ELECTRICAL GENERAL MAINTENANCE INSTRUCTIONS - CONTINUED
ELECTRICAL CONNECTORS INSPECTION (ENGINE) - CONTINUED
Check Wires for Damage to Insulation.
Carefully inspect each wire for signs of abrasion, nicks, and cuts. Also, inspect wires for the following conditions:
Rubbing of wire against engine
Rubbing of wire against sharp point
Check all wiring harness fasteners in order to verify harness is properly secured. Also check all fasteners in order
to verify harness is not compressed. Pull back harness sleeves in order to check for a flattened portion of wire. A
fastener that has been overtightened flattens harness. This damages wires that are inside harness.
Expected Result. Wires are free of abrasion, nicks, and cuts and harness is properly clamped.
If the harness is OK, proceed to step 3.
If there is damage to harness, repair wires or replace wires, as required. Verify repair eliminates problem.
Inspect Connector Terminals.
Visually inspect each terminal in connector. Verify terminals are not damaged. Verify terminals are properly
aligned in connector and verify terminals are properly located in connector.
Expected Result. The terminals are properly aligned and terminals appear undamaged.
If terminals are OK, go to step 4.
If terminals of connector are damaged, repair terminals and/or replace terminals, as required. Verify repair
Perform a Pull Test on Each Wire Terminal Connection.
Ensure locking wedge for connector is installed properly. Terminals cannot be retained inside connector if locking
wedge is not installed properly.
Perform the 10 lb (45 N) pull test on each wire. Each terminal and each connector should easily withstand 10 lb (45
N) of tension and each wire should remain in the connector body. This test checks whether wire was properly
crimped in terminal and whether terminal was properly inserted into connector.
Expected Result. Each terminal and each connector easily withstands 10 lb (45 N) of pull and each wire remains
in connector body.
If all terminals pass the pull test, go to step 5.
If a wire has been pulled from a terminal or a terminal has been pulled from connector, use the crimping
tool to replace terminal. Replace damaged connectors, as required. Verify repair eliminates the problem.