320 Excavator YBP00001-UP (MACHINE) POWERED BY C7.1 Engine(M0092767 - 0...

Page 1 of 8

Shutdown SIS

Previous Screen

Product: EXCAVATOR
Model: 320 EXCAVATOR YBP
Configuration: 320 Excavator YBP00001-UP (MACHINE) POWERED BY C7.1 Engine

Troubleshooting
2D, 2D Advanced, and 3D GRADE System for Next Gen Hydraulic Excavators
Media Number -M0082989-04 Publication Date -01/09/2018 Date Updated -28/09/2018

i07531377

Electrical Connector - Inspect

SMCS - 1408-040-CY; 7553-040-WW

Reference: Special Instruction, SEHS9615, "Servicing DT Connectors".

Reference: Special Instruction, SEHS9065, "Use Of CE Connector Tools".

Reference: Service Magazine, SEPD0342, 27, January 97, "Field Repair Of Single Wire Breaks In
Harnesses (Sealed Splice)".

Reference: Service Magazine, SEPD0371, 28, July 97, "Protection Of Unsealed Electrical
Terminations For Machines In Corrosive Applications".

Reference: Service Magazine, SEPD0473, 24, May 99, "New DT Connector Plugs With Improved
Seal Retention".

Reference: Service Magazine, SEPD0545, 09, October 00, "Dielectric Grease Should Not Be Used In
Electrical Connectors".

This information will assist in detecting problems with connectors and with wiring. If a problem is
found, correct the condition and verify that the problem is resolved.

Disconnecting and reconnecting connectors sometimes resolves intermittent electrical problems.

Checking for diagnostic codes immediately before disconnecting a connector is important. Also check
for diagnostic codes after reconnecting the connector. If the status of a diagnostic code is changed
after disconnecting and reconnecting a connector, there are several possible reasons. The likely
reasons are loose terminals, improperly crimped terminals, moisture, corrosion, and inadequate
mating of a connection.

Important Safety Information

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... 7/15/2019
320 Excavator YBP00001-UP (MACHINE) POWERED BY C7.1 Engine(M0092767 - 0... Page 2 of 8

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by
failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing
potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training,
skills, and tools to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar
cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all
inclusive. If a tool, procedure, work method, or operating technique, not recommended by Caterpillar
is used, make sure that the procedure is safe for all people involved.

Make sure that the product will not be damaged or be made unsafe by the operation, lubrication,
maintenance, or the repair procedures that are used.

Guidelines
• Always use a 1U-5804 Crimp Tool (12-GA TO 18-GA) to service Deutsch HD and DT
connectors. Never solder the terminals onto the wires. Refer to Tool Operating Manual,
SEHS9615, "Servicing Deutsch HD and DT Style Connectors".

• Always use a 147-6456 Wedge Removal Tool to remove wedges from DT connectors. Never
use a screwdriver to pry a wedge from a connector.

• Always use a breakout harness for a voltmeter probe or a test light. Never break the insulation
of a wire to access a circuit for measurements.

• If a wire is cut, always install a new terminal for the repair.

Tests
Check Connectors for Moisture and Corrosion

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... 7/15/2019
320 Excavator YBP00001-UP (MACHINE) POWERED BY C7.1 Engine(M0092767 - 0... Page 3 of 8

Illustration 1 g01960167
(1) Former Seal Design
(2) Current Seal Design

The plug end of the DT connector has a seal at the mating end of the connector. This seal has been
improved on black connectors to help prevent slipping. Additionally, this seal is replaceable. This
improvement will help keep moisture and dirt from entering the connector.

The current seal design (2) is not interchangeable with the former design (1). The receptacle has also
changed to the new colors.

Illustration 2 g06253207

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... 7/15/2019
320 Excavator YBP00001-UP (MACHINE) POWERED BY C7.1 Engine(M0092767 - 0... Page 4 of 8

(3) Seal for a three-pin connector (typical example)

Table 1
Troubleshooting Test Steps Values Results
1. Inspect All Wiring OK - The harness wiring, connectors, and seals
Harnesses are in good condition.

A. Ensure that the routing of Proceed to "Check the Wires for Damage to the
the wiring harness allows the Insulation".
wires to enter the face of each
connector at a perpendicular NOT OK - A problem has been found with the
angle. (Otherwise, the wire harness or the connectors.
will deform the seal bore. This The harness
condition will create a path for wiring, Repair: Repair the connectors or the wiring, as
the entrance of moisture.) connectors, required. Ensure that all of the seals are properly
and seals are in place. Ensure that the connectors have been
B. Verify that the seals for the in good reattached. If corrosion is evident on the pins,
wires are sealing correctly. condition. sockets or the connector, use only denatured
There is no alcohol to remove the corrosion. Use a cotton
C. Disconnect the suspect evidence of swab or a soft brush to remove the corrosion. If
connector and inspect the moisture in the moisture was found in the connectors, run the
connector seal. Ensure that the connectors. engine for several minutes and check again for
seals are in good condition. If moisture. If moisture reappears, the moisture is
necessary, replace the wicking into the connector. Even if the moisture
connector. entry path is repaired, replacing the wires may be
necessary. Verify that the repair eliminates the
D. Thoroughly inspect the problem.
connectors for evidence of
moisture entry. STOP.

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 problem will recur.
Simply drying the connector will not fix the problem. Check the following items for the possible
moisture entry path:

• Missing seals

• Improperly installed seals

• Nicks in exposed insulation

• Improperly mated connectors

Moisture can also travel to a connector through the inside of a wire. If moisture is found in a
connector, thoroughly check the connectors harness for damage. Also check other connectors that
share the harness for moisture.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... 7/15/2019
320 Excavator YBP00001-UP (MACHINE) POWERED BY C7.1 Engine(M0092767 - 0... Page 5 of 8

Check the Wires for Damage to the Insulation

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 chassis

• Rubbing of a wire against a sharp point

Table 2
Troubleshooting Test Steps Values Results
OK - The harness has passed
all checks.
1. Check All Wiring Harness
Proceed to "Inspect the
Fasteners
Connector Terminals".
A. Check all of the fasteners to verify
NOT OK - There is damage
that the harness is secure and is NOT The wires are free of
to the harness.
compressed. abrasion, of nicks, and
of cuts and the harness is
Repair: Repair the wires or
B. Pull back the harness sleeves to properly clamped.
replace the wires, as
check for a flattened portion of wire. (A
required. Verify that the
fastener that has been overtightened will
repair eliminates the
flatten the harness.)
problem.

STOP.

Inspect the Connector Terminals

Table 3
Troubleshooting Test Steps Values Results
1. Visually inspect each terminal in the OK - The terminals show
connector. The terminals are no signs of damage.
properly aligned and
A. Verify that the terminals are not the terminals appear Proceed to "Check
damaged. Verify that the terminals are undamaged. Individual Pin Retention
properly aligned in the connector and verify into the Socket".
that the terminals are properly located in the
connector. NOT OK - The terminals
of the connector are
damaged.

Repair: Repair the

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... 7/15/2019
320 Excavator YBP00001-UP (MACHINE) POWERED BY C7.1 Engine(M0092767 - 0... Page 6 of 8

terminals and/or replace the

terminals, as required.
Verify that the repair
eliminates the problem.

STOP.

Perform a Pull Test on Each Wire Terminal Connection

Illustration 3 g06253209
(4) Locking Wedge for 3-pin connector

Table 4
Troubleshooting Test Steps Values Results
1. Check Locking Wedge Of OK - All terminals pass the
Connector. This test confirms that pull test.
the wire was properly
A. Ensure that the locking wedge for crimped in the terminal Proceed to "Check Individual
the connector is installed properly. and the terminal was Pin Retention into the Socket".
(Refer to the figure above.) properly inserted into the
connector. NOT OK - A wire has been
B. Perform the 45 N (10 lb) pull test pulled from a terminal or a
on each wire. (Each terminal and each terminal has been pulled from
connector should easily withstand the connector.
45 N (10 lb) of tension and each wire
should remain in the connector body.) Repair: Use the 1U-5804
Crimp Tool (12-GA TO 18-
GA) to replace the terminal.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... 7/15/2019
320 Excavator YBP00001-UP (MACHINE) POWERED BY C7.1 Engine(M0092767 - 0... Page 7 of 8

Replace damaged connectors,

as required. Verify that the
repair eliminates the problem.

STOP.

Check Individual Pin Retention into the Socket

Table 5
Troubleshooting Test Steps Values Results
OK - The terminals are OK.

1. Confirm Pin Retention At Proceed to "Check the Locking

Sockets. Mechanism of the Connectors".

A. Disconnect the harness. The sockets NOT OK - Terminals are damaged.

provide good
B. Insert a new pin into each socket of retention for the Repair: Use the 1U-5804 Crimp Tool
the mating plug individually to check new pin. (12-GA TO 18-GA) to replace the
for a good grip on the pin by the damaged terminals. Verify that the
socket. repair eliminates the problem.

STOP.

Check the Locking Mechanism of the Connectors

Table 6
Troubleshooting Test Steps Values Results
1. Check Locking Mechanism Of OK - The connectors are in
Connectors. The connectors lock good condition.
securely. No cracks or
A. Lock the connectors, and ensure that breaks are found at the Proceed to "Perform the
the two halves cannot be pulled apart. connectors. Wiggle Test on the Cat
Electronic Technician (Cat
B. Verify that the latch tab of the ET)".
connector is properly latched. Also
verify that the latch tab of the connector NOT OK - A connector
returns to the locked position. locking mechanism is
damaged or missing.

Repair: Repair the connector

or replace the connector, as
required. Verify that the
repair eliminates the problem.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... 7/15/2019
320 Excavator YBP00001-UP (MACHINE) POWERED BY C7.1 Engine(M0092767 - 0... Page 8 of 8

STOP.

Perform the Wiggle Test on the Cat Electronic Technician (Cat ET)

Table 7
Troubleshooting Test
Values Results
Steps
1. Perform A Wiggle Test.
OK - No intermittent problems were found.
A. Select the Wiggle Test
The harness and connectors appear to be OK.
from the diagnostic tests on
If another procedure recommended this test,
Cat ET.
return to that procedure and continue testing.
If the problem has been resolved, return the
B. Choose the appropriate
machine to service.
group of parameters to
monitor. No intermittent
STOP.
problems were
C. Press the "Start" button. indicated during
NOT OK - At least one intermittent problem
Wiggle the wiring harness to the Wiggle Test.
was indicated.
reproduce intermittent
problems.
Repair: Repair the harness or the connector.
Verify that the repair eliminates the problem.
If an intermittent problem
exists, the status will be
STOP.
highlighted and an audible
beep will be heard.

Copyright 1993 - 2019 Caterpillar Inc. Mon Jul 15 00:28:38 UTC+0700 2019
All Rights Reserved.
Private Network For SIS Licensees.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... 7/15/2019