SEGMENT 8E9803 - Caterpillar

Expected Result
The harness wiring, connectors, and seals are in good condition. There is no evidence of moisture in the connectors.Results
OK - The harness wiring, connectors, and seals are in good condition. Proceed to "Check the Wires for Damage to the Insulation".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 of the seals are properly in place. Ensure 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.STOPCheck the Wires for Damage to the Insulation
Carefully inspect each wire for signs of abrasion, of nicks, and of cuts. Inspect the wires for the following conditions:
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. Also 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.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
A. Visually inspect each terminal in the connector. Verify that the terminals are not damaged. Verify that the terminals are properly aligned in the connector and 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
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 2.
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 can withstand 45 N (10 lb) of pull and each