LINE AS-FUEL INJECTION 4W3209 - Caterpillar

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
1. Check All Wiring Harness Fasteners
A. Check all the fasteners to verify that the harness is secure and is NOT compressed.
B. Pull back the harness sleeves to check for a flattened portion of wire. (A fastener that has been overtightened will flatten the harness.)
The wires are free of abrasion, of nicks, and of cuts and the harness is properly clamped. OK - The harness has passed all checks.
Proceed to "Inspect the Connector Terminals".
NOT OK - There is damage to the harness.
Repair: Repair the wires or replace the wires, as required. Verify that the repair eliminates the problem.
STOP Inspect the Connector Terminals
Table 3
Troubleshooting Test Steps Values Results
1. Visually Inspect Each Terminal In The Connector
A. Verify that the terminals are not damaged. Verify that the terminals are properly aligned in the connector and verify that the terminals are properly located in the connector.
The terminals are properly aligned and the terminals appear undamaged. OK - The terminals show no signs of damage.
Proceed to "Check Individual Pin Retention into the Socket".
NOT OK - The terminals of the connector are damaged.
Repair: Repair the 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 2 g02732798
(4) Locking Wedge for 3-pin connector
Table 4
Troubleshooting Test Steps Values Results
1. Check Locking Wedge Of Connector
A. Ensure that the locking wedge for the connector is installed properly. (Refer to the figure above.)
B. Perform the 45 N (10 lb) pull test on each wire. (Each terminal and each connector should easily withstand 45 N (10 lb) of tension and each wire should remain in the connector body.)
This test confirms that the wire was properly crimped in the terminal and the terminal was properly inserted into the connector. OK - All terminals pass the pull test.
Proceed to "Check Individual Pin Retention into the Socket".
NOT OK - A wire has been pulled from a terminal or a terminal has been pulled from the connector. The terminal may also have not been inserted correctly during manufacturing.
Repair: Use the 1U-5804 Crimp Tool (12-GA TO 18-GA) to replace the terminal. Replace damaged connectors, as required. Verify that the repair eliminates the problem. The connector may also be damaged. Examine the terminal latches in the connector for signs of damage and replace the connector body, if necessary.
If the wire was not assembled correctly when manufactured, remove the wedge and reinsert the terminal. Listen for the “click” to indicate that the terminal is locked in place. Insert the wedge into the connector.
STOP Check Individual Pin Retention into the Socket
Table 5
Troubleshooting Test Steps Values Results
1. Confirm Pin Retention At Sockets
A. Disconnect the harness.
B. Insert a new pin into each socket of the mating plug individually to check for a good