SPRING-LIFTER 7N1208 - Caterpillar

Engine: Commercial
All Engine: Truck
AllReference: 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 - blackIf 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 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 harnessThe 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 .