- Engine: Commercial
- All
- Engine: Truck
- All
- 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 1 | g00745578 |
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.
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.
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 2 | g00745638 |
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.
- Cut off the damaged R-terminal connector from the machine or engine harness.
- Prepare the wires. Refer to Special Instruction, SEHS9615, 01 MAY 93, "Servicing DT Connectors".
- 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.
- 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.
- 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 .