This information helps with detecting connector and wiring problems. If a problem is found, correct the problem and verify the problem resolution.
Disconnecting and reconnecting connectors sometimes resolves intermittent electrical problems. Check for diagnostic codes immediately before disconnecting and after reconnecting a connector. Following are the likely reasons the diagnostic code status changes due to disconnecting and reconnecting connectors:
- Loose terminals
- Improperly crimped terminals
- Moisture
- Corrosion
- Inadequate connection mating
Reference: Refer to the following documents for additional information when servicing electrical connectors:
- Special Instruction, SEHS9615, "Servicing DT Connectors"
- Special Instruction, REHS0148, "Listing Of Deutsch Connector Components"
- Special Instruction, SEHS9065, "Use Of CE Connector Tools"
- Service Magazine, SEPD0342, "Field Repair Of Single Wire Breaks In Harnesses (Sealed Splice)"
- Service Magazine, SEPD0371, "Protection Of Unsealed Electrical Terminations For Machines In Corrosive Applications"
- Service Magazine, SEPD0473, "New DT Connector Plugs With Improved Seal Retention"
- Service Magazine, SEPD0545, "Dielectric Grease Should Not Be Used In Electrical Connectors"
- Pocket Guide, SEBD0402, "Guidelines For Routing And Installing Wire Harness Assemblies"
- Use a calibrated 1U-5804 Crimp Tool (12-GA TO 18-GA) to service Deutsch HD and DT connectors. Never solder the terminals onto the wires. See Tool Operating Manual, SEHS9615, "Servicing Deutsch HD and DT Style Connectors".
- Use a 147-6456 Wedge Removal Tool to remove wedges from DT connectors. Never use a screwdriver to pry a wedge from a connector.
- Use a breakout harness for a voltmeter probe or a test light. Never break wire insulation to access a circuit.
- If a wire is cut, repair with a terminal.
Check Preparation and Repair Procedures
Check Connectors for Moisture and Corrosion
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| Illustration 1 | g01960167 |
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(1) Former seal design
(2) Current seal design | |
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| Illustration 2 | g01960176 |
| (3) Seal for a three-pin connector (Typical ) | |
The plug end of a DT connector has a seal. A black seal is replaceable and has been improved to help prevent slipping.
The current seal design (2) is not interchangeable with the former design (1). The receptacle colors have been changed.
Perform the following inspection to check for moisture and corrosion:
- Ensure that the harness routing allows the wires to enter each connector face at a perpendicular angle.
Note: If the angle is incorrect, the wire will deform the seal bore and create a path for moisture.
- Verify that the wire seals are sealing.
- Disconnect the suspect connectors.
- Inspect the connector seals. Ensure that the seals are in good condition. If necessary, replace the connector.
- Thoroughly inspect the connectors for evidence of moisture and correct the problem.
Find the source of the moisture entry and correct the problem. If the source problem is not corrected, the problem will reoccur. Simply drying the connector will not fix the problem. Check the following items for the possible moisture entry:
- Missing seals
- Improperly installed seals
- Nicks in exposed insulation
- Improperly mated connectors
Moisture can travel to a connector through the inside of a wire. If moisture is found in a connector, thoroughly check the harness for damage. Also check for moisture in other connectors that share the harness.
Minor seal abrasion on connector seals is normal and will not allow the entry of moisture. If moisture or corrosion is evident in the connector, perform the following:
The harness wiring, connectors, and seals are in good condition. There is no evidence of moisture in the connectors.
OK - The harness wiring, connectors, and seals are in good condition. Proceed to "Check the Wires for Damaged Insulation".
NOT OK - A problem has been found with the harness or connectors.
Perform the following actions to repair the connectors or wiring:
- Ensure that all seals are properly in place.
- Ensure that the connectors have been reattached.
- If corrosion or moisture was evident, use denatured alcohol and a cotton swab to remove the corrosion or dry the moisture.
- Operate the equipment for several minutes and check for moisture.
If moisture reappears, the moisture is wicking into the connector and the connector must be replaced.
- Verify that the problem has been corrected.
STOP
Check the Wires for Damaged Insulation
Perform the following inspection:
- Inspect each wire for the following conditions:
- Abrasion
- Nicks
- Cuts
- Exposed insulation
- Chafing on the chassis
- Chafing against a sharp point
- Check all the harness fasteners to verify that the harness is properly secured and not compressed.
- Pull back the harness sleeves to check for a flattened portion of wire.
An overtightened fastener will flatten the harness and damage the wires.
The wires are free of abrasion, nicks, and cuts. The harness is properly clamped and not compressed.
OK - The harness is OK. Proceed to "Inspect the Connector Terminals".
NOT OK - The harness has damage.
Repair or replace the harness.
Verify that the problem has been corrected.
STOP
Inspect the Connector Terminals
Perform the following inspection:
- Visually inspect each terminal in the connector:
- Terminal damage
- Terminal alignment in the connector
- Terminal location in the connector
The terminals are properly aligned and undamaged.
OK - The terminals are properly aligned and undamaged. Proceed to "Perform a Pull Test on Each Wire Terminal Connection".
NOT OK - The terminals are not properly aligned or are damaged.
Repair or replace the terminals.
Verify that the problem has been corrected.
STOP
Perform a Pull Test on Each Wire Terminal Connection
Perform the following inspection:
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| Illustration 3 | g03553061 |
| (4) Locking wedge (Typical) | |
- Ensure that the connector locking wedge (4) is installed properly.
Terminals cannot be retained inside the connector if the locking wedge (4) is not installed properly. See Illustration 3.
- Perform a
45 N (10 lb) pull test on each wire.Each terminal and connector should easily withstand
45 N (10 lb) of tension and each wire should remain in the connector body. This test checks the wire crimping and the terminal insertion into the connector.
Each terminal and connector with stands
OK - All terminals pass the pull test. Proceed to "Check Individual Socket Pin Retention".
NOT OK - A wire has been pulled from a terminal or a terminal has been pulled from the connector.
Replace damaged terminals and connectors.
Note: Use the calibrated 1U-5804 Crimp Tool (12-GA TO 18-GA) to replace the terminals or connectors.
Verify that the problem has been corrected.
STOP
Check Individual Socket Pin Retention
Perform the following inspection:
- Sockets provide good retention for the pins.
- If the pins are loose in the socket, perform the following:
- Disconnect the harness.
- Insert a new pin into each socket.
- Check for good pin grip by the socket.
The sockets provide good retention for the new pin.
OK - The sockets are OK. Proceed to "Check the Locking Mechanism of the Connectors".
NOT OK - Sockets are damaged.
Use a calibrated 1U-5804 Crimp Tool (12-GA to 18-GA) to replace the damaged sockets.
Verify that the problem has been corrected.
STOP
Check the Locking Mechanism of the Connectors
Perform the following inspection:
- Connectors lock properly.
- After locking the connectors, ensure that the two halves cannot be pulled apart.
- Verify that the connector latch tab is properly latched.
- Verify that the connector latch tab returns to the locked position.
The connector securely locks. The connector and the locking mechanism are without cracks or breaks.
OK - The connector locking mechanisms are in good repair. Proceed to "Perform a Wiggle Test With Cat® Electronic Technician (Cat ET)".
NOT OK - The connector locking mechanisms are damaged or missing.
Repair or replace the connector.
Verify that the problem has been corrected.
STOP
Perform a Wiggle Test With Cat® Electronic Technician (Cat ET)
Perform the following inspection:
- Select "Wiggle Test" from the diagnostic tests on Cat ET.
- Choose the appropriate parameters group to monitor.
- Press the "Start" button.
- Wiggle the wiring harness to reproduce intermittent problems.
If an intermittent problem exists, the status will be highlighted and an audible beep will be heard.
No intermittent problems were found.
OK - No intermittent problems were found. The harness and connectors appear to be OK. If another procedure recommended this test, return to that procedure and continue testing. If the problem has been resolved, approve the machine for return to service.
STOP
NOT OK - At least one intermittent problem was indicated.
Repair or replace the harness or connector.
Verify that the problem has been corrected.
STOP