LINES GP-FUEL INJECTION 7N5146 - Caterpillar

Guidelines
Use a 1U-5804 Crimp Tool (12-GA TO 18-GA) to service Deutsch HD and DT connectors. Never solder the terminals onto the wires.
Use a 147-6456 Wedge Removal Tool to remove wedges from DT connectors. Never use a screwdriver to pry a wedge from a connector.
Use a breakout harness for a voltmeter probe or a test light. Never break the wire insulation to access a circuit for measurements.
If a wire is cut, install a new terminal for the repair.Reference Tool Operating Manual, SEHS9615, "Servicing Deutsch HD and DT Style Connectors"Some minor seal abrasion on connector seals is normal. 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 repaired. If the source of the moisture entry is not repaired, the problem will recur. Simply drying the connector will not fix the problem. Moisture can also travel to a connector through the inside of a wire. If moisture is found in a connector, thoroughly check the connector harness for damage. Also check all of the remaining connectors on the harness for moisture.The plug end of the DT connector has a replaceable seal at the mating end of the connector. This seal has been improved on black connectors to help prevent slipping and to help keep moisture and dirt from entering the connector.The current seal design (2) is not interchangeable with the former design (1) . The receptacle has also changed to the new colors.
Illustration 1 g01960167
(1) Former seal design (2) Current seal design
Illustration 2 g01960176
(3) Seal for a three-pin connector (typical example)
Illustration 3 g02732798
(4) Locking wedge for 3- pin connectorTroubleshooting Steps
Table 1
Troubleshooting Steps    Values    Results    
1. Check Harnesses
A. Visually inspect the wiring.
B. Visually inspect the connectors.
C. Visually inspect the seals.    
Harnesses:
* Routing allows the wires to enter each connector face at a perpendicular angle
* No insulation nicks
Connectors:
* Are properly mated
* Have no moisture
Seals:
* Seals are sealing
* No seals missing    
OK - The harness is OK.
Go to Step 2.
Not OK - The harness is not OK.
Repair:
A. Repair or replace the harness.
B. Verify that the repair corrected the problem.
STOP    
2. Check Fasteners And Wires
A. Visually inspect the fasteners.
B. Visually inspect the wiring.    
Fasteners:
* Fasteners are not overtightened
Wiring:
* Is secure
* Is not compressed
* Has no abrasion
* Has no nicks
* Has no cuts
* Has no exposed insulation
* Has no rubbing against the chassis or a sharp point    
OK - The harness is OK.
Go to Step 3.
Not OK - The harness is not OK.
Repair:
A. Repair or replace the harness.
B. Verify that the repair corrected the problem.
STOP    
3. Inspect Connector Terminal And Locking Wedge
A. Visually inspect the terminals.
B. Visually inspect the locking wedges. (See Figure 3).    
Terminals:
* Properly aligned
* Undamaged
* Properly located in the connector
* Properly crimped in the terminal
Locking wedges:
* Properly installed    
OK - The terminals are OK.
Go to Step 4.
Not OK - The terminals are not OK.
Repair:
A. Repair and/or replace the terminals.
B. Verify that the repair corrected the