Instruction for Installing 3E-8866 Wire As to Fit Alternate Harness Lengths{1408, 1900, 1901} Caterpillar

Engine:

3508 (S/N: 6TJ1-UP)

3512 (S/N: 2WK1-UP)

3516 (S/N: 9KF1-UP)

3606 (S/N: 8RB1-UP)

3608 (S/N: 6MC1-UP)

3612 (S/N: 9RC1-UP)

3616 (S/N: 1PD1-UP)

Introduction

This Special Instruction is intended for the installation of the 3E-8866 Wire As . The 3E-8866 Wire As can be installed to fit alternate harness lengths.

Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.

If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used. Ensure that the tool, procedure, work method, or operating technique is safe to use. Ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Do not attempt to assemble this machine until you read and you understand the assembly instructions. Improper assembly procedures could result in injury or death.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, turn the battery disconnect switch to the OFF position. Remove the key for the battery disconnect switch. Use a secure padlock in order to lock the battery compartment access door. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

Special Instructions for 3E-8866 Installation in Place of 3E-8870 Wire As

These special instructions are used to install 3E-8866 Wire As in Place of 3E-8870 Wire As by removing excess wire material in 3E-8866 .

Instructions to modify 3E-8866 Wire As :

The illustrations 1 and 2 shows the 3E-8866 Wire As and the 3E-8870 Wire As .

Illustration 1	g02959377
(1) 5P-4571 Blade Terminal (2) 8T-1487 Electrical Wire

Illustration 2	g02959403
(1) 5P-4571 Blade Terminal (2) 8T-1487 Electrical Wire

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Illustration 3	g02959318

1. Cut the 8T-1487 Electrical Wire at position 1 & 2 in 3E-8866 Wire As as per the positions and dimensions shown in Illustration 3.

2. Remove excess wire material and Strip the wires 6 mm (0.2 inch) to 10 mm (0.4 inch), insert into opposite ends of the crimp barrel of 136-4877 Wire Splice .

3. Crimp the Splice to join the wires with Crimp tool.

4. The Insulation Sleeve of the splice must be heated along the entire length of the wire. This heating should be done until the crimp marks are gone and the ends of the sleeve recover onto the wires.

5. Assemble the Wire Assembly to NHL Control Gp - Mountings with the help of terminal locations shown in Table 1.

CAT P/N Required for this operation:

Mfg Tools Required:

• Cutter

• Crimp tool

Splice Sectional View:

Refer to the following Illustration for section view of Splice.

Illustration 4	g02959156
(1) Insulation Sleeve (2) Crimp Splice

Special Instructions for 3E-8866 Installation in Place of 8C-6110 Wire As

These special instructions are used to install 3E-8866 Wire As in place of 8C-6110 Wire As by removing excess wire material in 3E-8866 Wire As .

Instructions to modify 3E-8866 Wire As :

The illustrations 5 and 6 shows the 3E-8866 Wire As and the 8C-6110 Wire As .

Illustration 5	g02959377
(1) 5P-4571 Blade Terminal (2) 8T-1487 Electrical Wire

Illustration 6	g02969956
(1) 5P-4571 Blade Terminal (2) 8T-1487 Electrical Wire

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Illustration 7	g02969958

1. Cut the 8T-1487 Electrical Wire at position 1 & 2 in 3E-8866 Wire As as per the positions and dimensions shown in Illustration 7.

2. Remove excess wire material and Strip the wires 6 mm (0.2 inch) to 10 mm (0.4 inch), insert into opposite ends of the crimp barrel of 136-4877 Wire Splice .

3. Crimp the splice to join the wires with Crimp tool.

4. The Insulation Sleeve of the splice must be heated along its entire length until the crimp marks are gone and the ends of the sleeve recover onto the wires.

5. Assemble the Wire Assembly to NHL Control Gp - Mountings with the help of terminal locations shown in Table 3.
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   Table 3

   S.NO	CAT P/N	TERMINAL LOC-1	GAUGE	LENGTH	TERMINAL LOC-2
   1	8c-6110	TB392-R10	16	410	DP-L4

CAT P/N Required for this operation:

Mfg Tools Required:

• Cutter

• Crimp tool

Splice Sectional View:

Refer to the following Illustration for section view of Splice.

Illustration 8	g02959156
(1) Insulation Sleeve (2) Crimp Splice

Special Instructions for 3E-8866 Installation in Place of 9X-1387 Wire As

These special instructions are used to install 3E-8866 Wire As in Place of 9X-1387 Wire As by removing excess wire material in 3E-8866 Wire As .

Instructions to modify 3E-8866 Wire As :

The illustrations 9 and 10 shows the 3E-8866 Wire As and the 9X-1387 Wire As .

Illustration 9	g02959377
(1) 5P-4571 Blade Terminal (2) 8T-1487 Electrical Wire

Illustration 10	g02970016
(1) 5P-4571 Blade Terminal (2) 8T-1487 Electrical Wire

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Illustration 11	g02970017

1. Cut the 8T-1487 Electrical Wire at position 1 & 2 in 3E-8866 Wire As as per the positions and dimensions shown in Illustartion 11.

2. Remove excess wire material and Strip the wires 6 mm (0.2 inch) to 10 mm (0.4 inch), insert into opposite ends of the crimp barrel of 136-4877 Wire Splice .

3. Crimp the Splice to join the wires with Crimp tool.

4. The Insulation Sleeve of the splice must be heated along its entire length until the crimp marks are gone and the ends of the sleeve recover onto the wires.

5. Assemble the Wire Assembly to NHL Control Gp - Mountings with the help of terminal locations shown in Table 5.
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   Table 5

   S.NO	CAT P/N	TERMINAL LOC-1	GAUGE	LENGTH	TERMINAL LOC-2
   1	9X-1387	TB391-L4	16	310	DP-R2

CAT P/N Required for this operation:

Mfg Tools Required:

• Cutter

• Crimp tool

Splice Sectional View:

Refer to the following Illustration for section view of Splice.

Illustration 12	g02959156
(1) Insulation Sleeve (2) Crimp Splice

Special Instructions for 3E-8866 Installation in Place of 9X-9373 Wire As

These special instructions are used to install 3E-8866 Wire As in Place of 9X-9373 Wire As by removing excess wire material in 3E-8866 Wire As .

Instructions to modify 3E-8866 Wire As :

The illustrations 13 and 14 shows the 3E-8866 Wire As and the 9X-9373 Wire As .

Illustration 13	g02959377
(1) 5P-4571 Blade Terminal (2) 8T-1487 Electrical Wire

Illustration 14	g02970056
(1) 5P-4571 Blade Terminal (2) 8T-1487 Electrical Wire

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Illustration 15	g02970057

1. Cut the 8T-1487 Electrical Wire at position 1 & 2 in 3E-8866 Wire As as per the positions and dimensions shown in Illustration 15.

2. Remove excess wire material and Strip the wires 6 mm (0.2 inch) to 10 mm (0.4 inch), insert into opposite ends of the crimp barrel of 136-4877 Wire Splice .

3. Crimp the Splice to join the wires with Crimp tool.

4. The Insulation Sleeve of the splice must be heated along its entire length until the crimp marks are gone and the ends of the sleeve recover onto the wires.

5. Assemble the Wire Assembly to NHL Control Gp - Mountings with the help of terminal locations shown in Table 7.
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   Table 7

   S.NO	CAT P/N	TERMINAL LOC-1	GAUGE	LENGTH	TERMINAL LOC-2
   1	9X-9373	TB392-L11	16	75	TB392-R11

CAT P/N Required for this operation:

Mfg Tools Required:

• Cutter

• Crimp tool

Splice Sectional View:

Refer to the following Illustration for section view of Splice.

Illustration 16	g02959156
(1) Insulation Sleeve (2) Crimp Splice

Special Instructions for 3E-8866 Installation in Place of 9X-9381 Wire As

These special instructions are used to install 3E-8866 Wire As in Place of 9X-9381 Wire As by removing excess wire material in 3E-8866 Wire As .

Instructions to modify 3E-8866 Wire As :

The illustrations 17 and 18 shows the 3E-8866 Wire As and the 9X-9381 Wire As .

Illustration 17	g02959377
(1) 5P-4571 Blade Terminal (2) 8T-1487 Electrical Wire

Illustration 18	g02970076
(1) 5P-4571 Blade Terminal (2) 8T-1487 Electrical Wire

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Illustration 19	g02970057

1. Cut the 8T-1487 Electrical Wire at position 1 & 2 in 3E-8866 Wire As as per the positions and dimensions shown in Illustration 19.

2. Remove excess wire material and Strip the wires 6 mm (0.2 inch) to 10 mm (0.4 inch), insert into opposite ends of the crimp barrel of 136-4877 Wire Splice .

3. Crimp the Splice to join the wires with Crimp tool.

4. The Insulation Sleeve of the splice must be heated along its entire length until the crimp marks are gone and the ends of the sleeve recover onto the wires.

5. Assemble the Wire Assembly to NHL Control Gp - Mountings with the help of terminal locations shown in Table 9.
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   Table 9

   S.No	CAT P/N	TERMINAL LOC-1	GAUGE	LENGTH	TERMINAL LOC-2
   1	9X-9381	TB392-L10	16	75	TB392-R10

CAT P/N Required for this operation:

Mfg Tools Required:

• Cutter

• Crimp tool

Splice Sectional View:

Refer to the following Illustration for section view of Splice.

Illustration 20	g02959156
(1) Insulation Sleeve (2) Crimp Splice