BOOM GP 4645010 - Caterpillar

The MS connectors have a metal housing. The pins and the sockets are soldered to the electrical wires. The solder connections are usually protected by a chemical potting which prevents access to the solder point.
Illustration 2 g00700064Deutsch connectors have a plastic housing. The pins and the sockets are crimped onto the electrical wires. The connector has a locking mechanism in order to hold the pins and the sockets. These connectors are repairable without cutting the wires.
Illustration 3 g00928006Use the following test steps in order to thoroughly inspect the connectors and determine if the connectors are the cause of the problem.
Check the Connectors.
Remove the electrical power from the engine before you inspect electrical conductors.
For the MS connectors, make sure that the receptacle is turned fully in the clockwise direction. Check that the threading is properly aligned and securely mated.
For the Deutsch HD connectors, make sure that the plug and the receptacle are aligned properly with the index markings. Make sure that the receptacle is turned fully in the clockwise direction. Verify that the receptacle is clicked into the locked position. Make sure that the two halves cannot be pulled apart.
For the Deutsch DT style, make sure that the orange wedge is used in order to lock the pins. Check that the receptacle has clicked into the locked position. Make sure that the two halves cannot be pulled apart.
Check the Allen Head Screw on the Rectangular Connectors.
Ensure that each allen head screw is properly tightened. Be careful not to overtighten the screw and break the screw.
When you connect a 70-pin connector to an Electronic Control Module (ECM), do not exceed 6 1 N m (55 9 lb in) of torque on the screw.
When you connect a rectangular connector to the terminal box, do not exceed 2.25 0.25 N m (20 2 lb in) of torque on the screw.
Perform a Pull Test on Each Wire Connection.
Each terminal and each connector should easily withstand 45 N (10 lb) of pull 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.
The DT connectors use an orange wedge to lock the terminals in place. Ensure that the orange wedge is not missing and that the orange wedge is installed properly on the DT connectors. Note: Terminals should ALWAYS be crimped onto the wires with a crimp tool. Do not solder terminals. Use the 1U-5804 Crimp Tool.
Monitor the Electronic Service Tool While the Wiring and the Connectors Are Being Pulled.
If there is an active diagnostic code that pertains to the circuit, perform the following steps: Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.Connect the Caterpillar Electronic Technician (ET) to the service tool connector on the terminal box.Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. Then start the engine. Run the engine under normal operating conditions.Monitor the "Active