725C, 725C2, 730C, 730C Ejector, 730C2, 730C2 EJ, 735B, 735C, 740B, 740B Ejector, 740C Ejector and 745C Articulated Trucks VIMSTM 3G Electrical Connector - Inspect Caterpillar


Electrical Connector - Inspect
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725C, 725C2, 730C, 730C Ejector, 730C2, 730C2 EJ, 735B, 735C, 740B, 740B Ejector, 740C Ejector and 745C Articulated Trucks VIMS<SUP>TM</SUP> 3G [UENR0215]
1.1. Guidelines
2.1. Tests
3.2. Check Connectors for Moisture and Corrosion
4.3. Expected Result
5.3. Results
6.3. Repair
7.2. Check the Wires for Damaged Insulation
8.3. Expected Result
9.3. Results
10.3. Repair
11.2. Inspect the Connector Terminals
12.3. Expected Result
13.3. Results
14.3. Repair
15.2. Perform a Pull Test on Each Wire Terminal Connection
16.3. Expected Result
17.3. Results
18.3. Repair
19.2. Check Individual Socket Pin Retention
20.3. Expected Result
21.3. Results
22.3. Repair
23.2. Check the Locking Mechanism of the Connectors
24.3. Expected Result
25.3. Results
26.3. Repair
27.2. Perform a Wiggle Test With Cat<SUP>&reg;</SUP> Electronic Technician (Cat ET)
28.3. Expected Result
29.3. Results
30.3. Repair

Reference The following:

  • Special Instruction, SEHS9615, "Servicing DT Connectors"

  • Special Instruction, REHS0148, "Listing Of Deutsch Connector Components"

  • Special Instruction, SEHS9065, "Use Of CE Connector Tools"

  • Service Magazine, SEPD0342, "Field Repair Of Single Wire Breaks In Harnesses (Sealed Splice)"

  • Service Magazine, SEPD0371, "Protection Of Unsealed Electrical Terminations For Machines In Corrosive Applications"

  • Service Magazine, SEPD0473, "New DT Connector Plugs With Improved Seal Retention"

  • Service Magazine, SEPD0545, "Dielectric Grease Should Not Be Used In Electrical Connectors"

  • Pocket Guide, SEBD0402, "Guidelines For Routing And Installing Wire Harness Assemblies"

This information assists in detecting connector and wiring problems. If a problem is found, correct the problem and verify the problem resolution.

Disconnecting and reconnecting connectors sometimes resolves intermittent electrical problems. Check for diagnostic codes immediately before disconnecting and after reconnecting a connector. Following are the likely reasons the diagnostic code status changes due to disconnecting and reconnecting connectors:

  • Loose terminals

  • Improperly crimped terminals

  • Moisture

  • Corrosion

  • Inadequate connection mating

Guidelines

  • Use a calibrated 1U-5804 Crimp Tool (12-GA TO 18-GA) to service Deutsch HD and DT connectors. Never solder the terminals onto the wires. See Tool Operating Manual, SEHS9615, "Servicing Deutsch HD and DT Style Connectors".

  • Use a 147-6456 Wedge Removal Tool to remove wedges from DT connectors. Never use a screwdriver to pry a wedge from a connector.

  • Use a breakout harness for a voltmeter probe or a test light. Never break wire insulation to access a circuit.

  • If a wire is cut, repair with a terminal.

Tests

Check Connectors for Moisture and Corrosion




Illustration 1g01960167

(1) Former seal design

(2) Current seal design




Illustration 2g01960176

(3) Seal for a three-pin connector (Typical )

The plug end of a DT connector has a seal. A black seal is replaceable and has been improved to help prevent slipping.

The current seal design (2) is not interchangeable with the former design (1) . The receptacle colors have been changed.

Perform the following inspection to check for moisture and corrosion:

  1. Ensure that the harness routing allows the wires to enter each connector face at a perpendicular angle.

    Note: If the angle is incorrect, the wire will deform the seal bore and create a path for moisture.

  1. Verify that the wire seals are sealing.

  1. Disconnect the suspect connectors.

  1. Inspect the connector seals. Ensure that the seals are in good condition. If necessary, replace the connector.

  1. Thoroughly inspect the connectors for evidence of moisture and correct the problem.

    Find the source of the moisture entry and correct the problem. If the source problem is not corrected, the problem will reoccur. Simply drying the connector will not fix the problem. Check the following items for the possible moisture entry:

    • Missing seals

    • Improperly installed seals

    • Nicks in exposed insulation

    • Improperly mated connectors

Moisture can travel to a connector through the inside of a wire. If moisture is found in a connector, thoroughly check the harness for damage. Also check for moisture in other connectors that share the harness.

Minor seal abrasion on connector seals is normal and will not allow the entry of moisture. If moisture or corrosion is evident in the connector, perform the following:

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 connectors.

Repair

Perform the following actions to repair the connectors or wiring:

  1. Ensure that all seals are properly in place.

  1. Ensure that the connectors have been reattached.

  1. If corrosion or moisture was evident, use denatured alcohol and a cotton swab to remove the corrosion or dry the moisture.

  1. Operate the equipment for several minutes and check for moisture.

    If moisture reappears, the moisture is wicking into the connector and the connector must be replaced.

  1. Verify that the problem has been corrected.

STOP

Check the Wires for Damaged Insulation

Perform the following inspection:

  1. Inspect each wire for the following conditions:

    • Abrasion

    • Nicks

    • Cuts

    • Exposed insulation

    • Chafing on the chassis

    • Chafing against a sharp point

  1. Check all of the harness fasteners to verify that the harness is properly secured and not compressed.

  1. 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.

STOP

Inspect the Connector Terminals

Perform the following inspection:

  1. Visually inspect each terminal in the connector:

    1. Terminal damage

    1. Terminal alignment in the connector

    1. Terminal location in the connector

Expected 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.

STOP

Perform a Pull Test on Each Wire Terminal Connection

Perform the following inspection:




Illustration 3g03553061

(4) Locking wedge (Typical)

  1. 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.

  1. 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.

STOP

Check Individual Socket Pin Retention

Perform the following inspection:

  1. Sockets provide good retention for the pins.

  1. If the pins are loose in the socket, perform the following:

    1. Disconnect the harness.

    1. Insert a new pin into each socket.

    1. 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.

STOP

Check the Locking Mechanism of the Connectors

Perform the following inspection:

  1. Connectors lock properly.

  1. After locking the connectors, ensure that the two halves cannot be pulled apart.

  1. Verify that the connector latch tab is properly latched.

  1. 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 Test With Cat® Electronic Technician (Cat ET)".

Not OK - The connector locking mechanisms are damaged or missing.

Repair

Repair or replace the connector.

Verify that the problem has been corrected.

STOP

Perform a Wiggle Test With Cat® Electronic Technician (Cat ET)

Perform the following inspection:

  1. Select "Wiggle Test" from the diagnostic tests on Cat ET.

  1. Choose the appropriate parameters group to monitor.

  1. Press the "Start" button.

  1. Wiggle the wiring harness to reproduce intermittent problems.

    If an intermittent problem exists, the status will be highlighted and an audible beep will be heard.

Expected Result

No intermittent problems were found.

Results

OK - No intermittent problems were found. The harness and connectors appear to be OK. If another procedure recommended this test, return to that procedure and continue testing. If the problem has been resolved, approve the machine for return to service.

STOP

Not OK - At least one intermittent problem was indicated.

Repair

Repair or replace the harness or connector.

Verify that the problem has been corrected.

STOP

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