LIGHTING GP-SIGNAL 1246467 - Caterpillar

Check Connectors for Moisture and Corrosion
Illustration 1 g01131211
Leaky seal at the connector (typical example)
Inspect all the 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. Refer to Illustration 1. A deformation in the seal will create a path for the entrance of moisture. Verify that the seals for the wires are sealing correctly.
Illustration 2 g01131276
Diagram for the installation of a connector plug (typical example)
(1) Electronic Control Module (ECM) connector
(2) Correctly inserted plug
(3) Incorrectly inserted plug Ensure that the sealing plugs are in place. If any of the plugs are missing, replace the plug. Ensure that the plugs are inserted correctly into the connector. Refer to Illustration 2.
Illustration 3 g01131019
Seal for a three-pin connector (typical example)
Illustration 4 g01131165
Seal for the ECM connector (typical example)
Disconnect the suspect connector and inspect the connector seal. Ensure that the seal is in good condition. If necessary, replace the connector.Thoroughly inspect the connectors for evidence of moisture entry.Note: Some minor seal abrasion on connector seals is normal. Minor seal abrasion will not allow the entry of moisture.If moisture or corrosion is evident 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 fault will recur. Simply drying the connector will not fix the fault. Check the following items for the possible moisture entry path:
Missing seals
Incorrectly installed seals
Nicks in exposed insulation
Improperly mated connectorsMoisture 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.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.Check the Wires for Damage to the Insulation
Carefully inspect each wire for signs of abrasion, nicks, and cuts.Inspect the wires for the following conditions:
Exposed insulation
Rubbing of a wire against the engine
Rubbing of a wire against a sharp pointCheck all of the fasteners for the harness and the strain relief components on the ECM. Verify that the harness is correctly 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.Inspect the Connector Terminals
Visually inspect each terminal in the connector. Verify that the terminals are not damaged. Verify that the terminals are correctly aligned in the connector and verify that the terminals are correctly located in the connector.Perform a Pull Test on Each Wire Terminal Connection
Illustration 5 g01954779
Typical example of a wedge assembly
Ensure that the wedge assembly for the connector is installed correctly. The connector will not retain the terminals if the locking wedge is not installed correctly.Perform the