BAFFLE ASSEM. 2M0900 - Caterpillar

Results
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
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, it may be necessary to replace the wires. Verify that the repair eliminates the problem.STOP.Check the Wires for Damage to the Insulation
Carefully inspect each wire for signs of abrasion, nicks, and cuts. Inspect the wires for the following conditions:
Exposed insulation
Wire rubbing against the chassis
Wire rubbing against a sharp point
Check all of the wiring harness fasteners to verify that the harness is properly secured.
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. Note: A fastener that has been overtightened will flatten the harness. This damages the wires that are inside the harness.Expected Result
The wires are free of abrasion, nicks, and cuts. The harness is properly clamped.Results
OK - The harness is OK. Proceed to "Inspect the Connector Terminals".Not OK - There is damage to the harness.Repair
Repair or replace the wires as required. Verify that the repair eliminates the problem.STOP.Inspect the Connector Terminals
Visually inspect each terminal in the connector.
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. Expected Result
The terminals are properly aligned and the terminals appear undamaged.Results
OK - The terminals are OK. Proceed to "Expected Result".Not OK - The terminals of the connector are damaged.Repair
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
Illustration 3 g03206116
(4) Locking wedge
Ensure that the locking wedge (4) for the connector is installed properly. Note: Terminals cannot be retained inside the connector if the locking wedge is not installed properly. Refer to Illustration 3.
Perform the 45 N (10 lb) pull test on each wire. Note: Each terminal and each connector should easily withstand 45 N (10 lb) of tension and remain in the connector body. This test checks whether the wire was properly crimped and inserted into the connector.Expected Result
Each terminal and connector easily withstands 45 N (10 lb) of pull and remains in the connector body. Results
OK - All terminals pass the pull test. Proceed to "Expected Result".Not OK - A wire has been pulled from a terminal or from the connector.Repair
Use the 1U-5804 Crimp Tool (12-GA to 18-GA) to replace the