CLAMP 7E6455 - Caterpillar

Most electrical faults are caused by poor connections. The following procedure will assist in detecting faults with connectors and with wiring. If a fault is found, correct the condition and verify that the fault is resolved.Intermittent electrical faults are sometimes resolved by disconnecting and reconnecting connectors. Check for diagnostic codes immediately before you disconnect a connector. Also check for diagnostic codes after you reconnect 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.Follow these guidelines:
Always use a breakout harness for a voltmeter probe or a test light. Never break the insulation of a wire in order to access to a circuit for measurements.
If a wire is cut, always install a new terminal for the repair.
Determine if the problem is intermittent. If the problem is intermittent, attempt to test the circuit before you disconnect any electrical connectors. The test will help identify the root cause of intermittent problems. The "Wiggle Test" on Caterpillar Electronic Technician (ET) may be able to test the circuit. Refer to the documentation that accompanies Cat ET. Perform the wiggle test on the circuit, when possible. Otherwise, continue with this procedure.Check Connectors for Moisture and Corrosion
Inspect all the 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. The damaged seal will create a path for the entrance of moisture. Verify that the seals for the wires are sealing correctly. Ensure that the sealing plugs are in place. If any of the plugs are missing, replace the plug. Ensure that the plugs are inserted correctly into the connector.Disconnect the suspect connector and inspect the connector seal. Ensure that the seal is in good condition. If necessary, replace the connector.Thoroughly inspect the connectors for evidence of moisture entry.Note: 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. The source of the moisture entry must be repaired. If the source of the moisture entry is not repaired, the fault will recur. Simply drying the connector will not fix the fault. Check the following items for the possible moisture entry path:
Missing seals
Incorrectly installed seals
Nicks in exposed insulation
Improperly mated connectorsMoisture 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.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
Rubbing of a wire against the engine
Rubbing of a wire against a sharp pointCheck all of the fasteners for the harness