ENGINE AR 8N3902 - Caterpillar

Check the Wires for Damage to the Insulation
Perform the following inspection to check for damage to the insulation:
Inspect each wire for the following conditions:
Signs of abrasion
Nicks
Cuts
Exposed insulation
Rubbing of a wire against the chassis
Rubbing of a wire 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. 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, of nicks, and of cuts and the harness is properly clamped and has not been compressed.Results
OK - The harness is OK. Proceed to "Inspect the Connector Terminals".Not OK - There is damage to the harness.Repair
Repair the wires or replace the wires, as required. Verify that the repair eliminates the problem.STOPInspect the Connector Terminals
Perform the following inspection to check 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.STOPPerform a Pull Test on Each Wire Terminal Connection
Perform the following inspection to check each wire terminal connection:
Illustration 3 g01625756
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. Refer to Illustration 3.
Perform a 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.Expected Result
Each terminal and each connector with stands 45 N (10 lb) of pull and each wire 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 a terminal has been pulled from the connector.Repair
Use the calibrated 1U-5804 Crimp Tool (12-GA TO 18-GA) to replace the terminal. Replace damaged connectors, as required. Verify that the repair eliminates the problem.STOPCheck Individual Pin Retention in the Socket
Perform the following inspection to check individual pin retention in the socket:
Verify that the sockets provide good retention for the pins.
If the pins are loose in the socket, perform the following actions:
Disconnect the harness.
Insert a new pin into each socket of the mating plug.
Check for a good grip on the pin by the socket. Expected Result
The sockets provide good retention for the new pin.Results
OK - The terminals are OK. Proceed to "Check the Locking Mechanism of