Reference: Special Instruction, REHS0148, "Listing Of Deutsch Connector Components"
Reference: Special Instruction, SEHS9065, "Use Of CE Connector Tools".
Reference: Service Magazine, SEPD0342, 27, January 97, "Field Repair Of Single Wire Breaks In Harnesses (Sealed Splice)".
Reference: Service Magazine, SEPD0371, 28, July 97, "Protection Of Unsealed Electrical Terminations For Machines In Corrosive Applications".
Reference: Service Magazine, SEPD0473, 24, May 99, "New DT Connector Plugs With Improved Seal Retention".
Reference: Service Magazine, SEPD0545, 09, October 00, "Dielectric Grease Should Not Be Used In Electrical Connectors".
Reference: Pocket Guide, SEBD0402, "Guidelines For Routing And Installing Wire Harness Assemblies".
This information will assist in detecting problems with connectors and with wiring. If a problem is found, correct the condition and verify that the problem is resolved.
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 is changed due to disconnecting and reconnecting a connector, there are several possible reasons. The likely reasons are loose terminals, improperly crimped terminals, moisture, corrosion, and inadequate mating of a connection.
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, and tools 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. If any of the following are not recommended by Caterpillar, but are used, ensure the safety of all people involved:
- A tool
- A procedure
- A work method
- An operating technique
Ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.
- Use a 1U-5804 Crimp Tool (12-GA TO 18-GA) to service Deutsch HD and DT connectors. Never solder the terminals onto the wires. Refer to 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 the insulation of a wire to access to a circuit for measurements.
- If a wire is cut, install a new terminal for the repair.
Check Connectors for Moisture and Corrosion
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.
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| Illustration 1 | g03870168 |
|
(1) Former seal design
(2) Current seal design | |
| |
| Illustration 2 | g03870171 |
| (3) Seal for a three-pin connector (typical example) | |
The plug end of the DT connector has a seal at the end of the connector. This seal has been improved on black connectors to help prevent slipping. Additionally, this seal is replaceable. This improvement will help keep moisture and dirt from entering the connector.
The current seal design (2) is not interchangeable with the former design (1). The receptacle has also changed to the new colors.
- 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 found and repaired. 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.
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 Damage to the Insulation".
Not OK - A problem has been found with the harness or the connectors.
Repair the connectors or the wiring, as required. Ensure that all of the seals are properly in place. Ensure that the connectors have been reattached. If corrosion is evident on the pins, sockets or the connector, use only denatured alcohol to remove the corrosion. Use a cotton swab or a soft brush to remove the corrosion. If moisture was found in the connectors, run the engine for several minutes and check again for moisture. If moisture reappears, the moisture is wicking into the connector. Even if the moisture entry path is repaired, replacing the wires may be necessary. Verify that the repair eliminates the problem.
STOP
Check the Wires for Damage to the Insulation
- Carefully inspect each wire for signs of abrasion, of 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 of the wiring harness fasteners to verify that the harness is properly secured. Also check all of 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.
The wires are free of abrasion, of nicks, and of cuts and the harness is properly clamped.
OK - The harness is OK. Proceed to "Inspect the Connector Terminals".
Not OK - There is damage to the harness.
Repair the wires or replace the wires, as required. Verify that the repair eliminates the problem.
STOP
Inspect the Connector Terminals
A. Visually inspect each terminal in the connector. Verify that the terminals are not damaged. Verify that the terminals are properly aligned in the connector and verify that the terminals are properly located in the connector.
The terminals are properly aligned and the terminals appear undamaged.
OK - The terminals are OK. Proceed to "Perform a Pull Test on Each Wire Terminal Connection".
Not OK - The terminals of the connector are damaged.
Repair the terminals and/or replace the terminals, as required. Verify that the repair eliminates the problem.
STOP
Perform a Pull Test on Each Wire Terminal Connection
- Ensure that the locking wedge for the connector is installed properly. Terminals cannot be retained inside the connector if the locking wedge is not installed properly. Refer to Illustration 2.
- Perform the
45 N (10 lb) pull test on each wire.Each terminal and each connector should easily withstand
45 N (10 lb) of tension and each wire should remain in the connector body. This test checks whether the wire was properly crimped in the terminal and whether the terminal was properly inserted into the connector.
Each terminal and each connector can withstand
OK - All terminals pass the pull test. Proceed to "Check Individual Pin Retention into the Socket".
Not OK - A wire has been pulled from a terminal or a terminal has been pulled from the connector.
Use the 1U-5804 Crimp Tool (12-GA TO 18-GA) to replace the terminal. Replace damaged connectors, as required. Verify that the repair eliminates the problem.
STOP
Check Individual Pin Retention into the Socket
A. Verify that the sockets provide good retention for the pins. Disconnect the harness and insert a new pin into each socket of the mating plug. Insert the pins one at a time. Check for a good grip on the pin by the socket.
The sockets provide good retention for the new pin.
OK - The terminals are OK. Proceed to "Check the Locking Mechanism of the Connectors".
Not OK - Terminals are damaged.
Use a calibrated 1U-5804 Crimp Tool (12-GA TO 18-GA) to replace the damaged terminals. Verify that the repair eliminates the problem.
STOP
Check the Locking Mechanism of the Connectors
- Ensure that the connectors lock properly. After locking the connectors, ensure that the two halves cannot be pulled apart.
- Verify that the latch tab of the connector is properly latched. Also verify that the latch tab of the connector returns to the locked position
The connector will securely lock. The connector and the locking mechanism are without cracks or breaks.
OK - The connectors are in good repair. Proceed to "Perform the Wiggle Test on the Cat ® Electronic Technician (Cat ® ET) Service Tool".
Not OK - The locking mechanism of the connector is damaged or missing.
Repair the connector or replace the connector, as required. Verify that the repair eliminates the problem.
STOP
Perform the Wiggle Test on the Cat ® Electronic Technician (Cat ® ET) Service Tool
- Select the "Wiggle Test" from the diagnostic tests on the Cat ® ET.
- Choose the appropriate group of parameters 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 indicated during the wiggle test.
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, return the machine to service.
STOP
Not OK - At least one intermittent problem was indicated.
Repair the harness or the connector. Verify that the repair eliminates the problem.
STOP