Installation Procedure For The 138-7020 Harness Assembly{1408} Caterpillar


Installation Procedure For The 138-7020 Harness Assembly{1408}

Usage:

3406E (5EK)

Introduction

NOTE: Do not perform any procedure outlined in this Special Instruction until you have read and understood this information.

This Special Instruction provides the installation procedure for the 138-7020 Harness Assembly in the above 3406E Truck Engines.

1. Turn the ignition key OFF (engine is off).

2. Disconnect the engine harness from the electronic control module (ECM) (P2 connector).


Illustration 1. ECM Pin Locations: (A) Injector common 3 & 4. (B) Injector 1 & 2. (C) Injector 1. (D) Injector 2. (E) Injector 3. (F) Injector 4. (G) Injector 5. (H) Injector 6. (I) Injector common 5 & 6. (J) Retarder solenoid LO/HI. (K) Retarder solenoid MED/HI. (L) Retarder solenoid common. (M) Harness side. (N) ECM connector (P2). (O) ECM side.

3. As designated in Chart 1, remove the wires, one at a time, from the P2 connector. Insert the corresponding wire from the 138-7020 Harness Assembly into the P2 connector. Refer to Illustration 1.

4. Connect the P2 connector to the ECM.

5. Disconnect the P5 connector from the J5 connector on the valve cover base.

6. Connect the 12-Pin connector on the 138-7020 Wiring Harness to the J5 connector on the valve cover base.


Illustration 2. Electronic Control Wiring Group: (1) Unit injector. (2) 138-7020 Wiring Harness. (3) ECM (P2).

NOTE: Refer to Illustration 2 for the recommended routing of the 138-7020 Harness Assembly.

7. Start the engine. Check the operation of the engine and the engine compression brake (if installed) at low, medium, and high settings. Check for active diagnostic codes using a service tool.

8. Use tie straps to secure the 138-7020 Harness Assembly in the recommended position (away from any contact points that might cause abrasion to the harness).

9. Use tie straps to secure the disconnected engine harness wires or cut them off at the braiding.

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