BOSS 4839298 - Caterpillar

Illustration 5 g01131435
Receptacle lock wedge (typical example)
Table 2
Troubleshooting Test Steps Values Results
4. Perform a Pull Test on Each Wire Terminal Connection
A. 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.
B. 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.
45 N (10 lb)
Result: All terminals pass the pull test.
Proceed to Test Step 5.
Result: A wire has been pulled from a terminal or a terminal has been pulled from the connector.
Repair: Use the 1U-5804 Crimp Tool to replace the terminal. Replace damaged connectors, as required. Verify that the repair eliminates the problem.
STOP
Illustration 6 g01131604
Diagram for testing pin retention (typical example)
Table 3
Troubleshooting Test Steps Values Results
5. Check Individual Pin Retention into the Socket
A. Verify that the sockets provide good retention for the pins. Insert a new pin into each socket one at a time in order to check for a good grip on the pin by the socket.
Pin Retention
Result: The terminals are OK.
Proceed to Test Step 6.
Result: Terminals are damaged.
Repair: Use the 1U-5804 Crimp Tool to replace the damaged terminals. Verify that the repair eliminates the problem.
STOP
6. Check the Locking Mechanism of the Connectors
A. Ensure that the connectors lock properly. After locking the connectors, ensure that the two halves cannot be pulled apart.
B. 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.
Locking Mechanism of the Connectors
Result: The connectors are in good repair.
Proceed to Test Step 7.
Result: The connector's locking mechanism is damaged or missing.
Repair: Repair the connector or replace the connector, as required. Verify that the repair eliminates the problem.
STOP
Illustration 7 g01132827
Allen head screw for the 120 pin ECM connector (typical example)
Illustration 8 g01132849
Allen head screw for the 70 pin ECM connector (typical example)
Illustration 9 g01132863
Allen head screw for the 40 pin ECM connector (typical example)
Illustration 10 g01133047
Allen head screw for the 40