GEAR (47 TEETH) 2K8554 - Caterpillar

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Receptacle lock wedge (typical example)
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.
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. Expected Result:Each terminal and each connector easily withstands 45 N (10 lb) of pull and each wire remains in the connector body.Results:
OK - All terminals pass the pull test. Proceed to Test Step 5.
Not OK - 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.STOPTest Step 5. Check Individual Pin Retention into the Socket
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Diagram for testing pin retention (typical example)
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. Expected Result:The sockets provide good retention for the new pin.Results:
OK - The terminals are OK. Proceed to Test Step 6.
Not OK - Terminals are damaged.Repair: Use the 1U-5804 Crimp Tool to replace the damaged terminals. Verify that the repair eliminates the problem.STOPTest Step 6. Check the Locking Mechanism of the Connectors
Ensure that the connectors lock properly. After locking the connectors, ensure that the two halves cannot be pulled apart.
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. Expected Result:The connector will securely lock. The connector and the locking mechanism are without cracks or breaks.Results:
OK - The connectors are in good repair. Proceed to Test Step 7.
Not OK - 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.STOPTest Step 7. Check the Allen Head Screws on the ConnectorsVisually inspect the allen head screws for the ECM connectors. Ensure that the threads on each allen head screw are not damaged.
Connect the ECM connectors.
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Allen head screw for the 120 pin ECM connector (typical example)
Torque the allen head bolt for the 120 pin ECM connector to 7.0 0.5 N m (60 4 lb in).
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Allen head screw for the 70 pin ECM connector (typical example)
Torque the allen head screw for the 70 pin ECM connector to 6.0 + 1.5 - 0.5 N m (55 + 13 - 4 lb in).
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Allen head screw for