Test Step 3. Perform a Pull Test on Each Wire Terminal Connection

240

TM 9-2320-312-24-2

Troubleshooting Section

Test Step 3. Perform a Pull Test on Each

Results:

Wire Terminal Connection

OK Proceed to Test Step 5.

A. Each terminal and each connector should easily

Not OK

withstand 45 N (10 lb) of pull and each wire

should remain in the connector body. This test

Repair: Repair the circuit.

checks whether the wire was properly crimped

in the terminal and whether the terminal was

Verify that the repair eliminates the problem.

properly inserted into the connector.

STOP.

B. The DT connectors use a green wedge to lock

the terminals in place. Ensure that the green

Test Step 5. Check Wires for Nicks or

wedge is not missing and that the green wedge

Abrasion in the Insulation

is installed properly on the DT connectors.

A. Carefully inspect each wire for signs of abrasion,

Note: Terminals should always be crimped onto the

nicks, or cuts.

wires by using a crimp tool. Do not solder terminals.

Use the 1U-5804 Crimp Tool.

The following areas are locations that should

be checked:

Expected Result:

Exposed insulation

Each terminal and each connector easily withstands

45 N (10 lb) of pull and each wire remains in the

Points of rubbing wire against the engine

connector body.

Points of rubbing wire against a sharp point

Results:

B. Check all of the hold down clamps for the

OK Proceed to Test Step 4.

harness in order to verify that the harness is

properly clamped. Also check all of the hold

Not OK

down clamps for the harness in order to verify

that the harness is not compressed by the

Repair: Repair the circuit.

clamp. Pull back the harness sleeves in order

to check for a flattened portion of wire. The

Verify that the repair eliminates the problem.

flattened portion of wire is caused by the clamp

that holds the harness.

STOP.

Test Step 4. Perform the "Wiggle Test"

Expected Result:

on Cat ET

The wires are free of abrasion, nicks, or cuts and

the harness is properly clamped.

A. Select the "Wiggle Test" from the diagnostic tests

on Cat ET.

Results:

B. Press the "OK" button after you adhere to the

OK Proceed to Test Step 6.

warning.

Not OK

C. Choose the appropriate group of parameters to

monitor.

Repair: Repair the wires or replace the wires, as

required.

D. Press the "Start" button. Wiggle the wiring

harness in order to reproduce intermittent

Verify that the repair eliminates the problem.

problems.

STOP.

E. 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".