Usage:
3306C (7RJ, 9TL) Truck Engines
Description of Change: A new control for the air inlet heater is available for the above truck engines. The new control replaces the former control in truck applications where the control is mounted in a location exposed to the weather. The former control is mounted to the wheel well area of certain truck chassis such as Kenworth©. The new control reduces the possibility of "shorting out" caused by water getting into the wiring harness connector attached to the control.
Adaptable To: The 138-3318 Control is in production and is serviceable for Kenworth Trucks. The 101-9643 Control is still used in applications not exposed to the weather. The 138-3318 Control is available through parts service for all applications. When adapting the 138-3318 Control, a 136-4304 Wiring Harness Assembly and minor modifications to the Original Equipment Manufacturer (OEM) wiring harness are required.
Parts List
Diagram for replacement of the 101-9643 with the 138-3318 Control.
(1) 138-3318 Control. (2) Wire identification using the codes from the 101-9643 Control to the 136-4304 Wiring Harness Assembly. (3) 5W-1982 Terminal. (4) 136-4304 Wiring Harness Assembly. (5) 102-8811 Plug Kit. (6) 127-5485 Connecting Plug Assembly. (7) OEM wiring harness.
Installation Of The 138-3318 Control In Order To Replace The Existing 101-9643 Control In Kenworth Trucks
NOTE: The following installation instructions are used for the 3306C Kenworth Trucks. The installation instructions can be used in other truck engines as well. If the installation is for other truck engines, variations in wire color and size may occur.
1. Disconnect the battery.
2. Disconnect the wiring harness from the 101-9643 Control. Remove the 101-9643 Control from the Mounting Bracket.
Illustration 2.
Wiring identification using codes from the 101-9643 Control to the OEM wiring harness.
3. Inspect, verify and correct the wire colors indicated in Chart 2. See Illustration 2.
4. Cut off the 4 pin and 6 pin connectors that connect to the 101-9643 Control from the OEM wiring harness.
Illustration 3.
(6) 127-5485 Connection Plug Assembly. (7) 8N-1543 Connection Socket.
5. Identify the FGK wire to the glow plug and assemble the 127-5485 Connection Plug Assembly (6) with the 8N-1543 Connection Socket (7) (for the 10 AWG wire). Use the Deutsch© crimp tool or a heavy duty standard crimping tool in order to attach the socket to the wire.
NOTE: The Deutsch crimp tool part number is HDP-400. This is not a Caterpillar part number and not available through Caterpillar Parts Service.
Illustration 4.
Assembly of the 5W-1982 Terminal. (3) 5W-1982 Terminal.
6. Identify wire 30 (main power supply) and assemble the 5W-1982 Terminal (3) to the stripped end of the wire using a standard crimping tool.
Illustration 5.
102-8811 Plug Kit. See Chart 3.
7. Connect the remaining OEM wiring harness wires to a 102-8811 Plug Kit using the 9W-0844 Connection Sockets (for 14/16 AWG wire). Seal the Socket 8 hole with an 8T-8737 Seal Plug. See Chart 3 in order to locate the wires in the connector properly, and use the 1U-5804 Crimp Tool to connect the 9W-0844 Sockets to the wires.
Illustration 6.
Views of the 138-3318 Control. The 138-3318 Control should be mounted with the connector pointed downward as in the illustration.
8. The two mounting holes are not the same when switching from the 101-9643 to the 138-3318 Control. Modify the mounting bracket in the OEM Truck chassis in order to install the 138-3318 Control with two M6 (1/4 in) thread bolts at a spacing of 99.5 ± 1.5 mm (3.92 ± .06 in) on a horizontal plane.
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The 138-3318 Control should be installed with the connector pointed downward in order to minimize water damage. See Illustration 6.
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9. Install the 5W-1982 Terminal (3) on the wire 30 to the M6 stud on the 133-3318 Control with the nut that is supplied. An equivalent 5C-2890 Nut can be used.
10. Install the 133-3318 Control to the OEM truck chassis modified mounting bracket using two M6 or two 1/4 in bolts with washers.
11. Connect the 136-4304 Harness Assembly to the 133-3318 Control.
12. Connect the prepared OEM wiring harness connectors from steps 5 and 7 to the 136-4304 Harness Assembly connectors. Make sure the two parts "snap" together.
Illustration 7.
Instrument panel indicator lamp wiring diagram. (8) 8D-1429 Miniature Lamp.
13. The instrument panel indicator lamp is connected to wires L and 31. Cut wire 31 and connect the cut lead coming from the lamp to the key switch (key ON position). In order to prevent a short, make sure to insulate the other end of wire 31. Wire 31 is connected to ground, but is no longer used. See Illustration 7.
14. Replace the existing light bulb with an 8D-1429 Miniature Lamp (8). The lamp size must not exceed 2 watts in order to operate properly with the new 133-3318 Control.
15. Test the system for proper operation.