TM 5-3805-291-23-1
ELECTRICAL GENERAL MAINTENANCE INSTRUCTIONS - CONTINUED
0022 00
ELECTRICAL CONNECTOR INSPECTION (POWERTRAIN) - CONTINUED
2.
Check Connectors.
a.
Ensure connector is properly locked. Also, ensure two halves of connector cannot be pulled apart.
b.
Verify latch tab of connector is properly latched.
c.
Expected Result. Connector will securely lock and connector and locking mechanism are without cracks or
breaks.
(1)
If connector will securely lock and connector and locking mechanism are without cracks or breaks, pro-
ceed to step 3.
(2)
If a problem exists with connector, repair connector or replace connector, as required.
3.
Check Allen Head Screw on Harness Connector of ECM.
a.
Ensure connector bolt is properly tightened. Be careful not to tighten bolt too much. Bolt may break.
b.
Do not exceed 53.0 lb-in. (6.0 Nm) of torque on connector bolt of harness when connector is being installed on
ECM.
c.
Expected Result. Harness connector is secure and connector bolt of ECM is properly torqued.
(1)
If the harness connector is secure and the connector is properly torqued, go to step 4.
(2)
If a problem exists with the connector, go to step 3d.
d.
Repair: Secure harness connector of ECM, ensure connector bolt is properly torqued.
4.
Perform a Pull Test on Each Connector Contact.
CAU T I ON
A crimping tool should ALWAYS be used in order to crimp wires on connector contacts. Do not solder ter-
minals. Use proper crimping tool.
a.
Each connector contact should withstand 10 lb (45 N) of pull. Each wire should remain in connector body. This
test checks whether wire was properly crimped in contact and whether contact was properly inserted into connec-
tor.
b.
DT connectors use an orange wedge to lock terminals in place.
c.
Ensure orange wedge is not missing and orange wedge is installed properly on DT connectors.
d.
Expected Result. Each connector contact should withstand 10 lb (45 N) of pull. Each wire remains in connector
body.
(1)
If each connector contact withstands 10 lb (45 N) of pull and each wire remains in connector body, pro-
ceed to step 5.
(2)
If a problem exists with connector, repair wiring or replace connector contact.
5.
Check Wires for Nicks or Abrasions in Insulation.
a.
Carefully inspect each wire for signs of abrasion, nicks, or cuts. These areas should be checked:
(1)
Exposed insulation
(2)
Points of rubbing wire
b.
Check all hold-down clamps for harness to verify harness is properly clamped. Also, check all hold-down clamps
for harness in order to verify harness is not compressed by clamp. Pull back harness sleeves in order to check for a
flattened portion of wire. Flattened portion of wire is caused by clamp that holds harness.
0022 00-20
