MOTOR & MTG GP-TRAVEL 2159982 - Caterpillar

Illustration 1 g01960176
(3) Seal for a three-pin connector (typical example)
Illustration 2 g02732798
(4) Locking Wedge for 3-pin connector
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(1) Former Seal Design
(2) Current Seal DesignTests
Table 1
Troubleshooting Test Steps Values Results
1. Inspect All Wiring Harnesses
A. Ensure that the routing of the wiring harness allows the wires to enter the face of each connector at a perpendicular angle. Otherwise, the wire will deform the seal bore. This condition will create a path for the entrance of moisture.
B. Verify that the seals for the wires are sealing correctly.
C. Disconnect the suspect connector and inspect the connector seal. Ensure that the seals are in good condition. If necessary, replace the connector.
D. Thoroughly inspect the connectors for evidence of moisture entry.
E. Check the following items for a possible moisture entry path: missing seals, improperly installed seals, nicks in exposed insulation, and improperly mated connectors.
The harness wiring, connectors, and seals are in good condition.
There is no evidence of moisture in the connectors. OK: The harness wiring, connectors, and seals are in good condition.
Proceed to Test Step 2.
NOT OK: A problem has been found with the harness or the connectors.
REPAIR: Repair the connectors or the wiring as required. Ensure that all the seals are properly in place. Make sure that the connectors have been reattached.
If corrosion is evident on the pins, sockets, or the connector, use only denatured alcohol to remove the corrosion. Use a cotton swab or a soft brush to remove the corrosion.
If moisture was found in the connectors, run the engine for several minutes and check again for moisture. If moisture reappears, the moisture is wicking into the connector. Even if the moisture entry path is repaired, replacing the wires may be necessary. Verify that the repair eliminates the problem.
STOP.
2. Check The Wires For Damage To The Insulation
A. Check all the fasteners to verify that the harness is secure and is NOT compressed.
B. Pull back the harness sleeves to check for a flattened portion of wire. A fastener that has been overtightened will flatten the harness.
C. Carefully inspect each wire for signs of abrasion, nicks, or cuts. Inspect the wires for the following conditions: exposed insulation, rubbing of a wire against the chassis, or rubbing of a wire against a sharp point.
The wires are free of abrasion, nicks, or cuts. The harness is properly clamped. OK: The harness has passed all checks.
Proceed to Test Step 3.
NOT OK: There is damage to the harness.
REPAIR: Repair or replace the wires as required. Verify that the repair eliminates the problem.
STOP.
3. Visually Inspect Each Connector Terminal
A. Verify that the terminals are not damaged. Verify that the terminals are properly aligned and properly located in the connector.
The terminals are properly aligned and the terminals appear undamaged. OK: The terminals show no signs of damage.
Proceed to Test Step 4.
NOT OK: The terminals of the connector are damaged.
REPAIR: Repair and/or replace the terminals as required. Verify that the repair eliminates the problem.
STOP.
4. Perform a Pull Test on Each Wire Terminal Connection
A. Ensure that the locking wedge for the connector is installed properly.