Checking Terminal Contact

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

Testing terminal contact is easy as long as you have a supply of new terminals handy. The J 38125-B Terminal Repair kit, is a good source of terminals for testing terminal contact. It contains a supply of all currently used terminal series. To test terminal contact, start by inspecting the male terminals. They should be straight and aligned with other terminals in the row. They should not be twisted, bent or otherwise damaged. The female terminal should be, likewise, inspected for alignment and damage. Finally, take a new male terminal of the same series (e.g Metri-pack 150, Weatherpack, etc.) and connect it to the female terminals to be tested. It should not fall out or be easily jarred out of connection. It should require some force to disconnect it. The force required to disconnect it will depend on the size of the terminal being tested. Larger terminals, Metri-pack series for example, should be very difficult to remove by hand. Smaller terminals, Micro-pack series for example, should be easier to disconnect by hand but still should not fall out. Replace, do not repair, any damaged terminals.