RACE 1J9226 - Caterpillar

Reference: Special Instruction, SEHS9615, "Servicing DT Connectors".Reference: Special Instruction, REHS0148, "Listing Of Deutsch Connector Components"Reference: Special Instruction, SEHS9065, "Use Of CE Connector Tools".Reference: Service Magazine, SEPD0342, "Field Repair Of Single Wire Breaks In Harnesses (Sealed Splice)".Reference: Service Magazine, SEPD0371, "Protection Of Unsealed Electrical Terminations For Machines In Corrosive Applications".Reference: Service Magazine, SEPD0473, "New DT Connector Plugs With Improved Seal Retention".Reference: Service Magazine, SEPD0545, "Dielectric Grease Should Not Be Used In Electrical Connectors".Reference: Pocket Guide, SEBD0402, "Guidelines For Routing And Installing Wire Harness Assemblies".This information will assist in detecting problems with connectors and with wiring. If a problem is found, correct the condition and verify that the problem is resolved.Disconnecting and reconnecting connectors sometimes resolves intermittent electrical problems. Checking for diagnostic codes immediately before disconnecting a connector is important. Also check for diagnostic codes after reconnecting the connector. If the status of a diagnostic code is changed due to disconnecting and reconnecting a connector, there are several possible reasons. The likely reasons are loose terminals, improperly crimped terminals, moisture, corrosion, and inadequate mating of a connection.Important Safety Information
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by a failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, procedure, work method, or operating technique, not recommended by Caterpillar is used, make sure that the procedure is safe for all people.Make sure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.Guidelines
Always 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. Refer to Tool Operating Manual, SEHS9615, "Servicing Deutsch HD and DT Style Connectors".
Always use a 147-6456 Wedge Removal Tool to remove wedges from DT connectors. Never use a screwdriver to pry a wedge from a connector.
Always use a breakout harness for a voltmeter probe or a test light. Never break the insulation of a wire to access a circuit for measurements.
If a wire is cut, always install a new terminal for the repair.Tests
Check Connectors for Moisture and Corrosion
Illustration 1 g01960167
(1) Former Seal Design
(2) Current Seal DesignThe plug end of the DT connector has a seal at the mating end of the connector. This seal is replaceable. This connection is designed to keep moisture and dirt from entering the connector.The current seal design (2) is not interchangeable with the former