Special Instruction

Installation Procedure for 257-4183 Injector Wiring Harness Kit {1408}

Media Number -REHS2421-01 Publication Date -27/02/2007 Date Updated -27/02/2007

i02703642

SMCS - 1408

Generator Set Engines:

3406E (S/N: 9NN1-UP)
3456 (S/N: EPE1-UP; 3PG1-UP; 9BZ1-UP; 7WG1-UP)
C-12 (S/N: BCY1-UP)
Industrial Engines:
3176B (S/N: 3NL1-UP)
3176C (S/N: 2AW1-UP)
3196 (S/N: 1DW1-UP)
3406E (S/N: 6BR1-UP)
3408E (S/N: 7PR1-UP)
3412 (S/N: BDT1-UP)
3412C (S/N: 8AR1-UP)
3412E (S/N: BFT1-UP; 4CR1-UP)
3456 (S/N: 3LW1-UP; BGA1-UP)
C-10 (S/N: BCX1-UP)
C11 (S/N: GLS1-UP)
C-12 (S/N: BDL1-UP)
C13 (S/N: LGK1-UP)
C15 (S/N: JRE1-UP)
C-15 (S/N: BEM1-UP; Z2C1-UP)
C-16 (S/N: BFM1-UP)
C18 (S/N: WJH1-UP)
Marine Engine:
3176B (S/N: 9WK1-UP)
3176C (S/N: 6BW1-UP)
3196 (S/N: 2XR1-UP)
3406E (S/N: 9WR1-UP)
3412E (S/N: 9PW1-UP; 9KS1-UP)
C-12 (S/N: 9HP1-UP)
C12 (S/N: C1Z1-UP)
C18 (S/N: C1J1-UP; CKH1-UP; CYN1-UP)
C30 (S/N: CLX1-UP)
C32 (S/N: RXB1-UP)
C18 MARINE (S/N: NAX1-UP; NAY1-UP)
On-Highway Engines:
3126B (S/N: 8YL1-UP)
3126E (S/N: 9SZ1-UP)
3176 (S/N: 7LG1-UP)
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 3176B (S/N: 9CK1-UP)
3406E (S/N: 5EK1-UP; 1LW1-UP; 5DS1-UP; 1MM1-UP; 6TS1-UP; 2WS1-UP)
C-10 (S/N: MBJ1-UP; 2PN1-UP; 3CS1-UP; 8YS1-UP)
C11 (S/N: KCA1-UP)
C-12 (S/N: 8YF1-UP; 2KS1-UP; 9NS1-UP; MBL1-UP; CPD1-UP; 9SM1-UP; 1YN1-UP)
C13 (S/N: KCB1-UP)
C15 (S/N: MXS1-UP; BXS1-UP)
C-15 (S/N: EGH1-UP; 6NZ1-UP; MBN1-UP)
C-16 (S/N: 7CZ1-UP; W1A1-UP)
C18 (S/N: MEP1-UP)
C-18 (S/N: CJP1-UP)
Agricultural Tractor:
65E (S/N: 1GM1-UP; 6GS1-UP)
75 (S/N: 4CJ1-UP)
75C (S/N: 4KK1-UP)
75D (S/N: 5AR1-UP)
75E (S/N: 1HM1-UP; 6HS1-UP)
85C (S/N: 9TK1-UP)
85D (S/N: 4GR1-UP)
85E (S/N: 1NM1-UP; 6JS1-UP)
95E (S/N: 1SM1-UP; 6KS1-UP)
MT735 (S/N: AKN1-UP)
MT835 (S/N: BAM1-UP)
MT845 (S/N: BBP1-UP)
MT855 (S/N: BCC1-UP)
MT865 (S/N: BDS1-UP)
MTC835 (S/N: 8161-UP)
MTC845 (S/N: 8171-UP)
MTC855 (S/N: 8181-UP)
MTC865 (S/N: 8191-UP)
Articulated Truck:
725 (S/N: AFX1-UP)
730 (S/N: AGF1-UP)
735 (S/N: AWR1-UP)
740 (S/N: AXM1-UP)
D300E (S/N: 7FN1-UP)
D350E Series II (S/N: 2XW1-UP)
D400E Series II (S/N: APF1-UP; 8PS1-UP)
Cold Planer:
PM-565 (S/N: 3TK1-UP)
PM-565B (S/N: 8GS1-UP)
Combine:
Lexion 480 (S/N: 2BZ1-UP)
Lexion 480 R (S/N: 8661-UP)
Lexion 485 (S/N: 8ZW1-UP)
Lexion 485 R (S/N: 8681-UP)
Landfill Compactor:
816F (S/N: BMR1-UP)
826G Series II (S/N: AYH1-UP)
836 (S/N: 7FR1-UP)
836G (S/N: BRL1-UP; 7MZ1-UP)
Soil Compactor:
815F (S/N: BKL1-UP)
825G Series II (S/N: AXB1-UP)
Pumper:
SBF214 (S/N: CSB1-UP)
SUF557 (S/N: LTF1-UP)

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Excavator:
345B (S/N: CFM1-UP; 9GS1-UP; 2NW1-UP; 4SS1-UP)
385B (S/N: ANS1-UP)
5110B (S/N: AAA1-UP; AAT1-UP; AAK1-UP)
W345B Series II (S/N: ANJ1-UP; CDY1-UP)
345B Series II (S/N: ALB1-UP; APB1-UP; AGS1-UP; DCW1-UP)
Track Feller Buncher:
TK1051 (S/N: 9HZ1-UP)
Load Haul Dump:
R1600 (S/N: 9EW1-UP)
R1700 II (S/N: 4LZ1-UP)
Motor Grader:
135H (S/N: AMX1-UP)
140H (S/N: APM1-UP)
14H (S/N: ASE1-UP)
160H (S/N: ASD1-UP)
163H (S/N: ARL1-UP)
16H (S/N: ATS1-UP)
24H (S/N: 7KK1-UP)
Off-Highway Truck/Tractor:
69D (S/N: 9XS1-UP)
769C (S/N: 01X1-UP)
772B (S/N: 64W1-UP)
773B (S/N: 63W1-UP)
773E (S/N: BDA1-UP)
769D (S/N: BBB1-UP; 5TR1-UP; 5SS1-UP)
773D (S/N: 7ER1-UP; 7CS1-UP)
Quarry Truck:
771C (S/N: 3BJ1-UP)
775E (S/N: BEC1-UP)
771D (S/N: BCA1-UP; 6JR1-UP; 6YS1-UP)
775D (S/N: 6KR1-UP; 8AS1-UP)
Track-Type Tractor:
D7R (S/N: AEC1-UP; AGN1-UP; ACS1-UP; ADW1-UP; AFG1-UP)
D7R Series II (S/N: ABJ1-UP)
D8L (S/N: 53Y1-UP)
D8R Series II (S/N: 6YZ1-UP)
D9L (S/N: 14Y1-UP)
D9N (S/N: 1JD1-UP)
D9R (S/N: ABK1-UP; ACL1-UP; 7TL1-UP; 8BL1-UP)
D10N (S/N: 3SK1-UP)
D10R (S/N: 3KR1-UP; AKT1-UP)
Wheel Dozer:
814F (S/N: BGF1-UP)
824G Series II (S/N: AWW1-UP)
834B (S/N: 7BR1-UP; 92Z1-UP)
834G (S/N: BPC1-UP; 6GZ1-UP)
844 (S/N: BBN1-UP; 2KZ1-UP)
Wheel Loader:
972G Series II (S/N: ANY1-UP)
980G Series II (S/N: AWH1-UP)
988B (S/N: 50W1-UP)
988F Series II (S/N: 2ZR1-UP)
988F (S/N: 8YG1-UP)
988G (S/N: 2TW1-UP)
990 (S/N: 7HK1-UP)
966G Series II (S/N: ANT1-UP; ANZ1-UP)

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 990 Series II (S/N: BCR1-UP; 4FR1-UP)
Wheel Tractor-Scraper:
621F (S/N: 4SK1-UP)
631D (S/N: 24W1-UP)
631E (S/N: 1AB1-UP)
633D (S/N: 25W1-UP)
633E Series II (S/N: 2PS1-UP)
639D (S/N: 99X1-UP)
651E (S/N: 4YR1-UP)
621G (S/N: CEN1-UP; ALP1-UP)
623G (S/N: CES1-UP; ARW1-UP)
627G (S/N: AXF1-UP; CEX1-UP)
631G (S/N: AWK1-UP; CLR1-UP)
637D (S/N: 26W1-UP; 27W1-UP)
637E (S/N: 1FB1-UP; 1JB1-UP)
637G (S/N: CEH1-UP; AXT1-UP)
657E (S/N: 6MB1-UP; 5YR1-UP; 6PR1-UP; 6TR1-UP; 7KR1-UP; 86Z1-UP; 87Z1-UP)

Do not perform any procedure in this Special Instruction until you read this information and you understand
this information. This Special Instruction is intended for the installation of the 257-4183 Injector Wiring
Harness Kit . The 257-4183 Injector Wiring Harness Kit can be used to repair fuel injector connectors.

Table 1
Required Tools
Tool Part Number Part Name Qty

A 9S-9150 Terminal Crimp Tool As 1

B 9U-6070 Heat Gun Gp 1

The following steps can be used in order to remove a faulty connector for an injector on the wire harness
that is located under the valve mechanism cover.

1. Identify the connector that needs to be replaced. Wiring for the injector solenoid is not sensitive to
polarity.

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 Illustration 1 g01111254

Connector that is cut from the wire harness

2. Cut wire (1) at a distance of 70 mm (2.8 inch) from the rear surface of the connector.

3. Cut wire (2) at a distance of 65 mm (2.6 inch) from the rear surface of the connector.

Illustration 2 g01111314

(3) Wire from the harness for side (B) on the connector

(4) Wire from the harness for side (A) on the connector

Note: The wires on the old connector are cut to length so that the wires on the wire harness will
match up to the new connector. Cutting the wires to the proper length will aid in matching the harness
wires to the wires on the new connector.

4. Discard the old connector.

The following steps can be used in order to install a new connector for an injector on the wire harness that
is located under the valve mechanism cover.
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1. Use Tool (A) in order to remove 5 mm (0.2 inch) of the plastic from wires (3) and (4) .

Illustration 3 g01111333

Connecting the connector to the wire harness

(A) Side (A) of the new connector

(B) Side (B) of the new connector

(3) Wire from the harness for side (B) on the new connector

(4) Wire from the harness for side (A) on the new connector

(5) Heat shrink tubes

(6) Butt splice on the wire that is on side (A) of the new connector

(7) Butt splice on the wire that is on side (B) of the new connector

2. Use heat shrink tubes (5) from the 257-4183 Injector Wiring Harness Kit . Slide the heat shrink tubes
toward the connector in order to expose the butt splices.

3. Insert wire (4) into butt splice (6) .

4. Insert wire (3) into butt splice (7) .

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 Illustration 4 g01111364

(6) Butt splice on the wire that is on side (A) of the new connector

(7) Butt splice on the wire that is on side (B) of the new connector

5. Use Tool (A) to crimp butt splices (6) and (7) in order to secure the wires together.

Illustration 5 g01035814

(A) 9S-9150 Terminal Crimp Tool As

6. Slide the heat shrink tubes (5) over the splices. Evenly cover the splices with the heat shrink tubes.

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 Illustration 6 g01111377

(B) 9U-6070 Heat Gun Gp

Note: Do not overheat the heat shrink tubes.

7. Use Tool (B) to heat the heat shrink tubes. Heat the tubes until the tubes shrink around the wires.

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