2.4 Electrical Connector Inspect

16H Motor Grader ATS00001-UP (MACHINE) POWERED BY 3196 Engine(SEBP3329...
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Product: MOTOR GRADER

Model: 16H MOTOR GRADER ATS00580
Configuration: 16H Motor Grader ATS00001-UP (MACHINE) POWERED BY 3196 Engine
Troubleshooting
3176C and 3196 Engines for Caterpillar Built Machines
Media Number -SENR9515-05 Publication Date -01/05/2007 Date Updated -08/05/2007
i06595732
Electrical Connectors - Inspect

SMCS - 1408-040-CY
System Operation Description:
Most electrical problems are caused by poor connections. The following procedure will assist in
detecting problems with connectors and with wiring. If a problem is found correct the condition and
verifies that the problem is resolved.
Intermittent electrical problems are sometimes resolved by disconnecting and reconnecting

connectors. It is very important to 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.
Follow these guidelines:
• Always use a 1U-5804 Crimp Tool to service Deutsch HD and DT connectors. Never solder the
terminals onto the wires. Refer to "SEHS9615, ServicingDeutschHDand DT Style Connectors".
• Always use a 147-6456 Wedge Removal Tool 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.
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16H Motor Grader ATS00001-UP (MACHINE) POWERED BY 3196 Engine(SEBP3329... Page 2 of 12
The connection of any electrical equipment and the disconnection of any

electrical equipment may cause an explosion hazard which may result in
injury or death. Do not connect any electrical equipment or disconnect
any electrical equipment in an explosive atmosphere.
Illustration 1 g01131211
Leaky seal at the connector (typical example)
Diagram for the installation of a connector plug (typical example)
(1) Electronic Control Module (ECM) connector
(2) Correctly inserted plug
(3) Incorrectly inserted plug
Seal for a three-pin connector (typical example)
Seal for ECM connector (typical example)
Table 1
Troubleshooting Test Steps Values Results
1. Check Connectors for Moisture and Connectors Result: The harness wiring,
Corrosion connectors, and seals are in good
condition.
A. Inspect all wiring harnesses. Ensure that the
routing of the wiring harness allows the wires to Proceed to Test Step 2.
enter the face of each connector at a
perpendicular angle. Otherwise, the wire will Result: A problem has been
deform the seal bore. Refer to Illustration 1. This found with the harness or the
will create a path for the entrance of moisture. connectors.
Verify that the seals for the wires are sealing
correctly. Repair: Repair the connectors or
the wiring, as required. Ensure

B. Ensure that the sealing plugs are in place. If that all of the seals are properly
any of the plugs are missing, replace the plug. in place. Ensure that the
Ensure that the plugs are inserted correctly into connectors have been reattached.
the connector. Refer to Illustration 2.
If corrosion is evident on the
C. Disconnect the suspect connector and inspect pins, sockets or the connector,
the connector seal. Ensure that the seals are in use only denatured alcohol to
good condition. If necessary, replace the remove the corrosion. Use a
connector. cotton swab or a soft brush to
remove the corrosion.
D. Thoroughly inspect the connectors for
evidence of moisture entry. If moisture was found in the
connectors, run the engine for
Note: It is normal to see some minor seal several minutes and check again
abrasion on connector seals. Minor seal abrasion for moisture. If moisture
will not allow the entry of moisture. reappears, the moisture is
wicking into the connector. Even
If moisture or corrosion is evident in the if the moisture entry path is
connector, the source of the moisture entry must repaired, it may be necessary to
be found and the source of the moisture entry replace the wires.
must be repaired. If the source of the moisture
entry is not repaired, the problem will recur. Verify that the repair eliminates
Simply drying the connector will not fix the the problem.
problem. Check the following items for the
possible moisture entry path: STOP
• Missing seals
• Improperly installed seals
• Nicks in exposed insulation
• Improperly mated connectors
Moisture can also travel to a connector through

the inside of a wire. If moisture is found in a
connector, thoroughly check the connector's
harness for damage. Also check other connectors
that share the harness for moisture.
Note: The ECM is a sealed unit. If moisture is

found in an ECM connector, the ECM is not the
source of the moisture. Do not replace the ECM.
2. Check the Wires for Damage to the Wiring Result: The harness is OK.
Insulation
Proceed to Test Step 3.

A. Carefully inspect each wire for signs of
abrasion, of nicks, and of cuts. Result: There is damage to the
harness.
Inspect the wires for the following conditions:
Repair: Repair the wires or
• Exposed insulation replace the wires, as required.
Verify that the repair eliminates
• Rubbing of a wire against the engine the problem.
• Rubbing of a wire against a sharp point STOP
B. 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 flattens the harness. This damages
the wires that are inside the harness.
Result: The terminals are OK.

3. Inspect the Connector Terminals
Result: The terminals of the
A. Visually inspect each terminal in the
Connector connector are damaged.
connector. Verify that the terminals are not
Terminals
damaged. Verify that the terminals are properly
Repair: Repair the terminals
aligned in the connector and verify that the
and/or replace the terminals, as
terminals are properly located in the connector.
required.
STOP
Receptacle lock wedge (typical example)
Table 2
Result: All terminals pass

the pull test.
4. Perform a Pull Test on Each Wire Terminal
Connection Proceed to Test Step 5.
A. Ensure that the locking wedge for the connector is Result: A wire has been
installed properly. Terminals cannot be retained inside pulled from a terminal or a
the connector if the locking wedge is not installed terminal has been pulled
properly. 45 N from the connector.
(10 lb)
B. Perform the 45 N (10 lb) pull test on each wire. Each Repair: Use the 1U-5804
terminal and each connector should easily withstand Crimp Tool to replace the
45 N (10 lb) of tension and each wire should remain in terminal. Replace damaged
the connector body. This test checks whether the wire connectors, as required.
was properly crimped in the terminal and whether the Verify that the repair
terminal was properly inserted into the connector. eliminates the problem.
STOP
Diagram for testing pin retention (typical example)
Table 3
Result: The terminals are OK.

5. Check Individual Pin Retention into the
Result: Terminals are
Socket
damaged.
A. Verify that the sockets provide good Pin Retention
Repair: Use the 1U-5804
retention for the pins. Insert a new pin into
Crimp Tool to replace the
each socket one at a time in order to check for
damaged terminals. Verify that
a good grip on the pin by the socket.
the repair eliminates the
problem.
STOP
6. Check the Locking Mechanism of the Locking Result: The connectors are in
Connectors Mechanism of good repair.
the Connectors
A. Ensure that the connectors lock properly. Proceed to Test Step 7.
After locking the connectors, ensure that the
two halves cannot be pulled apart. Result: The connector's
locking mechanism is damaged
B. Verify that the latch tab of the connector is or missing.

properly latched. Also verify that the latch tab
of the connector returns to the locked Repair: Repair the connector
position. or replace the connector, as
required. Verify that the repair
eliminates the problem.
STOP
Allen head screw for the 120 pin ECM connector (typical example)
Allen head screw for the 40 pin customer connector and the 70 pin customer connector (typical example)
Table 4
7. Check the Allen Head Screws on the

Connectors
Note: Visually inspect the allen head screws for

the ECM connectors. Ensure that the threads on
Result: The ECM connectors and
each allen head screw are not damaged.
the customer connector is properly
connected.
A. Connect the ECM connectors.
1. Torque the allen head bolt for the 120 pin
ECM connector to 7.0 ± 0.5 N·m (60 ± 4 lb in).
Result: The allen head screws for
Allen
the ECM connector or the customer
2. Torque the allen head screw for the 70 pin Head
connector is damaged.
ECM connector to 6.0 + 1.5 - 0.5 N·m Screws
(55 + 13 - 4 lb in).
Repair: Repair the connector or
replace the connector, as required.
3. Torque the allen head screw for the 40 pin
Verify that the repair eliminates the
ECM connector to 2.25 ± 0.25 N·m
problem.
(20 ± 2 lb in).
STOP
B. Connect the customer connector.
1. Torque the allen head screw for the 40 pin

customer connector and the 70 pin customer
connector to 2.25 ± 0.25 N·m (20 ± 2 lb in).
8. Perform the "Wiggle Test" On Cat™ ET. Result: No intermittent problems

were found. The harness and
A. Select the "Wiggle Test" from the diagnostic connectors appear to be OK.
tests on Cat ET.
Return the unit to service.
B. Choose the appropriate group of parameters
to monitor. Wiggle Result: At least one intermittent
Test problem was indicated.
C. Press the "Start" button. Wiggle the wiring
harness in order to reproduce intermittent Repair: Repair the harness or the
problems. connector. Verify that the repair
eliminates the problem.
Note: If an intermittent problem exists, the
status will be highlighted and an audible beep STOP
will be heard.
Test Step 1.
The procedure corrected the issue. Return to service.
Results:
• The procedure did not correct the issue. -
Repair: Contact your Cat dealer Technical Communicator (TC). For further assistance, your
TC can confer with the Dealer Solutions Network (DSN).
STOP
Copyright 1993 - 2018 Caterpillar Inc. Wed Dec 12 13:33:50 UTC+0800 2018
All Rights Reserved.
Private Network For SIS Licensees.

2.4 Electrical Connector Inspect

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16H Motor Grader ATS00001-UP (MACHINE) POWERED BY 3196 Engine(SEBP3329...

Product: MOTOR GRADER

Electrical Connectors - Inspect

System Operation Description:

Intermittent electrical problems are sometimes resolved by disconnecting and reconnecting

Follow these guidelines:

• If a wire is cut, always install a new terminal for the repair.

The connection of any electrical equipment and the disconnection of any

the wiring, as required. Ensure

• Improperly installed seals

• Nicks in exposed insulation

• Improperly mated connectors

Moisture can also travel to a connector through

Note: The ECM is a sealed unit. If moisture is

Proceed to Test Step 3.

• Rubbing of a wire against a sharp point STOP

B. Check all of the wiring harness fasteners in

Result: The terminals are OK.

Proceed to Test Step 4.

Result: All terminals pass

Result: The terminals are OK.

Proceed to Test Step 6.

B. Verify that the latch tab of the connector is or missing.

Troubleshooting Test Steps Values Results

7. Check the Allen Head Screws on the

Note: Visually inspect the allen head screws for

1. Torque the allen head screw for the 40 pin

8. Perform the "Wiggle Test" On Cat™ ET. Result: No intermittent problems

The procedure corrected the issue. Return to service.

• The procedure did not correct the issue. -

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