Checking Terminal Contact

Many tables will have you checking terminal contact before replacing a component. This is done because the checks performed in tables can only check the continuity of a circuit across a wire or an in-line connection, not the continuity across the connection at a component. Checking the terminal contact will prevent the replacement of good components, prevent comebacks due to intermittent connection problems, and make some repair jobs easier by replacing a terminal instead of a component. For this reason it is very important to check terminal contact when instructed to do so.

Checking the terminal contact is easy as long as you have a supply of new terminals handy. The J 38125 terminal repair kit is a good source of terminals for checking terminal contact. The kit contains a supply of all of the currently used terminal series. To check the terminal contact, start by inspecting the male terminals. The terminals should be straight and aligned with all the other terminals in the row. The terminals should not be twisted, bent, or otherwise damaged. The female terminal should also be inspected for alignment and damage. Finally,take a new male terminal of the same series (e.g. Metripack 150, Weatherpack, etc.) and connect the male terminal to the female terminals to be checked. The male terminal should not fall Out or be easily jarred out of connection. The male terminal should require some force to disconnect. The force required to disconnect the terminal will depend upon the size of the terminal being checked. Larger terminals, Metripack 630 series for example, should be very difficult to remove by hand. Smaller terminals, Micropack series for example, should be easier to disconnect by hand, but still should not fall out. Replace, do not repair, any damaged terminals. For identification of terminal series and repair procedures, refer to the terminal repair kit and to Testing for Intermittent and Poor Connections in Diagrams.