Perkins 1106D Troubleshooting Manual page 143

SENR9982
Test Step 2. Check the Wires for Damage
to the Insulation
A. 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 engine
•
Rubbing of a wire against a sharp point
B. Check all of the fasteners for the harness and the
strain relief components on the ECM in order to
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.
Expected Result:
The wires are free of abrasion, of nicks, and of cuts
and the harness is correctly clamped.
Results:
•
OK – The harness is OK. Proceed to Test Step 3.
•
Not OK – There is damage to the harness.
Repair: Repair the wires or replace the wires, as
required.
Verify that the repair eliminates the fault.
STOP.
Test Step 3. Inspect the Connector
Terminals
A. 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.
Expected Result:
The terminals are correctly aligned and the terminals
appear undamaged.
Results:
• OK – The terminals are OK. Proceed to Test Step
4.
•
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 fault.
STOP.
Test Step 4. Perform a Pull Test on Each
Wire Terminal Connection
Illustration 43
A typical example of the lock wedge.
(1) Lock wedge
A. Ensure that the locking wedge for the connector is
installed correctly. Terminals cannot be retained
inside the connector if the locking wedge is not
installed correctly.
B. 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 correctly crimped
in the terminal and whether the terminal was
correctly inserted into the connector.
Expected Result:
Each terminal and each connector easily withstands
45 N (10 lb) of pull and each wire remains in the
connector body.
Results:
•
OK – All terminals pass the pull test. Proceed to
Test Step 5.
•
Not OK – A wire has been pulled from a terminal
or a terminal has been pulled from the connector.
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Troubleshooting Section
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