825700 Mercury COVER-THERMOSTAT

During testing, abnormal operating conditions must be simulated.The tests must be performed correctly in order to prevent possible damage to the engine.
Perform a Static Test
Inspect the components of the alarm and shutoff systems for good condition. Test the operation of the alarms and shutoffs.A static test of the engine protective devices will ensure that the alarms and shutoffs are functioning properly.To prevent damage to the engine, only authorized service personnel or your Caterpillar dealer should perform the tests.Consult your Caterpillar dealer or refer to the Service Manual for more information.Inspect the Connections of the Engine Protective Devices
Inspect the wiring and the electrical connections for these components:
Connectors
Control panel
Junction box
Sensors
Turn the engine control switch to the "OFF/RESET" position. Open the circuit breaker or circuit breakers of the main power supply.
Inspect all of the wiring for the following conditions:
Fraying
Damaged insulation
CorrosionMake repairs, as needed.
Illustration 1 g01173779
(1) Terminal strips on the back plate of the enclosure
(2) Terminal strips on the rear of the panel
Check the wiring for secure connections at these points of the junction box and the control panel:
Connectors
Relays
Switches
Terminal stripsPerform a pull test for each wire. This test will ensure that the wiring is properly attached. Test each wire individually.
Pull each wire with approximately 45 N (10 lb) of force. Pull the wire firmly. If a wire is loose, repair the connection.
Inspect the wiring at the relays and terminal strips for these conditions:
Corrosion
Fraying
If corrosion is found, scrape large deposits. Use cotton swabs with denatured alcohol to clean any corrosion that remains. Investigate the source of the corrosion. Correct the condition.If damage is found, replace the part.
Remove frayed strands of wire or tin the wire.
Perform Steps 6 and 7 for the connectors of the control panel and the junction box.
Illustration 2 g01230500Note: The wiring is crimped into the pins and sockets of Deutsch DT connectors.
Illustration 3 g01230207
Deutsch DT connectors
Check the wiring for secure connections at these points:
Connectors
SensorsPerform a pull test for each wire. This test will ensure that the wiring is properly attached. Test each wire individually.
For wiring that is attached to a connector, hold the body of the connector with one hand. Pull each wire with approximately 45 N (10 lb) of force. Pull the wire firmly.
Before testing the wiring of the sensors, ensure that the sensors are securely installed. Then pull each wire with approximately 45 N (10 lb) of force. If a wire is loose, repair the connection.
Disconnect the connectors at the following locations. Inspect the connectors.
Engine sensors
Junction box
Modules of the control panel
Inspect each pin and each socket for corrosion and damage. If corrosion is found, scrape large deposits. Use cotton swabs with denatured alcohol to clean any corrosion that remains.Investigate the source of the corrosion. Correct the condition.If damage is found, replace the part.
Reconnect the connectors.
For Military Standard and Jaeger connectors, ensure the following conditions:
The connection is threaded properly.
The connection is threaded completely. Very little thread or no thread is visible.
For Deutsch DT connectors, ensure that the plug and the receptacle are securely connected.
Close the circuit breaker or circuit breakers of the main power supply.