WIRING HARNESS AND WIRING HARNESS CONNECTORS INSPECTION CONTINUED
Inspect Wiring Harness for Damage to Insulation
1. Inspect each wire for signs of abrasion, burns, cracks, nicks, and cuts. Replace affected wiring harness if con-
dition is found.
2. Inspect fasteners, wiring harness connectors, and strain relief components to ensure wiring harness is cor-
rectly secured. Remove strain relief components, adjust wiring harness, and secure strain relief components if
condition is found.
3. Position wiring harness sleeves aside and inspect wiring harness for flattened or pinched portion of wire.
Replace affected wiring harness if condition is found.
Inspect Connector Terminals
Inspect connector terminals for corrosion and damage. Replace affected wiring harness if terminals are damaged.
Replace affected wiring harness if corrosion cannot be removed.
Inspect Individual Pin Retention at Socket
Ensure terminal is properly secured in connector body by firmly pulling each wire. Terminal should not pull free
from connector body. Replace affected harness if condition is found.
Inspect Locking Mechanism of Connectors
1. Ensure connectors lock correctly. After locking connectors, ensure two halves cannot be pulled apart.
2. Verify latch tab of connector is correctly latched. Also verify latch tab of connector returns to locked position.
3. Verify if connector is locked securely. Inspect connector body and locking mechanism for damage. Replace
affected wiring harness if condition is found.
Inspect Screws on Electronic Control Module (ECM) and Other Threaded Connectors
Inspect threads on screws of mating connectors for wear and damage. Replace affected wiring harness if condition
END OF TASK
WIRING HARNESS OPEN CIRCUIT TEST
An open circuit is a failure of any electrical circuit that results in no flow of electrical current. An open circuit is
usually caused by failed electrical wires or a poor connection of wiring harness connectors. If an electrical wire or a
connection is broken, flow of electrical current through the circuit is interrupted. A normal circuit will have less than
Take care not to damage electrical terminals when probing them with test equipment.
Terminal damage will occur when forcing a test probe into an electrical terminal.
Failure to follow this caution may induce additional symptoms and lead to an inaccurate
Failure to follow these cautions may result in equipment failure.
1. Use electrical schematic of machine to identify wiring harness connectors and wire numbers of suspect cir-
2. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2420-231-10).