MUFFLER GROUP 6F1254 - Caterpillar

Image1.4.1
Tube Wire Bundle
Changing the Socket to the Plug
TWB Socket Plug Removal:
With the socket plug removed, unscrew the wedge cap and wire protector. Expose the wires inside the socket plug to verify wire layout inside the plug.
Remove the wires in the center first to expose the wire on the outer circle.
Remove C and D (Thermocouple wires) then F, G and H 120VAC wires by removing these wires
first. There will be plenty of room to get the Deutsch pin removal tool inside the connector along the rim.
If needed, mark the Pre and Post NOx sensor wires before removing each wire bundle.
Image1.5.1
The Tube Wire Bundle (TWB) was originally fitted with a female connector mated to the male connector on the dosing cabinet. In the first part of the instructions, the male connector was removed and replaced with a female connector in dosing cabinet. This section provides detail for removing the female connector on TWB and replacing with male connector.
The wire color scheme and lettering layout are the same as the dosing cabinet.
Follow the plug layout below to verify the installation is correct.
Note:
Optional Communications Wire: (Same as above)
On the 23 pin connector there is the possibility of a 5th wire (brown).
If this wire is present, move this wire to the correct location in the new connector.
Image1.6.1
TWB connector repair when completed should have the same look as Image below .
Image1.7.1
Tube Wire Bundle Assembly requiring Pigtail
(Only on systems with Heat Trace)
Early tube wire bundle assemblies did not include a three wire pair extension or "pig tail" to the 23 pin wiring.
Inside the TWB assembly the heat trace extends through the shrink boot and into the 23 pin plug direct. Removal of this wire and trimming to correct length
will be necessary to attach the three wire pair extension.
The following instructions are needed for successful installation.
To access to the heat trace in the tube wire bundle cutting the heat shrink boot off the TWB will be necessary. Do not use a razor blade using a razor blade to cut into the outer sheathing of the TWB will ruin its outer core. The preferred method is to use a pair of side cutters and a heat gun to warm up the glue and cut as it is heated.
Once the heat trace has been exposed follow these steps to connect the wire extension. Using wire cutters, cut heat tape down to 2 inch. See Image below.
Image1.8.1
Carefully cut off grey insulation. Be sure to leave mesh wire.
Image1.9.1
Carefully cut down and around the mesh wire leaving a few strands for ground wire. Twist the strands together.
Image1.10.1
Strip the next layer of insulation from the heat tape (polymer outer jacket),
revealing the self-regulating electrical heat trace. Cut straight down the middle, trim both wires and twist strands of mesh wire down to 1 1/2 inch. Also strip the ends of the two black wires.
Image1.11.1
Crimp the three connectors (from the pigtail) to the stripped wires. Crimp green wire to the mesh ground wire.
Image1.12.1
Use a heat gun to shrink the pink connectors on ends.
Image1.13.1
Cut a