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Special Instruction
Electrical Connector Servicing & Cleaning Instructions for Large Mining Truck Applications {0374, 0709,
1408, 7553}
Media Number -M0100651-00 Publication Date -10/07/2019 Date Updated -10/07/2019

i07580668

Electrical Connector Servicing & Cleaning Instructions for Large Mining

Truck Applications {0374, 0709, 1408, 7553}
SMCS - 0374; 0709; 1408; 7553

Off-Highway Truck/Tractor
785C (S/N: APX1-UP)
785D (S/N: DMC1-UP; MSY1-UP)
785G (S/N: RTL1-UP)
789D (S/N: SPD1-UP; SHH1-UP)
793D (S/N: FDB1-UP)
793F (S/N: SND1-UP; SSP1-UP; SXP1-UP; D3T1-UP; RBT1-UP)
794 AC (S/N: MT51-UP; HRT1-UP)
795F AC (S/N: ERM1-UP)
795FAC XQ (S/N: SNT1-UP)
796 AC (S/N: HRY1-UP; HRZ1-UP)
797 (S/N: 5YW1-UP)
797B (S/N: JSM1-UP)
797F (S/N: LAJ1-UP; WSP1-UP; LTZ1-UP)
798 AC (S/N: ST71-UP)

Introduction
Safety Section
Do not perform any procedure in this Special Instruction until the information in this Special Instruction has been fully read
and understood. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow
these procedures can result in personal injury. The following procedures should be observed.

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, tools, and proper
personal protective equipment (PPE) 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. Ensure that any
tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.

Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication,

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maintenance, or repair procedures used.

Note: Prior to operation of the machine read the Operation and Maintenance Manual.

Before starting installation and in addition to the normal safety precautions that are taken in the day to day maintenance of
heavy machinery, the following preliminary steps are recommended:

1. Move the machine to a smooth, level location, and away from other working machines and personnel.

2. Ground all implements.

3. Engage the parking brake for the machine.

4. Stop the engine.

5. Move the hydraulic control levers to all positions to release the pressure in the hydraulic system.

6. Turn the battery disconnect switch to the OFF position. Remove the key for the battery disconnect switch. Use a
secure padlock to lock the battery compartment access door.

7. Place a lockout tag on the disconnect switch.

8. Chock the wheels.

 Only mount the machine and dismount the machine at locations that have steps and/or handholds.

 Inspect the steps and the handholds before mounting and dismounting. Clean the steps and the handholds, if necessary.
Repair the steps and the handholds, if necessary.

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Illustration 1 g00037367

 Face the machine when you are mounting and dismounting.

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 Maintain a three-point contact with the steps and the handholds. Three-point contact is maintained when two feet and
one hand are in contact or one foot and two hands are in contact.

 Never get on a moving machine or off a moving machine.

 Never jump off the machine.

 Do not try to climb on the machine or climb off the machine when you are carrying tools or supplies. Use a hand line
to pull equipment up to the operator platform.

 Do not use any of the controls as handholds as you are climbing into the machine or exiting the machine .

Do not operate or work on this product unless you have read and
understood the instruction and warnings in the relevant Operation and
Maintenance Manuals and relevant service literature. Failure to follow
the instructions or heed the warnings could result in injury or death.
Proper care is your responsibility.

Failure to follow all safety guidelines prescribed in this document and

by governing authorities and regulatory agencies may result in severe
injury or death of personnel or machine damage.

When removing a major component or attachment, ensure that it is

properly blocked or secured before removing mounting hardware. An
assembly that is disconnected without proper blocking may shift or fall,
resulting in serious injury or death of personnel or machine damage.

Personal injury or death can result from improper maintenance

procedures. To avoid injury or death, follow the procedures exactly as
stated below.

Personal injury can result from improper handling of chemicals.

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Make sure you use all the necessary protective equipment required to
do the job.

Make sure that you read and understand all directions and hazards
described on the labels and material safety data sheet of any chemical
that is used.

Observe all safety precautions recommended by the chemical

manufacturer for handling, storage, and disposal of chemicals.

Climbing equipment may be required to access this service point. Refer

to the Operation and Maintenance Manual, "Mounting and
Dismounting" topic for safety information.

Before servicing/performing maintenance on the machine, electrical

power must be physically disconnected; battery plugs must be
disconnected from the batteries, or the trailing cable must be
unplugged, and warning tags and padlocks shall be applied by a
certified electrician. Certified electricians shall perform or direct any
electrical work, including any energized testing, repair work in
controllers, motors, or other approved compartments, and shall insure
that all compartments are properly closed and inspected prior to re-
energization. All applicable lock out and tag out procedures must be
followed.

Do not operate the machine if any guards or covers are missing or

inadequately secured. Personnel could be seriously injured or machine
damage may occur.

Observe the safe working load limits of all lifting and blocking devices
and keep a safe distance from suspended/blocked loads. Personnel may
be seriously injured or killed by falling loads.

Required Tools

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 Cleaning solution containing 75 percent isopropyl alcohol

 Flat screwdriver

 Electrical contact tool

Table 1

Tools Required for Electrical Connector Cleaning and Servicing Parts

Part Number Description

326-8203 Tool

1U-9919 Brush

1U-9978 Brush

452-6867 Tool

Other Recommended Tools

 Compressed air at 620 kPa (90.0psi) maximum pressure

 Cleaning swabs

Required Parts
Table 2

Required Parts for Electrical Connector Cleaning and Servicing

Quantity Part Number Description

1 175-3700 Connector Repair Kit

As needed 483-4287 Plate

As needed 204-2281 Cable Strap

Table 3

Contents of 175-3700 Connector Repair Kit

Quantity Part Number Description

10 3E-3365 Receptacle Lock Wedge

10 3E-3371 Receptacle Lock Wedge

5 3E-3377 Receptacle Lock Wedge

5 3E-3383 Receptacle Lock Wedge

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5 3E-3389 Receptacle Lock Wedge

5 3E-5180 Receptacle Lock Wedge

30 8T-8737 Seal Plug

30 9X-3401 Connector Pin

30 9X-3402 Connector Socket

3 102-8801 Receptacle Kit

10 102-8802 Receptacle Kit

5 102-8803 Receptacle Kit

5 102-8804 Receptacle Kit

3 102-8805 Receptacle Kit

3 102-8806 Receptacle Kit

30 126-1767 Connector Pin

30 126-1768 Connector Socket

1 147-6456 Wedge Removal Tool

6 151-6320 Wire Removal Tool

1 152-7997 Utility Box

3 155-2255 Connecting Plug Kit

5 155-2258 Plug Lock Wedge

5 155-2259 Plug Lock Wedge

5 155-2260 Connecting Plug Kit

10 155-2261 Plug Lock Wedge

5 155-2262 Plug Lock Wedge

5 155-2263 Plug Lock Wedge

3 155-2265 Connecting Plug Kit

10 155-2270 Connecting Plug Kit

5 155-2271 Connecting Plug Kit

3 155-2274 Connecting Plug Kit

10 155-2276 Plug Lock Wedge

1 209-0629 Seal Gp

1 209-0631 Seal Gp

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209-0632 Seal Gp

1 209-0633 Seal Gp

1 209-0634 Seal Gp

1 209-0635 Seal Gp

Disconnecting Connectors
1. Spray the outside of connector with cleaning solution to remove as much dirt as possible without the use of any other
tools.

Note: Replace connectors if more than 5 to 10 minutes of cleaning service is anticipated.

2. Orient the receptacle facing down, to avoid possible debris falling into the receptacle.

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Illustration 2 g06370279
Orientation of receptacle down and plug up

3. Press down on the latch of the plug, pulling on the bodies of both connectors to disconnect.

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Illustration 3 g06370288
Back of latch

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Illustration 4 g06370614
Connector side view with dirt pack

Note: If the connectors did not disconnect, use 1U-9978 Brush and 147-6456 Wedge Removal Tool to scrape the dirt and
mud pack from underneath the latch on the plug. Refer to Illustrations 3 and 4 for locations that will need to be cleaned.

Important Notes
Unsuccessful Disconnecting

If you cannot disconnect two connectors and have tried all the techniques described in the steps above, then it may be
necessary to take pliers or a hammer to the connector pair and brake the connectors apart.

If this technique is used, it is unlikely the terminals will survive in a workable condition, so the terminals will also have to be
replaced. This method will result in shortening the wires, be cautious not to run out of enough wire length and not be able to
reconnect the connectors.

Larger Connectors

Replacing connectors is preferred for 2 through 12 position connectors. Larger connection interfaces of 23 position and up
may require more review.

Testing Circuits with Pinching Technique

The practice of pinching wires and breaking the insulation is highly discouraged. Using the spoon tools with a multi meter is
better for the durability of the wires.

Definition of Terms

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Illustration 5 g06380030
Plug

Plug - A type of connector, referred to as the male connector, which typically has pin terminals and inserts into a receptacle
connector.

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Illustration 6 g06380034
Receptacle

Receptacle - A type of connector, referred to as the female connector, which typically has pin terminals and connects to a
plug connector.

Terminal / Contact - The point at which a conductor from an electrical component (in the connector) comes to an end and
provides a point of connection to the external circuits.

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Illustration 7 g06380040
Socket

Socket - Terminal designed to fit a pin. Referred to as the female terminal.

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Illustration 8 g06380043
Pin

Pin - Terminal designed to fit a socket. Referred to as the male terminal.

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Illustration 9 g06380046
Wedge

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Wedge - Small locking device internal to connectors typically a different color from the connector that holds the terminals
in place to prevent terminals from pulling out of the back of the connector or to provide a key.

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Illustration 10 g06380050
Connector seal

Connector Seal - Rubber material that lines the edge of a plug, typically orange.

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Illustration 11 g06380051
Wire seal

Wire Seal - Viewable from the backside of a connector that seals between the outside of the wire and inside the connector
from the environment.

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Illustration 12 g06380053
Wire seal plug

Wire Seal Plug - White plastic plug that inserts into the back of a connector for when a wire is not present.

Inspecting Connector Seals

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Illustration 13 g06370297
Damaged connector seal that should be replaced

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Illustration 14 g06370325
Damaged connector seal that should be replaced

Inspect the interface seals on the plugs. If there are any signs of damage or torn seals, remove the wedge from the plug.
Refer to "Wedge Removal" for instructions.

Note: The entire connector will not need to be replaced.

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Illustration 15 g06370329
Close-up view of damaged wire entry seal

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Illustration 16 g06370343
Close-up view of damaged wire entry seal

Inspect the wire entry seals at the back of each connector.

Note: The connector must be replaced if there are any signs of cut or distorted seals.

Cleaning Inside of Connectors

1. Spray the interior of the receptacle to remove any loose debris with compressed air at a maximum 620 kPa (90.0 psi)
pressure.

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2. Spray inside the receptacle and the outside of the plug with cleaning solution if there are still signs of dirt.

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Illustration 17 g06370344
Cleaning swab

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Illustration 18 g06370349
Cleaning with cleaning swab

3. Clean the inside surfaces of the receptacle with a cleaning swab as shown in Illustration 18.

4. Use a similar tool with a tip that will not deteriorate or fall apart when wiping out the inside of the connector if a
cleaning swab is not available.

Inspecting Wire Terminals

Check the visible sections of the wire terminals for signs of corrosion or deformity. If there are any signs of damage, the
wire terminals must be removed from the connector and replaced.

Note: Replace all damaged wire terminals with 9X-3401 Connector Pin and 9X-3402 Connector Socket for wire gauges 16
through 20. Use 126-1767 Connector Pin and 126-1768 Connector Socket for 14 gauge wire.

Inspecting Seal Contact Surfaces

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View Image

Illustration 19 g06370350
Example of a clean interior surface of a connector

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Illustration 20 g06370363
Example of a clean interior surface of a connector

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Illustration 21 g06370361
Example of a clean interior surface of a connector

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View Image

Illustration 22 g06370364
Example of an unclean interior surface of a connector

Inspect the seal contact surfaces inside the receptacles. The seal contact surface is located farthest inside the receptacle and
is the area which contacts the seal of the plug when fully connected.

Note: If the seal contact surfaces cannot be cleaned with only the use of the cleaning solution & swab, then the connector
must be replaced.

Inspecting Latches

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Illustration 23 g06370367
Straight latch

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Illustration 24 g06370370
Flat latch

Inspect the plug latch to check for signs of deformation.

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Illustration 25 g06370371
Bent latch

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Illustration 26 g06370373
Sagging latch

Replace the connector if the connector latch is bent and does not retain a straight flat form. A bent latch will not properly

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lock into the mating connector.

The best way to determine if a latch is damaged is to listen for an audible click when mating connectors and then pulling
slightly apart. If the latch does not click or the connectors pull apart and do not lock, the connector with the latch should be
replaced because the latch is damaged.

Wedge Removal

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Illustration 27 g06370376
Wedge removal

1. Insert the 147-6456 Wedge Removal Tool into the slot between the wedge and the housing.

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Illustration 28 g06370378
Wedge removal

2. Twist the tool to force the wedge loose once the tool is completely between the wedge and the housing.

Note: To prevent damaging the wire terminals or the connector housing, avoid prying off the wedge.

3. Replace the seal with a new seal, if damaged. Once the seal has been replaced, replace the wedge.

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Wire Terminal Insertion

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Illustration 29 g06370379
Crimped contact

1. Grasp the crimped contact behind the terminal.

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Illustration 30 g06370381
Wire into connector

2. Hold the connector with the rear wire seals facing towards you and push straight into the connector until a click is felt.

Note: To check the connection, slightly pull back on the wire to feel that the wire is locked in place.

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Illustration 31 g06370383
Wedge

3. Insert the wedge to hold all the terminals in place.

Wire Terminal Removal

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Illustration 32 g06370386
Wedge removal

1. Remove the wedge using the 147-6456 Wedge Removal Tool or needle nose pliers to pull out the wedge straight.

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Illustration 33 g06370388
Electrical contact tool

2. Gently pull the wire backwards while releasing the locking finger inside by moving it away from the contact with the
contact tool or a flat screwdriver.

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Illustration 34 g06370390
Contact removal

3. Hold the rear seal in place while removing the contact not to displace the seal from the connector.

Re-Connecting the Connectors

Reconnect the connectors now that the connectors are cleaned or replaced.

Note: If the latch does not click when reconnected, then the connector must be replaced.

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Illustration 35 g06370393
Plate and strap

Replace all clips with the 483-4287 Plate and 204-2281 Cable Strap. Reinstall the connector horizontally and use the 326-
8203 Tool to attach the mated connectors to the connector plate.

Note: The recommended torque setting is 8 on the 326-8203 Tool.

Copyright 1993 - 2019 Caterpillar Inc. Tue Jul 16 05:50:35 EST 2019
All Rights Reserved.
Private Network For SIS Licensees.

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