101607-9701 ZEXEL INJECTION-PUMP ASSEMBLY Cross 1016079701

Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Caterpillar dealer for replacement manuals. Proper care is your responsibility.
Personal injury or death can result from improper assembly procedures.Do not attempt any assembly until you have read and understand the assembly instructions.
Accidental engine starting can cause injury or death to personnel working on the equipment.To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system.Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.
Required Parts
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 Removal of a Connector from the Wire Harness
The following steps can be used to remove a connector for an injector on the wire harness.
Identify the connectors that need to be replaced. Wiring for the injector solenoid is not sensitive to polarity.
Illustration 1 g06093848
Connectors that are cut from the wire harness
Each injector will have two connectors. The wire on one connector will be longer than the other. Wire (A) is identified as the longer wire and wire (B) is identified as the shorter wire.
Cut wire (2) at a distance of 50 mm (1.9 inch) from the rear surface of the connector.
Cut wire (1) at a distance of 5 mm (0.2 inch) from the cut made on wire (2).
Illustration 2 g01111314
Wire from the harness for side (B) on the connector.
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.
Discard the old connectors.Installation of a New Connector
The following steps can be used to install a new connector for an injector on the wire harness that is located under the valve mechanism cover.
Use Tool (A) to remove 5 mm (0.2 inch) of the plastic from wires (3) and (4).
Illustration 3 g06125254
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
Use heat shrink tubes (5) from the 257-4183 Injector Wiring Harness Kit. Slide the heat shrink tubes toward the connector to expose the butt splices.
Insert wire (4) into