21258489 Volvo.Penta Propeller kit

Illustration 1 g00700045The MS connectors have a metal housing. The pins and the sockets are soldered to the electrical wires. The solder connections are usually protected by a chemical potting which prevents access to the solder point.
Illustration 2 g00700064Deutsch connectors have a plastic housing. The pins and the sockets are crimped onto the electrical wires. The connector has a locking mechanism in order to hold the pins and the sockets. These connectors are repairable without cutting the wires.
Illustration 3 g00928006Use the following test steps in order to thoroughly inspect the connectors and determine if the connectors are the cause of the problem.
Check the Connectors.
Remove the electrical power from the engine before you inspect electrical conductors.
For the MS connectors, make sure that the receptacle is turned fully in the clockwise direction. Check that the threading is properly aligned and securely mated.
For the Deutsch HD connectors, make sure that the plug and the receptacle are aligned properly with the index markings. Make sure that the receptacle is turned fully in the clockwise direction. Verify that the receptacle is clicked into the locked position. Make sure that the two halves cannot be pulled apart.
For the Deutsch DT style, make sure that the orange wedge is used in order to lock the pins. Check that the receptacle has clicked into the locked position. Make sure that the two halves cannot be pulled apart.
Check the Allen Head Screw on the Rectangular Connectors.
Ensure that each allen head screw is properly tightened. Be careful not to overtighten the screw and break the screw.
When you connect a 70-pin connector to an Electronic Control Module (ECM), do not exceed 6 1 N m (55 9 lb in) of torque on the screw.
When you connect a rectangular connector to the terminal box, do not exceed 2.25 0.25 N m (20 2 lb in) of torque on the screw.
Perform a Pull Test on Each Wire Connection.
Each terminal and each connector should easily withstand 45 N (10 lb) of pull and each wire should remain in the connector body. This test checks whether the wire was properly crimped in the terminal and whether the terminal was properly inserted into the connector.
The DT connectors use an orange wedge to lock the terminals in place. Ensure that the orange wedge is not missing and that the orange wedge is installed properly on the DT connectors. Note: Terminals should ALWAYS be crimped onto the wires with a crimp tool. Do not solder terminals. Use the 1U-5804 Crimp Tool.
Monitor the Electronic Service Tool While the Wiring and the Connectors Are Being Pulled.
If there is an active diagnostic code that pertains to the circuit, perform the following steps: Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.Connect the Caterpillar Electronic Technician (ET) to the service tool connector on the terminal box.Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode. Then start the engine. Run the engine under normal operating conditions.Monitor the "Active Diagnostic Code" screen on Cat ET while you pull on all harnesses and connectors for the circuit with the active code.If the harness is being pulled and the active diagnostic code disappears, there is a problem in the wiring or the connector.
If there are no active diagnostic codes that pertain to the circuit, perform the following test: Run the engine under normal operating conditions.Monitor the "Display Status" screen on Cat ET while you pull on all harnesses and connectors for the circuit.If the harness is being pulled and the reading changes erratically, there is a problem in the wiring or in the connector.
If there are no active diagnostic codes and there are complaints about intermittent changes in speed or power cutouts, perform the following test: Run the engine under normal operating conditions.Listen for speed burps or power cutouts while the wiring and/or the connectors are pulled.If the harness is being pulled and the engine has a speed burp or a power cutout, there could be a problem in the wiring or the connector.
Check Wires for Nicks or Abrasion in the Insulation.
Set the engine control to the STOP mode. Allow the engine to coast to a stop.
Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.
Carefully inspect each wire for signs of abrasion, of nicks, or of cuts. The following areas are likely locations:
Places with exposed insulation
Points with wiring that rubs against the engine
Places with wiring that rubs against a sharp point
Check all of the hold down clamps for the harness in order to verify that the harness is properly clamped. Also, check all of the hold down clamps in order to verify that the harness is not compressed by the clamps. Pull back the harness sleeves in order to check for flattening of the wires by the clamps.
Check the Connectors for Moisture or Corrosion.
Illustration 4 g00690571
Ensure that the connector seals and the white sealing plugs are in place. If any of the seals or plugs are missing, replace the seal or plug. If necessary, replace the connector.
Illustration 5 g00690568
Check all of the wiring harnesses in order to verify that the harness does not make a sharp bend out of a connector. This will deform the connector seal and this will create a path for the entrance of moisture. Thoroughly inspect each ECM connector for evidence of moisture entry.Note: It is normal to see some minor seal abrasion on the ECM connector seals. 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 the source of the moisture entry must be repaired. If the repair is not made, the problem will recur. Simply drying the connector will not fix the problem. The following list includes likely paths for the entrance of moisture:
Missing seals or plugs
Improperly installed seals or plugs
Nicks in exposed insulation
Improperly mated connectorsMoisture can also wick from one connector through the inside of a wire to an ECM