CYLINDER HEAD GP 2051273 - Caterpillar

Name = #009>Electrical Connectors
Many of the procedures in this guide will direct you to a specific electrical connector. The connectors have a locking mechanism to hold the pins and sockets and are repairable without cutting the wires. Connector pins and sockets are crimped onto the wires using a 1U5804 Crimp Tool. HD-10 Connector- Ensure the plug and receptacle are aligned using the index markings. Rotate the plug until it slips into the receptacle, rotate the coupling approximately one-quarter turn, until a click is heard. Ensure the two halves cannot be pulled apart. The acceptable range for the wire installation outside diameter is 2.4 to 3.68 mm (.09 to .14 in). DT Connector- The DT connectors use an orange wedge to lock the pins in place. Check to ensure all seals are present and properly seated. Check pins and sockets before joining connectors. Verify proper alignment and locations of pins and sockets in each connector. Check DT connector locking tab for damage. Replace the connector if tab is damaged. Ensure that the connector is properly locked together (you will hear an audible click) and that the two mating halves can not be pulled apart. The acceptable range for the wire installation outside diameter is 2.4 to 3.68 mm (.09 to .14 in).
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