAY1-UP)
- 3176C (S/N: 6BW1-UP)
- On-Highway Engines:
- 3126B (S/N: 8YL1-UP)
- 3126E (S/N: 9SZ1-UP)
- 3176 (S/N: 7LG1-UP)
- 3176B (S/N: 9CK1-UP)
- 3406E (S/N: 5EK1-UP; 1LW1-UP; 5DS1-UP; 1MM1-UP; 6TS1-UP; 2WS1-UP)
- C-10 (S/N: MBJ1-UP; 2PN1-UP; 3CS1-UP; 8YS1-UP)
- C11 (S/N: KCA1-UP)
- C-12 (S/N: 8YF1-UP; 2KS1-UP; 9NS1-UP; MBL1-UP; CPD1-UP; 9SM1-UP; 1YN1-UP)
- C13 (S/N: KCB1-UP)
- C15 (S/N: MXS1-UP; BXS1-UP)
- C-15 (S/N: EGH1-UP; 6NZ1-UP; MBN1-UP)
- C-16 (S/N: 7CZ1-UP; W1A1-UP)
- C18 (S/N: MEP1-UP)
- C-18 (S/N: CJP1-UP)
- 3126E (S/N: 9SZ1-UP)
- Agricultural Tractor:
- 65E (S/N: 1GM1-UP; 6GS1-UP)
- 75 (S/N: 4CJ1-UP)
- 75C (S/N: 4KK1-UP)
- 75D (S/N: 5AR1-UP)
- 75E (S/N: 1HM1-UP; 6HS1-UP)
- 85C (S/N: 9TK1-UP)
- 85D (S/N: 4GR1-UP)
- 85E (S/N: 1NM1-UP; 6JS1-UP)
- 95E (S/N: 1SM1-UP; 6KS1-UP)
- MT735 (S/N: AKN1-UP)
- MT835 (S/N: BAM1-UP)
- MT845 (S/N: BBP1-UP)
- MT855 (S/N: BCC1-UP)
- MT865 (S/N: BDS1-UP)
- MTC835 (S/N: 8161-UP)
- MTC845 (S/N: 8171-UP)
- MTC855 (S/N: 8181-UP)
- MTC865 (S/N: 8191-UP)
- 75 (S/N: 4CJ1-UP)
- Articulated Truck:
- 725 (S/N: AFX1-UP)
- 730 (S/N: AGF1-UP)
- 735 (S/N: AWR1-UP)
- 740 (S/N: AXM1-UP)
- D300E (S/N: 7FN1-UP)
- D350E Series II (S/N: 2XW1-UP)
- D400E Series II (S/N: APF1-UP; 8PS1-UP)
- 730 (S/N: AGF1-UP)
- Cold Planer:
- PM-565 (S/N: 3TK1-UP)
- PM-565B (S/N: 8GS1-UP)
- Combine:
- Lexion 480 (S/N: 2BZ1-UP)
- Lexion 480 R (S/N: 8661-UP)
- Lexion 485 (S/N: 8ZW1-UP)
- Lexion 485 R (S/N: 8681-UP)
- Lexion 480 R (S/N: 8661-UP)
- Landfill Compactor:
- 816F (S/N: BMR1-UP)
- 826G Series II (S/N: AYH1-UP)
- 836 (S/N: 7FR1-UP)
- 836G (S/N: BRL1-UP; 7MZ1-UP)
- 826G Series II (S/N: AYH1-UP)
- Soil Compactor:
- 815F (S/N: BKL1-UP)
- 825G Series II (S/N: AXB1-UP)
- Pumper:
- SBF214 (S/N: CSB1-UP)
- SUF557 (S/N: LTF1-UP)
- Excavator:
- 345B (S/N: CFM1-UP; 9GS1-UP; 2NW1-UP; 4SS1-UP)
- 385B (S/N: ANS1-UP)
- 5110B (S/N: AAA1-UP; AAT1-UP; AAK1-UP)
- W345B Series II (S/N: ANJ1-UP; CDY1-UP)
- 345B Series II (S/N: ALB1-UP; APB1-UP; AGS1-UP; DCW1-UP)
- 385B (S/N: ANS1-UP)
- Track Feller Buncher:
- TK1051 (S/N: 9HZ1-UP)
- Load Haul Dump:
- R1600 (S/N: 9EW1-UP)
- R1700 II (S/N: 4LZ1-UP)
- Motor Grader:
- 135H (S/N: AMX1-UP)
- 140H (S/N: APM1-UP)
- 14H (S/N: ASE1-UP)
- 160H (S/N: ASD1-UP)
- 163H (S/N: ARL1-UP)
- 16H (S/N: ATS1-UP)
- 24H (S/N: 7KK1-UP)
- 140H (S/N: APM1-UP)
- Off-Highway Truck/Tractor:
- 69D (S/N: 9XS1-UP)
- 769C (S/N: 01X1-UP)
- 772B (S/N: 64W1-UP)
- 773B (S/N: 63W1-UP)
- 773E (S/N: BDA1-UP)
- 769D (S/N: BBB1-UP; 5TR1-UP; 5SS1-UP)
- 773D (S/N: 7ER1-UP; 7CS1-UP)
- 769C (S/N: 01X1-UP)
- Quarry Truck:
- 771C (S/N: 3BJ1-UP)
- 775E (S/N: BEC1-UP)
- 771D (S/N: BCA1-UP; 6JR1-UP; 6YS1-UP)
- 775D (S/N: 6KR1-UP; 8AS1-UP)
- 775E (S/N: BEC1-UP)
- Track-Type Tractor:
- D7R (S/N: AEC1-UP; AGN1-UP; ACS1-UP; ADW1-UP; AFG1-UP)
- D7R Series II (S/N: ABJ1-UP)
- D8L (S/N: 53Y1-UP)
- D8R Series II (S/N: 6YZ1-UP)
- D9L (S/N: 14Y1-UP)
- D9N (S/N: 1JD1-UP)
- D9R (S/N: ABK1-UP; ACL1-UP; 7TL1-UP; 8BL1-UP)
- D10N (S/N: 3SK1-UP)
- D10R (S/N: 3KR1-UP; AKT1-UP)
- D7R Series II (S/N: ABJ1-UP)
- Wheel Dozer:
- 814F (S/N: BGF1-UP)
- 824G Series II (S/N: AWW1-UP)
- 834B (S/N: 7BR1-UP; 92Z1-UP)
- 834G (S/N: BPC1-UP; 6GZ1-UP)
- 844 (S/N: BBN1-UP; 2KZ1-UP)
- 824G Series II (S/N: AWW1-UP)
- Wheel Loader:
- 972G Series II (S/N: ANY1-UP)
- 980G Series II (S/N: AWH1-UP)
- 988B (S/N: 50W1-UP)
- 988F Series II (S/N: 2ZR1-UP)
- 988F (S/N: 8YG1-UP)
- 988G (S/N: 2TW1-UP)
- 990 (S/N: 7HK1-UP)
- 966G Series II (S/N: ANT1-UP; ANZ1-UP)
- 990 Series II (S/N: BCR1-UP; 4FR1-UP)
- 980G Series II (S/N: AWH1-UP)
- Wheel Tractor-Scraper:
- 621F (S/N: 4SK1-UP)
- 631D (S/N: 24W1-UP)
- 631E (S/N: 1AB1-UP)
- 633D (S/N: 25W1-UP)
- 633E Series II (S/N: 2PS1-UP)
- 639D (S/N: 99X1-UP)
- 651E (S/N: 4YR1-UP)
- 621G (S/N: CEN1-UP; ALP1-UP)
- 623G (S/N: CES1-UP; ARW1-UP)
- 627G (S/N: AXF1-UP; CEX1-UP)
- 631G (S/N: AWK1-UP; CLR1-UP)
- 637D (S/N: 26W1-UP; 27W1-UP)
- 637E (S/N: 1FB1-UP; 1JB1-UP)
- 637G (S/N: CEH1-UP; AXT1-UP)
- 657E (S/N: 6MB1-UP; 5YR1-UP; 6PR1-UP; 6TR1-UP; 7KR1-UP; 86Z1-UP; 87Z1-UP)
- 631D (S/N: 24W1-UP)
Introduction
Do not perform any procedure in this Special Instruction until you read this information and you understand this information. This Special Instruction is intended for the installation of the 257-4183 Injector Wiring Harness Kit . The 257-4183 Injector Wiring Harness Kit can be used to repair fuel injector connectors.
Required Tools     | |||
Tool     | Part Number     | Part Name     | Qty     |
A     | 9S-9150     | Terminal Crimp Tool As     | 1     |
B     | 9U-6070     | Heat Gun Gp     | 1     |
Removal of a Faulty Connector from the Wire Harness
The following steps can be used in order to remove a faulty connector for an injector on the wire harness that is located under the valve mechanism cover.
- Identify the connector that needs to be replaced. Wiring for the injector solenoid is not sensitive to polarity.
- Cut wire (1) at a distance of 70 mm (2.8 inch) from the rear surface of the connector.
Illustration 1 | g01111254 |
Connector that is cut from the wire harness |
- Cut wire (2) at a distance of 65 mm (2.6 inch) from the rear surface of the connector.
- Discard the old connector.
Illustration 2 | g01111314 |
(3) Wire from the harness for side (B) on the connector (4) 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 will match up to the new connector. Cutting the wires to the proper length will aid in matching the harness wires to the wires on the new connector.
Installation of a New Connector
The following steps can be used in order to install a new connector for an injector on the wire harness that is located under the valve mechanism cover.
- Use Tool (A) in order to remove 5 mm (0.2 inch) of the plastic from wires (3) and (4) .
- Use heat shrink tubes (5) from the 257-4183 Injector Wiring Harness Kit . Slide the heat shrink tubes toward the connector in order to expose the butt splices.
Illustration 3 | g01111333 |
Connecting the connector to the wire harness (A) Side (A) of the new connector (B) Side (B) of the new connector (3) Wire from the harness for side (B) on the new connector (4) Wire from the harness for side (A) on the new connector (5) Heat shrink tubes (6) Butt splice on the wire that is on side (A) of the new connector (7) Butt splice on the wire that is on side (B) of the new connector |
- Insert wire (4) into butt splice (6) .
- Insert wire (3) into butt splice (7) .
- Use Tool (A) to crimp butt splices (6) and (7) in order to secure the wires together.
Illustration 4 | g01111364 |
(6) Butt splice on the wire that is on side (A) of the new connector (7) Butt splice on the wire that is on side (B) of the new connector |
- Slide the heat shrink tubes (5) over the splices. Evenly cover the splices with the heat shrink tubes.
Illustration 5 | g01035814 |
(A) 9S-9150 Terminal Crimp Tool As |
- Use Tool (B) to heat the heat shrink tubes. Heat the tubes until the tubes shrink around the wires.
Illustration 6 | g01111377 |
(B) 9U-6070 Heat Gun Gp |
Note: Do not overheat the heat shrink tubes.