Replacement Procedure of the Electronic Filter Control for the Service Hour Meter on Certain Track-Type Tractors{1623, 7478} Caterpillar

Track-Type Tractor:

D6 (S/N: 5HF1-UP; 4LG1-UP)

D6H Series II (S/N: 4RC1-UP; 6FC1-UP; 3ZF1-UP; 5HF1-UP; 6CF1-UP; 2TG1-UP; 3YG1-UP; 4LG1-UP; 1FJ1-UP; 8ZJ1-UP; 9KJ1-UP; 5KK1-UP; 6CK1-UP; 8KK1-UP; 9LK1-UP; 1YL1-UP; 2BL1-UP)

D6H (S/N: 8KB1-UP)

D7H Series II (S/N: 5BF1-UP; 4FG1-UP; 79Z1-UP; 80Z1-UP)

D8R (S/N: 7XM1-358; 9EM1-7399)

Introduction

This Special Instruction provides the necessary information for the replacement of the Service Hour Meter Filter Wire Assembly on certain Track-Type Tractors.

Important Safety Information

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.

Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.

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Improper operation of an access platform could result in injury or death. Operators must carry out their duties properly and follow all instructions and guidelines given for the machine and access platform.

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Be sure all personnel are clear of the equipment while the equipment is being lowered. Failure to stay clear of the equipment while the equipment is being lowered may result in personal injury.

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.

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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. Prevent possible injury by performing the procedure that follows before working on the machine. Move the machine to a smooth and level location that is away from working machines and personnel. Ground all implements. Engage the parking brake. Stop the engine. Move the hydraulic control levers to all positions to release the pressure in the hydraulic system. To avoid accidental engine starting, turn the battery disconnect switch to the OFF position. Remove the key for the battery disconnect switch. Use a secure padlock in order to lock the battery compartment access door. Place a "Do Not Operate" tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

Required Parts

Replacement Procedure

Illustration 1	g03345050

Installing a 141-7556 Electronic Filter Control in place of a 100-5052 Electronic Filter Control requires converting the 141-7556 Electronic Filter Control to a 100-5052 Electronic Filter Control by replacing the 3E-3370 Connector Receptacle As with the 7N-7781 Receptacle Housing .

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Illustration 2	g03345054
141-7556 Electronic Filter Control (2) Remove and discard 3E-3370 Connector Receptacle As

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Illustration 3	g03345055
100-5052 Electronic Filter Control (3) Attach to 141-7556 Electronic Filter Control wiring

1. Remove the Receptacle As, pin-connector, wedge-receptacle lock of 141-7556 Electronic Filter Control and replace them with the Housing-receptacle, Pin-connector, and socket-connector of the 100-5052 Electronic Filter Control .

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Illustration 4	g03345164
141-7556 Electronic Filter Control (2) Remove and discard 3E-3370 Connector Receptacle As (4) Cut line 5 mm (0.19 inch) behind the 3E-3370 Connector Receptacle As

2. Cut the wires (4) of the 141-7556 Electronic Filter Control 5 mm (0.19 inch) behind the 3E-3370 Connector Receptacle As (2) to remove the 3E-3370 Connector Receptacle As . Refer to Illustration 4.

3. Check the wire length

   1. If the length is sufficient to assemble in the Next Higher Level (NHL), refer to""Basic Installation Procedure" ".

   2. If the length is not sufficient to assemble in the NHL, the technician needs to splice in extra wire length. Refer to ""Extended Installation Procedure" ".

Basic Installation Procedure

1. Strip the existing wires still on the machine from 3.94 mm (0.1551 inch) to 4.7 mm (0.185 inch). Crimp the pins and socket to the harness as specified in Table 2.
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   Table 2

   Part Number	Description	Wire Color
   7N-7780	Connector Pin	Brown
   7N-7780	Connector Pin	Green
   7N-7779	Connector Socket	Black

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Illustration 5	g03345137
7N-7781 Receptacle Housing

2. Insert the pins and socket into the 7N-7781 Receptacle Housing using the pin and socket locations specified in Table 3 and Illustration 5. Modification is now complete.
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   Table 3

   Pin Number	Wire Color
   1	Black
   2	Brown
   3	Green

Extended Installation Procedure

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Illustration 6	g03345145

1. Take approximately 40 mm (1.57 inch) length of black 5P-5677 Wire . Strip 5P-5677 Wire and 5P-3075 Wire from 6 mm (0.23 inch) to 10 mm (0.39 inch). Insert into opposite ends of the 136-4878 Wire Splice . Refer to Illustration 6.

2. Crimp the splice to join the wires with crimp tool.

3. Heat the insulation sleeve of the splice along the entire length, until the crimp marks are gone and the ends of the sleeve recover onto the wires.

4. Repeat Step 1 thru Step 3 to increase the length of brown 5P-9072 Electrical Wire and green 5P-9080 Electrical Wire by using 40 mm (1.57 inch) length of black 5P-5677 Wires .

5. Strip the wires from 3.94 mm (0.15 inch) to 4.7 mm (0.18 inch). Crimp the pins and socket to the harness as specified in Table 4.
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   Table 4

   Part Number	Description	Wire Color
   7N-7780	Connector Pin	Brown & Black
   7N-7780	Connector Pin	Green & Black
   7N-7779	Connector Socket	Black & Black

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Illustration 7	g03345137
7N-7781 Receptacle Housing

6. Insert the pins and socket to the 7N-7781 Receptacle Housing using the pin and socket locations specified in Table 5 and Illustration 7. Modification is now complete.
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   Table 5

   Pin Number	Wire Color
   1	Black & Black
   2	Brown & Black
   3	Green & Black