COVER 3L6085 - Caterpillar

Figure 1.4 Electrical Connectors
Figure 1.5 Plug Insertion In Unused Pins Do not solder sockets/pins and wires. Sockets/pins should always be crimped onto the wires using the 1U5804 Deutsch Crimp Tool. All unused connector socket slots must be filled with plugs to insure connector sealing. Proper insertion of connector plugs, used to fill unused pins and socket cavities of connectors, is also critical. The illustration above demonstrates the correct insertion of the plug. The plug cap is designed to rest against the seal, not inserted in the hole in the seal.ECM And Customer Connectors
Ensure the ECM and Customer Connector Allen head bolts are properly tightened. DO NOT exceed 2.25 N m (20 lb in) of torque on the Allen head connector bolt when connecting the connector halves.Perform 45 N (10 lb) pull test on each socket/pin and wire. Each socket/pin and wire should easily withstand the pull test value and remain in the connector body. This test ensures the wire was properly crimped in the socket/pin, and the socket/pin properly inserted in the connector.The acceptable range for the wire insulation outside diameter is 2.54 to 3.43 mm (0.100 to 0.135 in) for the ECM and Customer Connectors.
Figure 1.6 Customer ConnectorsWiring Harnesses Requirements
As stated previously, all unused ECM connector and Customer Connector socket slots MUST be sealed with plugs to ensure connector sealing.Wire Size Requirements
The wire size to all Caterpillar components must be of adequate size to handle the maximum current of the circuit. All +Battery and -Battery connections to the ECM Customer connector should be made with 14 AWG wire. The connections from the -Battery Bus Bar to the bridge displays should be made with a minimum of 12 AWG wire. All other connection should be made with 16 AWG wire minimum.All Data Link connection (Cat Data Link and ATA) should be made with the 143-5018 Data Link Cable. No other components are allowed to be connected to the Caterpillar -Battery wire to the bridge displays.
Figure 7 - Engine Room Battery And Ground Wiring some ECM's do not require an unswitched +Battery connection. Refer to the Engine Electronic Installation Guide for details.OEM Harness Routing/Design
Figure 8 - Improper Harness Routing At ECM and Customer ConnectorsRouting of harnesses should ensure connector seals are not stressed because the harness wiring curvature is too close to a connector. The previous diagram illustrates the problem if the harness curvature is too close to the connector. When this occurs the connector seal is stretched away from the wire, providing an opening for moisture entry. The wire should exit perpendicular to the connector with 25 mm (1.0 inch) of straight length before curving as necessary for routing. The harness bundle should have a bend radius greater than twice the harness diameter. All Twisted pair wires should not be twisted within an inch of the connector to avoid seal stress.
Figure 9 - Harness Routing At ECM and Customer ConnectorsCaterpillar requires all ring terminals and splices connected to the Customer Connector be sealed using Raychem ES2000 adhesive lined