ReferenceSpecial Instruction, SEHS9615, "Servicing DT Connectors".
ReferenceSpecial Instruction, REHS0148, "Listing Of Deutsch Connector Components"
ReferenceSpecial Instruction, SEHS9065, "Use Of CE Connector Tools".
ReferenceService Magazine, SEPD034227 January 97, "Field Repair Of Single Wire Breaks In Harnesses (Sealed Splice)".
ReferenceService Magazine, SEPD037128 July 97, "Protection Of Unsealed Electrical Terminations For Machines In Corrosive Applications".
ReferenceService Magazine, SEPD047324 May 99, "New DT Connector Plugs With Improved Seal Retention".
ReferenceService Magazine, SEPD054509 October 00, "Dielectric Grease Should Not Be Used In Electrical Connectors".
ReferencePocket Guide, SEBD0402, "Guidelines For Routing And Installing Wire Harness Assemblies".
This information will assist in detecting problems with connectors and with wiring. If a problem is found, correct the condition and verify that the problem is resolved.
Disconnecting and reconnecting connectors sometimes resolve intermittent electrical problems. Check for diagnostic codes immediately before disconnecting a connector. Also check for diagnostic codes after reconnecting the connector. If the status of a diagnostic code is changed due to disconnecting and reconnecting a connector, there are several possible reasons. The likely reasons are loose terminals, improperly crimped terminals, moisture, corrosion, and inadequate mating of a connection.
Important Safety Information
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.
A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.
Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. AVSpare cannot anticipate every possible circumstance that might involve a potential hazard.
Guidelines
- Always use a 1U-5804 Crimp Tool (12-GA TO 18-GA) to service Deutsch HD and DT connectors. Never solder the terminals onto the wires. Refer to Tool Operating Manual, SEHS9615, "Servicing Deutsch HD and DT Style Connectors".
- Always use a 147-6456 Wedge Removal Tool in order to remove wedges from DT connectors. Never use a screwdriver to pry a wedge from a connector.
- Always use a breakout harness for a voltmeter probe or a test light. Never break the insulation of a wire in order to access to a circuit for measurements.
- If a wire is cut, always install a new terminal for the repair.
Tests
Check Connectors for Moisture and Corrosion
Inspect all wiring harnesses. 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. Verify that the seals for the wires are sealing correctly.
 | |
| Illustration 1 | g01960167 |
(1) Former Seal Design (2) Current Seal Design | |
 | |
| Illustration 2 | g01960176 |
(3) Seal for a three-pin connector (typical example) | |
The plug end of the DT connector has a seal at the mating end of the connector. This seal has been improved on black connectors in order to help prevent slipping. Additionally, this seal is replaceable. This improvement will help keep moisture and dirt from entering the connector.
The current seal design (2) is not interchangeable with the former design (1). The receptacle has also changed to the new colors.
- Inspect all wiring harnesses. 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. Verify that the seals for the wires are sealing correctly.
- Disconnect the suspect connector and inspect the connector seal. Ensure that the seals are in good condition. If necessary, replace the connector.
- Thoroughly inspect the connectors for evidence of moisture entry.
Some minor seal abrasion on connector seals is normal. Minor seal abrasion will not allow the entry of moisture. If moisture or corrosion is in the connector, the source of the moisture entry must be found and repaired. If the source of the moisture entry is not repaired, the problem will recur. Simply drying the connector will not fix the problem. Check the following items for the possible moisture entry path:
- Missing seals
- Improperly installed seals
- Nicks in exposed insulation
- Improperly mated connectors
- Missing seals
Moisture can also travel to a connector through the inside of a wire. If moisture is found in a connector, thoroughly check the connector harness for damage. Also check other connectors that share the harness for moisture.
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. Verify that the repair eliminates the problem.
STOP
Check 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
- Exposed insulation
- Check all of the wiring harness fasteners in order to verify that the harness is properly secured. Also check all of the fasteners in order to verify that the harness is not compressed. Pull back the harness sleeves in order 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.
STOP
Inspect 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 "Perform a Pull Test on Each Wire Terminal Connection".
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.
STOP
Perform a Pull Test on Each Wire Terminal Connection
 | |
| Illustration 3 | g01625756 |
- 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 must withstand 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 into the Socket".
Not OK - A wire has been pulled from a terminal or a terminal has been pulled from the connector.
Repair
Use the 1U-5804 Crimp Tool (12-GA TO 18-GA) to replace the terminal. Replace damaged connectors, as required. Verify that the repair eliminates the problem.
STOP
Check Individual Pin Retention into the Socket
A. Verify that the sockets provide good retention for the pins. Disconnect the harness and insert a new pin into each socket of the mating plug. Check for a good grip on the pin by the socket.
Expected Result
The sockets provide good retention for the new pin.
Results
OK - The terminals are OK. Proceed to "Check the Locking Mechanism of the Connectors".
Not OK - Terminals are damaged.
Repair
Use the 1U-5804 Crimp Tool (12-GA TO 18-GA) to replace the damaged terminals. Verify that the repair eliminates the problem.
STOP
Check the Locking Mechanism of the Connectors
- Ensure that the connectors lock properly. After locking the connectors, ensure that the two halves cannot be pulled apart.
- Verify that the latch tab of the connector is properly latched. Also verify that the latch tab of the connector returns to the locked position.
Expected Result
The connector will securely lock. The connector and the locking mechanism are without cracks or breaks.
Results
OK - The connectors are in good repair. Proceed to "Perform the Wiggle Test on the AVSpare Electronic Technician (Cat ET)".
Not OK - The connector locking mechanism is damaged or missing.
Repair
Repair the connector or replace the connector, as required. Verify that the repair eliminates the problem.
STOP
Perform the Wiggle Test on the AVSpare Electronic Technician (Cat ET)
- Select the Wiggle Test from the diagnostic tests on Cat ET.
- Choose the appropriate group of parameters to monitor.
- Press the "Start" button. Wiggle the wiring harness in order 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 indicated during the Wiggle Test.
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, return the machine to service.
STOP
Not OK - At least one intermittent problem was indicated.
Repair
Repair the harness or the connector. Verify that the repair eliminates the problem.
STOP