Product Link - PL102C Caterpillar

Reference: Special Instruction, REHS0148, "Listing Of Deutsch Connector Components"

Reference: Special Instruction, SEHS9065, "Use Of CE Connector Tools".

Reference: Service Magazine, SEPD034227 January 97, "Field Repair Of Single Wire Breaks In Harnesses (Sealed Splice)".

Reference: Service Magazine, SEPD037128 July 97, "Protection Of Unsealed Electrical Terminations For Machines In Corrosive Applications".

Reference: Service Magazine, SEPD047324 May 99, "New DT Connector Plugs With Improved Seal Retention".

Reference: Service Magazine, SEPD054509 October 00, "Dielectric Grease Should Not Be Used In Electrical Connectors".

Reference: Pocket Guide, SEBD0402, "Guidelines For Routing And Installing Wire Harness Assemblies".

Use this procedure under the following situation:

Use the following steps to help determine if the connector is the cause of the problem. If a problem is found in the electrical connector, repair the connector and verify that the problem has been corrected.

The following background information is related to this procedure:

Many of the operational procedures in this troubleshooting guide will instruct you to check a specific electrical connector.

Intermittent electrical problems are often caused by poor connections.

Simply disconnecting the connectors and then reconnecting the connectors can temporarily solve a problem at times. If this occurs, likely causes are loose terminals, bent terminals, improperly crimped terminals, corrosion, or harness routing that is improper.

The original source of the problem must then be identified in order to ensure that the problem does not reoccur.

Follow this procedure to thoroughly inspect the connectors in order to determine if the connectors are the cause of the problem.

Illustration 1	g01072254
DT Type sealing plug The Connector Pin (2) and the Connector Socket (1) is designed to accept only one 16/18 AWG wire. Do not insert multiple wires of a smaller wire size. An incorrect method would be using two 24 AWG wires. The larger size Connector Pin and the Connector Socket also is designed to accept only one 14 AWG wire. Do not insert multiple wires of a smaller wire size. An example of an incorrect method is the use of two 20 AWG wires.

1. CHECK THE CONNECTORS.

   1. Ensure that the connector is properly locked. Also, ensure that the two halves of the connector can not be pulled apart.

   2. Verify that the latch tab of the connector is properly latched. Verify that the latch tab of the connector is fully latched.

      Expected Result: The connector will securely lock. The connector and the locking mechanism are without cracks or breaks.

      Results:

      OK - The connector will securely lock. The connector and the locking mechanism are without cracks or breaks. Proceed to test step 2.

      NOT OK - A problem exists with the connector.

      Repair: Repair the connector or replace the connector, as required.

      STOP.

2. PERFORM A PULL TEST ON EACH CONNECTOR CONTACT.

   1. Each connector contact should withstand 45 N (10 lb) of pull. Each wire should remain in the connector body. This test checks whether the wire was properly crimped in the contact and whether the contact was properly inserted into the connector.

   2. The DT connectors use an orange wedge to lock the terminals in place.

   3. Check in order to ensure that the orange wedge is not missing and that the orange wedge is installed properly on the DT connectors.

      Note: A Crimp Tool should ALWAYS be used in order to crimp wires on connector contacts. Do not solder the terminals. Use the proper Crimp Tool.

      Expected Result: Each connector contact should withstand 45 N (10 lb) of pull. Each wire remains in the connector body.

      Results:

      OK - Each connector contact withstands 45 N (10 lb) of pull. Each wire remains in the connector body. Proceed to test step 3.

      NOT OK - A problem exists with the connector.

      Repair: Repair the wiring or replace the connector contact.

      STOP.

3. CHECK THE WIRES FOR NICKS OR ABRASIONS IN THE INSULATION.

   1. Carefully inspect each wire for signs of abrasion, nicks, or cuts.

      The following areas are locations that should be checked:

      • Exposed insulation

      • Points of rubbing wire

   2. Check all of the hold down clamps for the harness in order to verify that the harness is properly clamped. Also check all of the hold down clamps for the harness in order to verify that the harness is not compressed by the clamp. Pull back the harness sleeves in order to check for a flattened portion of wire. The flattened portion of wire is caused by the clamp that holds the harness.

      Expected Result: The wires are free of abrasion, nicks, or cuts and the harness is properly clamped.

      Results:

      OK - The wires are free of abrasion, nicks, or cuts and the harness is properly clamped. Proceed to test step 4.

      NOT OK - A problem exists with the wiring.

      Repair: Repair the wires or replace the wires, as required.

      STOP.

4. CHECK THE CONNECTORS FOR MOISTURE OR CORROSION.

   1. Ensure that the connector seals and the white sealing plugs are in place. If any of the seals or plugs are missing, replace the seal or plug. If necessary, replace the connector.

   2. Check all of the wiring harnesses in order to verify that the harness does not make a sharp bend out of a connector. This will deform the connector seal and this will create a path for the entrance of moisture.

   3. Thoroughly inspect connectors for evidence of moisture entry. If moisture or corrosion is evident in the connector, the source of the moisture entry must be found and the source of the moisture entry must be repaired. If the source of the moisture entry is not repaired, the problem will reoccur. Simply drying the connector will not fix the problem. Likely paths for the entrance of moisture are from missing seals, improperly installed seals, nicks in exposed insulation, and improperly mated connectors.

      Note: Moisture can also travel from one connector through the inside of a wire to another connector. If moisture is found in the PL102C connector, thoroughly check all connectors and wires on the harness that connect to the PL102C module. The PL102C module is not the source of the moisture. Do not replace a PL102C module if moisture is found in either PL102C connector.

      Note: If corrosion is evident on the contacts or the connector, use only denatured alcohol to remove the corrosion. Use a cotton swab or a soft brush to remove the corrosion. Do not use cleaners that contain trichloro-ethylene because trichloro-ethylene may damage the connector.

      Expected Result: All of the connectors should be completely coupled and all of the seals should be completely inserted. The harness and the wiring should be free of corrosion, moisture, abrasion or pinch points.

      Results:

      OK - All of the connectors are completely coupled and all of the seals are completely inserted. The harness and the wiring are free of corrosion, moisture, abrasions or pinch points. Proceed to test step 5.

      NOT OK - A problem exists with the connector, the wiring or the wiring harness. Moisture is present.

      Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled. Verify that the repair eliminates the problem by operating the machine for several minutes and by checking again for moisture.

      STOP.

5. INSPECT THE CONNECTOR CONTACTS.

   1. Verify that the contacts are not damaged. Verify that the contacts are properly aligned in the connector and verify that the contacts are properly located in the connector.

      Expected Result: The contacts are properly aligned and the contacts appear undamaged.

      Results:

      OK - The contacts are properly aligned and the contacts appear undamaged. Proceed to test step 6.

      NOT OK - A problem exists with the connector contacts.

      Repair: Repair the contacts and wiring and/or replace the contacts and wiring.

      STOP.

6. CHECK THE FIT OF THE CONTACTS.

   Note: This is especially important for intermittent problems.

   1. Use a new pin contact. Insert the pin contact into each socket contact one at a time in order to check for a good grip on the pin contact by the socket contact.

   2. Use a new socket contact. Insert the pin contact into each socket contact one at a time in order to check for a good grip on the pin contact by the socket contact. The pin contact are located on the mating side of the connector.

   3. The connector contact should stay connected when the connector is held in a vertical position. The connector contact is the pin contact or the socket contact.

      Expected Result: The pin contacts and the socket contacts appear to be OK.

      Results:

      OK - The pin contacts and the socket contacts appear to be OK. STOP.

      NOT OK - A problem exists with the connector terminal.

      Repair: Replace the connector contact.

      STOP.