2000/10/02 Caterpillar


Harness Repair of Alternator R-Terminal Connector {1405, 1408, 7553}

Usage:

D3400 01T
Engine: Commercial
  • All
    Engine: Truck
  • All
  • Reference: Special Instruction, SEHS9615, "Servicing DT Connectors"

    Reference: Service Magazine, SEPD0342, 27 January 97, "Field Repair of Single Wire Breaks in Harnesses"

    Description




    Illustration 1g00745578

    110-8769 Wire Assembly

    (1) Rubber boot

    (2) Terminal

    (3) 6A-3361 Electrical Wire (410 mm (16.1 inch), 16 gauge - black

    If it becomes necessary to repair the harness connection to the alternator R-terminal, the damaged connector can be cut off and replaced by the 110-8769 Wire Assembly (Illustration 1). The 110-8769 Wire Assembly will service the R-terminal connector on machines and engines equipped with the alternators that are listed in Table 1.

    Table 1
    ALTERNATORS SERVICED WITH 110-8769 WIRE ASSEMBLY    
    Description     Service Manual     Alternator Part Numbers    
    10-SI/CS-121 Series     SENB8373     -    
    20-SI Series     SENR4978     7G-7889, 6N-9294, 3T-6352, 5N-5692    
    21-SI Series     SENR4757     107-7977, 132-2156, 121-4134, 121-4135, 117-1379, 125-9597    
    26-SI Series     SENR7508     3E-7577, 112-5041, 3E-7892    
    30-SI Series     SENR7508     9X-7803, 114-2401, 4N-3986, 8C-6163    

    A 115-8109 Wire Splice is used to attach the 110-8769 Wire Assembly to machine harnesses and engine harnesses. This sealed splice does not require soldering. The parts that are required for a sealed splice are listed in Table 2.

    Table 2
    PARTS REQUIRED FOR A SEALED SPLICE    
    Quantity     Description     Part Number     Wire Size    
    1     Wire Splice     115-8109     16 &18 AWG    
    1     Connector Pin     8T-8729     16 &18 AWG    
    1     Connector Socket     8T-8730     16 &18 AWG    

    Procedure




    Illustration 2g00745638

    Sealed splice

    (1) 6A-3361 Electrical Wire (from 110-8769 Wire Assembly )

    (2) 186-3735 Connector Pin

    (3) 115-8109 Wire Splice

    (4) 186-3736 Connector Socket

    (5) Wire from engine or machine harness

    The following procedure explains how to splice the 6A-3361 Electrical Wire to the engine or machine harness. Refer to Illustration 2.

    1. Cut off the damaged R-terminal connector from the machine or engine harness.

    1. Prepare the wires. Refer to Special Instruction, SEHS9615, 01 MAY 93, "Servicing DT Connectors".

    1. Use a 1U-5804 Crimp Tool (12-18 AWG) to secure an 8T-8729 Connector Pin to the end of the 110-8769 Wire Assembly. After the 8T-8729 Connector Pin has been crimped on the wire, insert the connector pin into the socket-end of the 115-8109 Wire Splice. After the connector pin has been inserted into the wire splice, tug on the wire to ensure that the connector pin is locked in place.

    1. Use a 1U-5804 Crimp Tool (12-18 AWG) to secure an 8T-8730 Connector Socket to the machine or engine harness. After the 8T-8730 Connector Socket has been crimped on the wire, insert the connector socket into the pin-end of the 115-8109 Wire Splice. After the connector socket has been inserted into the wire splice, tug on the wire to ensure that the connector socket is locked in place.

    1. Reconnect the R-terminal connector to the alternator. Confirm proper operation.

    Note: The 8T-8729 Connector Pin and the 8T-8730 Connector Socket can be removed from the 115-8109 Wire Splice with a 4C-4074 Contact Removal Tool .

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