MOTOR A 27 VDC 9G0396 - Caterpillar

Check the Wires for Damaged Insulation
Perform the following inspection:
Inspect each wire for the following conditions:
Abrasion
Nicks
Cuts
Exposed insulation
Chafing on the chassis
Chafing against a sharp point
Check all of the harness fasteners to verify that the harness is properly secured and not compressed.
Pull back the harness sleeves to check for a flattened portion of wire.An overtightened fastener will flatten the harness and damage the wires.Expected Result
The wires are free of abrasion, nicks, and cuts. The harness is properly clamped and not compressed.Results
OK - The harness is OK. Proceed to "Inspect the Connector Terminals".Not OK - The harness has damage.Repair
Repair or replace the harness.Verify that the problem has been corrected.STOPInspect the Connector Terminals
Perform the following inspection:
Visually inspect each terminal in the connector:
Terminal damage
Terminal alignment in the connector
Terminal location in the connectorExpected Result
The terminals are properly aligned and undamaged.Results
OK - The terminals are properly aligned and undamaged. Proceed to "Perform a Pull Test on Each Wire Terminal Connection".Not OK - The terminals are not properly aligned or are damaged.Repair
Repair or replace the terminals. Verify that the problem has been corrected.STOPPerform a Pull Test on Each Wire Terminal Connection
Perform the following inspection:
Illustration 3 g03553061
(4) Locking wedge (Typical)
Ensure that the connector locking wedge (4) is installed properly. Terminals cannot be retained inside the connector if the locking wedge (4) is not installed properly. See Illustration 3.
Perform a 45 N (10 lb) pull test on each wire.Each terminal and connector should easily withstand 45 N (10 lb) of tension and each wire should remain in the connector body. This test checks the wire crimping and the terminal insertion into the connector.Expected Result
Each terminal and 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 "Check Individual Pin Retention in the Socket".Not OK - A wire has been pulled from a terminal or a terminal has been pulled from the connector.Repair
Replace damaged terminals and connectors.Note: Use the calibrated 1U-5804 Crimp Tool (12-GA TO 18-GA) to replace the terminals or connectors.Verify that the problem has been corrected.STOPCheck Individual Socket Pin Retention
Perform the following inspection:
Sockets provide good retention for the pins.
If the pins are loose in the socket, perform the following:
Disconnect the harness.
Insert a new pin into each socket.
Check for good pin grip by the socket.Expected Result
The sockets provide good retention for the new pin.Results
OK - The sockets are OK. Proceed to "Check the Locking Mechanism of the Connectors".Not OK - Sockets are damaged.Repair
Use a calibrated 1U-5804 Crimp Tool (12-GA to 18-GA) to replace the damaged sockets.Verify that the problem has been corrected.STOPCheck the Locking Mechanism of the Connectors
Perform the following inspection:
Connectors lock properly.
After locking the connectors, ensure that the two halves cannot be pulled apart.
Verify that the connector latch tab is properly latched.
Verify that the connector latch tab returns to the locked position.Expected Result
The connector securely locks. The connector and the locking mechanism are without cracks or breaks.Results
OK - The connector locking mechanisms are in good repair. Proceed to "Perform a Wiggle