BOLT-SOCKET HEAD 1538004 - Caterpillar

Machines With Air Conditioning And 24 Volt SystemsReference: Service Manual Module, SENR5664-02, "Air Conditioning And Heating Systems With R-134a Refrigerant".Description of Change: An integral connector is now used at the air conditioning (A/C) condenser fan motor relay assembly. This connector is typically inside the remote mounted condenser enclosure on most machines. This connector is used with a relay for improved reliability and ease of service; however, earlier machines did not have an integral (built-in) connector installed in the harness. The earlier machines have individual blade terminals that must be connected to each terminal when servicing the relay assembly. The relay assembly plugs into the connector which provides a more reliable connection, free from dirt and moisture build-up which can cause corrosion and reduced life of the relay assembly. Adaptable To: Earlier builds of machines using the 3E-5239 Relay Assembly and individual blade terminals can be updated to the new 9X-1054 Plug Assembly Connector. A new 3E-5239 Relay Assembly should be installed when updating the harness to accept the 9X-1054 Plug Assembly Connector. This procedure can also be applied to machines using the 3T-2170 Relay Assembly. The chart lists the parts required. Procedure:
1. Carefully document the wires that are connected to the relay coil and the relay contacts before cutting off the individual blade terminals. Insert the appropriate wires through the holes in the bottom of the 9X-1054 Plug Assembly Connector . Pull the wires through the connector as the terminals will be installed in front of the connector and then the wires are pulled back to seat each terminal in place. The coil wires are installed at positions 2 and 5. The wires connecting to the contacts are installed at positions 1 and 4. On some models two wires will need to be hooked to one terminal on the 9X-1054 Plug Assembly Connector. To accomplish this, connect both wires in one end of a 092-8226 Splice and connect an appropriate length of 5P-5624 Wire in the other end of the splice. Secure the wires in the splice by using a crimping tool. Use 6V-2689 Heat Shrinkable Tubing to protect the splice.2. Use the 6V-3001 Crimping Tool to install the 9X-1055 Terminals on the wires connecting to the relay contact and the 9X-1056 Terminals on the wires connecting to the coil leads of the relay. Note: In the event the coil leads are #12 wire, install 9X-1055 Terminals instead of 9X-1056 Terminals on the coil leads. 3. Pull each wire one at a time and lock the terminals in place on the 9X-1054 Plug Assembly Connector.4. Plug the assembled integral connector into the bottom of the relay until it latches. Secure loose leads as needed with 3S-2093 Cable Straps using the 4C-5877 Cable Tie Tool.5. Test the air conditioner for proper operation.
Illustration 1. Relay Electrical Symbol And Bottom View Of 3E-5239 Relay Assembly.
Illustration 2. Bottom View Of 9X-1054 Plug Assembly Connector.