HEAD 4257736 - Caterpillar

of the troubleshooting procedures in this Testing And Adjusting section require the inspection of electrical connectors and crimp terminals. Perform the following steps in order to test an electrical connector or crimp terminal. These steps can be helpful when you are troubleshooting an intermittent problem. If a faulty connection is found, repair the connection. Then return to the original troubleshooting procedures. Check if the original fault is solved. Continue with the original troubleshooting procedure.Note: Avoid unnecessary disconnecting and connecting of connector halves in order to troubleshoot system faults. This practice can cause the connector contacts within the connector to wear out prematurely.
Check the hex screw for the connector. Make sure that the 40-pin harness connector on the rear of the GSC is aligned and seated properly and that the hex screw is tight. Any unused locations in the 40-pin harness connector should be plugged to keep out dirt, water and other contaminates.
Pull test each wire. Each connector contact and wire in the various harness connectors should easily withstand 10 pounds of pull and the wires should remain in the connector body. This test checks whether the wire in each connector contact was crimped properly. This test also checks that the connector contact was inserted into the connector body completely. Repair the connectors or repair the crimped wires as the repair is needed. When you are replacing connector contacts, use only the 1U-5804 Crimp Tool. Make sure that the connector contact and the tool are matched to the american wire gauge. Connector contacts should always be crimped onto the wire. Connector contacts should never be soldered.Also do the pull test for the pre-insulated crimp terminals on the terminal strips. Repair the terminals, as needed. When you are replacing crimp terminals, use the proper crimping tool and use the techniques for the type and brand of crimp terminal. Use an adequately sized terminal for the american wire gauge. If desired, crimp-on spade terminals and ring terminals may be soldered to the wire for an improved electrical connection.
Visually inspect the wiring. Look for worn out wires. Check for pinched harnesses or damaged harnesses.
Visually inspect connectors and crimp terminals. Verify that connector contacts within the connectors are not corroded or damaged. Verify proper alignment of connectors and location of connector contacts within the connector. Verify that the two halves of the connector are seated and locked together.Check all crimp terminals for corrosion and damage. When you are wiggling each wire on a crimp terminal, the ends of the bare wires on the open end of the terminal barrel should be tight and not move. Also, check tightness of the screws on the terminal strip. Repair the wires, as needed.
Check individual connector contacts. This is especially important for intermittent problems. Using a new connector contact, insert it into each of the mating connector contacts. Check for a snug fit between the mating connector contacts. Repeat this procedure for the other half of the connector. Use a new connector contact of the correct type.