- Caterpillar Products
- All Machines
Introduction
This information will assist in detecting problems with connectors and wiring. If a problem is found, correct the condition and verify that the problem is resolved.
Replacement Connectors
Size 20 Terminals
Size 12 Terminals
Accessories
- 169-0705 Seal
- 358-4098 Wire As
- 8T-8737 Seal Plug
- 435-5221 Special Bolt As
- 435-5222 Seal
- 435-5223 Seal-Flange
Electrical Connector – Inspect
Disconnecting and reconnecting connectors sometimes resolve intermittent electrical problems. Check for diagnostic codes immediately before disconnecting a connector. Also check for diagnostic codes after reconnecting the connector. If the status of a diagnostic code changed due to disconnecting and reconnecting a connector, the likely reasons are:
- Loose terminals
- Improperly crimped terminals
- Moisture
- Corrosion
- Inadequate mating of a connection
Guidelines
- Use a 1U-5804 Crimp Tool (12-GA TO 18-GA) to service Deutsch connector HD and DT connectors. Never solder the terminals onto the wires. Refer to Tool Operating Manual, SEHS9615, "Servicing Deutsch HD and DT style connectors".
- To remove the Terminal Position Assurance TPA, insert a small screwdriver and 147-6456 Wedge Removal Tool into each of the slots on the long sides of the connector. Grasp the TPA and pull the TPA away from the plug body.
- If a wire is cut, always install a new terminal for the repair.
- Do not probe through the wire seals using spoons for troubleshooting. Using probes on the connector will damage the seals. Use the 416-1027 Harness As to troubleshoot the connector.
DRCP 80/86 Pin Connector Installation
- Insure that the TPA device is correctly installed on the plug body. There should not be any gaps between the plug seal and the TPA.
- Place the DRCP connector into the correct receptacle. The connectors are keyed to aid in the assembly to insure correct orientation.
- Use a
4 mm (0.16 inch) internal hex drive to tighten the jack screw to a torque of6 ± 1 N·m (4 ± 1 lb ft) . - Install the required covers, wire ties and/or supporting devices.
Check the Jack Screw for Proper Installation
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| Illustration 1 | g03583897 |
- Verify that the jack screw has been properly tightened.
- Using a
4 mm (0.16 inch) internal hex drive, turn the jack screw counter-clockwise to loosen the connector. - Uninstall the connector.
- Inspect the threads on the jack screw for damage. Insure that the retention washer on the mating side of the connector is not damaged.
- Reinstall the connector using the
4 mm (0.16 inch) internal hex drive. - Tighten the jack screw to
6 ± 1 N·m (4 ± 1 lb ft) .
Check the Connectors for Moisture and Corrosion
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| Illustration 2 | g03583899 |
The DRCP 80/86 Pin Connector has a seal around the base of the TPA device on the mating plug. This replaceable seal helps prevent moisture and dirt from entering the connector.
- Inspect all wiring harnesses. Ensure that the routing of the wiring harness allows the wires to enter the face of each connector at a perpendicular angle. Otherwise, the wire will deform the seal bore. This deformation will create a path for the entrance of moisture. Verify that the seals for the wires are sealing correctly.
- Disconnect the suspect connector and inspect the connector seal. Ensure that the seals are in good condition. If necessary, replace the connector.
- Thoroughly inspect the connectors for evidence of moisture entry.
Some minor seal abrasion on connector seals is normal. Minor seal abrasion will not allow the entry of moisture. If moisture or corrosion is evident in the connector, the source of the moisture entry must be corrected. If the source of the moisture entry is not repaired, the problem will recur. Simply drying the connector will not fix the problem. Check the following items for the possible moisture entry path:
- Missing seals
- Improperly installed seals
- Nicks in exposed insulation
- Improperly mated connectors
Moisture can also travel to a connector through the inside of a wire. If moisture is found in a connector, thoroughly check the connector harness for damage. Also check other connectors that share the harness for moisture.
- Repair or replace any bad connector. Correct any moisture problems.
Check the Wire Insulation for Damage
- Carefully inspect each wire for signs of abrasion, nicks, and of cuts. Inspect the wires for the following conditions:
- Exposed insulation
- Rubbing of a wire against the chassis
- Rubbing of a wire against a sharp point
Check all the wiring harness fasteners to verify that the harness is properly secured.
- Check all the fasteners to verify that the harness is not compressed. Pull back the harness sleeves to check for a flattened portion of wire. A fastener that has been overtightened will flatten the harness. This damages the wires that are inside the harness.
- Repair or replace any wire with insulation damage.
Inspect the Connector Terminals
Visually inspect each terminal in the connector.
- Verify that the terminals are not corroded.
- Verify that the terminals are not damaged.
- Verify that the terminals are properly aligned in the connector.
- Verify that the terminals are properly located in the connector.
- Replace any bad terminal.
Check Individual Pin Retention into the Socket
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| Illustration 3 | g03583901 |
Inspect pin retention.
- Verify that the sockets provide good retention for the pins.
- Disconnect the harness. Insert a new pin into each socket one at a time to check for a good grip on the pin by the socket.
- Replace any bad pins or sockets.
Perform the Wiggle Test with Cat Electronic Technician (Cat ET)
- Select the wiggle test from the diagnostic tests on Cat ET.
- Choose the appropriate group of parameters to monitor.
- Press the "Start" button.
- Wiggle the wiring harness to reproduce intermittent problems.
Note: If an intermittent problem exists, the status will be highlighted and an audible beep will be heard.
- Repair or replace any loose connections.
Repair
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| Illustration 4 | g03583903 |
Wire Removal
- Remove the TPA device. To remove the TPA, insert two small screwdrivers into the slots on the long sides of the connector. Refer to Illustration 5.
- Grasp the TPA and pull the TPA away from the plug body completely.
- Once the TPA is removed, use the 147-6456 Wedge Removal Tool to pull the contact retention finger away from the contact while pulling the wire from the connector.
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| Illustration 5 | g03583905 |
Wire Installation
- Once the wire terminal has been replaced / repaired, reinsert the terminal into the plug body.
- When inserting the terminal into the plug, insure that the terminal is aligned properly. Misalignment of the terminal may damage the contacts.
- Insure that the retention finger is seated on the terminal socket.
- Before reinstalling the TPA, ensure that the terminals are aligned in the correct rows.
- Reinstall the TPA. The TPA is keyed and can only be installed in one direction.
Note: Do not use excessive force to install the TPA.