Usage:
Introduction
This manual provides the necessary information on how the DT and HD family of connectors (shown in Illustration 1) are properly serviced.
Do not perform any procedure, outlined in this manual, or order any parts until you read and understand the information contained within.
Deutsch HD and DT style connectors are very similar. Differing only in shape and color, the function and servicing techniques are the same. Both consist of a plug and receptacle.
Illustration 1. Typical DT
Gray colored DT style connectors were changed in mid-1999 to improve the replaceable seal between the plug and receptacle. For easy recognition, the most current DT style connector plugs and receptacles found in this kit will be colored black. The current green wedge design will also be easily identified from the former orange color.
The plug half of the DT style connector has a seal at the mating end. This seal has been improved on black connectors to help prevent slipping and is replaceable. This improvement will help keep moisture and dirt from entering the connector. The current seal design (2, Illustration 2) is not interchangeable with the former design (1, Illustration 2). The receptacle has also changed to the new colors.
Illustration 2. Seal Designs. (1) Former Seal On Gray Plug. (2) Current Seal On Black Plug.
NOTE: The seals, shown in Illustration 2, are NOT interchangeable.
The Pin and Socket terminal crimping procedure (shown on page 8) is identical for both HD and DT style connectors.
Receptacles accept pin terminals. Wedges, assembled at the mating interface, lock the terminals into position. The original orange wedges are now green and fit into the current black connectors. Plugs accept sockets. Wedges lock the sockets into position. Green and orange receptacle wedges are interchangeable (refer to the "DT Style Connector Compatibility" section in this manual for additional information). DT style connectors are joined by aligning the latching mechanisms and pushing the connectors together.
Illustration 3. Typical HD Style Connector.
HD style connectors are easily recognizable, by the round connector bodies. HD style connectors are sealed with rubber gaskets, which are not replaceable. Wedges are not required with this design. The connectors are joined using a quarter-turn locking ring.
Serviceable Parts
Illustration 4. Current DT Style Connector Nomenclature.
Illustration 5. Current HD Style Connector Nomenclature.
Illustration 6. Service Tools.
Service Kits
NOTE: The 175-3700 DT Style Field Service Group and the 190-8900 HD Style Deutsch Connector Group do not contain the 1U-5804 Crimp Tool. The 1U-5804 Crimp Tool should be ordered separately.
DT Style Connector Compatibility
The original gray colored DT style Deutsch connectors with orange wedges have been redesigned to improve the plug and receptacle body sealing. The redesigned connectors are black with green wedges.
Interchangeability between plug, receptacle, and wedges is possible in some cases.
NOTE: The seals for the black and gray plugs are NOT interchangeable.
Use the information in the "Acceptable Color Combinations" section of this manual for acceptable combinations of colors and parts when servicing DT style connectors.
Acceptable Color Combinations
Mating Pairs
Illustration 7. Mating Part Color Combinations.
Receptacle
Illustration 8. Receptacle Color Combinations.
Plug
Illustration 9. Plug Color Combinations.
Connector Unmating
No tools are required to unmate DT or HD style connectors.
| NOTICE |
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The use of tools could damage the locking latch (DT) or ring (HD) and prevent securely remating the connector. |
1. Unmate the connector by grasping the plug and receptacle housings with each hand. The plug housing contains the locking latch (DT) or locking ring (HD).
Illustration 10. Do Not Use Tools To Unmate Connectors.
2. On DT style connectors, completely depress the locking latch to separate the connector housings.
NOTE: If there is dirt build-up under the latch (DT), tap the side of the connector, dislodging the dirt particles, until the latch can be fully depressed.
3. With the latch fully depressed, pull the plug from the receptacle.
Illustration 11. Larger DT Style Connectors With Two Locking Latches.
4. The larger DT style connectors are unmated in the same manner as the smaller ones, except they have two locking latches.
Illustration 12. Unmating The HD Style Connectors.
5. On HD style connectors, grasp the locking ring on the plug body and rotate the ring counterclockwise. This action will unlock and force the connector bodies apart.
| NOTICE |
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DO NOT pull on the wires to separate the two halves of any connector. This can cause damage to both the wires and connectors. |
Terminal Removal
Plug Housing
The DT style connectors use a wedge to secure the socket and pin terminals. This wedge must first be removed before terminals are separated from the connector.
1. Remove the wedge by inserting 147-6456 Wedge Removal Tool between the wedge and connector housing.
Illustration 13. Remove Wedge From Plug.
| NOTICE |
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When removing the wedge, insert the removal tool along the side of the wedge, not the corners, which could cause damage |
Illustration 14. Removing The Wire From A Plug.
2. With the wedge removed, place 147-6456 Wedge Removal Tool against the terminal locking finger. Push the finger away from the terminal while gently pulling the wire out of the connector.
Receptacle Housing
Illustration 15. Removing 3-Pin Connector Wedge From Receptacles.
1. Remove the terminals from the connector by first removing receptacle wedge (2), as shown in Illustration 15. Remove wedge (2) by grasping it with long nose pliers and pulling straight out.
Illustration 16. Removing The Wedge From Receptacles.
2. The receptacle wedge, in other than 3-pin connector configurations, is removed by inserting one end of 147-6456 Wedge Removal Tool into the center of the wedge and hooking the outside edge.
3. Hold the receptacle in one hand and apply upward pressure on 147-6456 Wedge Removal Tool with the opposite hand. Pull the wedge straight out.
Illustration 17. Removing The Wire From A Receptacle.
4. With the wedge removed, place the 147-6456 Wedge Removal Tool against the terminal locking finger. Push the finger away from the terminal while gently pulling the wire out of the connector.
HD Style Terminal Removal
Terminals should be removed from the HD style connectors using the 151-6320 Pin/Socket Removal Tool. This method works on both the HD style receptacle and plug.
Illustration 18. Removing Terminals Using The 151-6320 Pin/Socket Removal Tool.
1. Insert the tool into the housing around the wire.
2. Firmly push the removal tool inward until it disengages the terminal locking fingers.
3. Remove the terminal, wire, and removal tool together from the connector body.
Terminal Crimp Procedure
To ensure proper electrical performance, terminals must be crimped using the 1U-5804 Crimping Tool and the following procedure. DO NOT solder the wires into the terminals.
1. Cut the end of the wire square and clean.
Illustration 19. Typical Terminal.
2. Strip 6.4 to 7.0 mm (.25 to .31 in) of insulation from the wire being careful not to cut or nick the copper wire strands. A properly stripped wire will bottom out in the terminal with the insulation 1.5 mm (.06 in) from the end of the terminal. On the socket terminal, the wire is inserted into the end with inspection hole (M).
Illustration 20. 1U-5804 Crimp Tool.
3. Make sure the wire selector gauge (G, Illustration 20) on 1U-5804 Crimp Tool is set to the wire size being crimped. If the wire selector gauge is properly set, proceed to Step 4. If the selector gauge setting does not match the wire size being crimped, proceed as follows:
a. Remove lock clip (H).
b. Raise selector knob (J) and rotate it until the arrow is aligned with the wire size to be crimped.
c. Lower the selector knob and insert the lock clip.
Illustration 21. Adjust The Crimp Tool.
4. Loosen locknut (K) and turn adjusting screw (L) in until it stops.
Illustration 22. Insert Terminal (6) Into Crimping Tool.
5. Insert terminal (6) and turn adjusting screw (L) until the wire/crimp end of the terminal is flush with the tool face. Tighten locknut (K).
Illustration 23. Wire/Crimp End Of Terminal Is Flush With Tool Face.
6. Insert the wire into the terminal (the terminal must be centered between crimp fingers). Make sure that all wire strands are in the crimp barrel.
Illustration 24. Center The Terminal Between The Crimp Fingers.
7. Crimp the wire in the terminal by squeezing the handles of the crimp tool together until the handle hits the stop and automatically releases.
8. Remove the crimped terminal.
9. Inspect the terminal to make sure that all wire strands are in the crimped barrel and that the crimp indent falls in the center of the terminal crimp barrel.
Illustration 25. Inspect The Terminal. Good Quality Crimp, Correctly Positioned.
Illustration 26. Bad Crimp (Not Centered On Length Of Pin).
Terminal Insertion
1. Grasp the wire approximately 25 mm (1.0 in) from the crimped terminal. Insert the terminal into the connector, as shown in Illustrations 27 and 29.
Illustration 27. Insert The Terminal Into The DT Style Receptacle/Plug.
Illustration 28. Typical Example Of DT Style Terminal Locked Into Position.
Illustration 29. Insert The Terminal Into The HD Style Receptacle/Plug.
2. Push the terminal straight into the connector until the terminal locks in place. A slight tug on the wire will confirm the terminal is properly locked in place.
3. Insert 8T-8737 Sealing Plugs (7) in all unused terminal cavities.
Illustration 30. Insert Sealing Plugs (7).
4. After all the terminals have been assembled into the receptacle/plug housing, insert the wedge (long nose pliers may be required to insert some receptacle wedges). Make sure the wedge snaps completely into place.
Illustration 31. Install The Wedge In DT Style Connectors
Connector Cleaning
Connectors that have been unmated for service purposes must be cleaned before reconnecting.
| NOTICE |
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Many solvents have been found to damage some connector materials. Solvent-type cleaners are not recommended. It is important that the connector mating surfaces be clean and dry before remating. If dirt or corrosion cannot be removed from the mating surfaces, the connector and/or terminals must be replaced. |
The interior mating surfaces of the connector (i.e. terminals, seals, and insulators) should be cleaned using a cotton swab and denatured alcohol.
 |
Use all cleaning solutions with care and in a well ventilated area. Always wear eye protection when using cleaning solutions. Failure to follow the precautions provided by the manufacturer on using, storing and disposing of any cleaning solution can result in bodily injury. |
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Connector Mating
Illustration 32. Mating Connector Plug And Receptacle.
1. DT style connectors are mated by grasping each half of the connector and aligning the locking latch of the plug housing with the receptacle housing.
NOTE: For the 8 and 12-pin connector, it may be necessary to rotate the plug housing 180 degrees in order to achieve the correct alignment.
2. Push the two connector halves together until the latch(es) lock into place.
3. Make sure the connector housings are locked together by attempting to pull the housings apart.
4. HD style connectors are mated by aligning the external alignment marks (1), pushing the two connector bodies together, and then turning the locking ring 1/4 turn clockwise until the ring clicks into the locked position.
Illustration 33. Mating Connector Plug And Receptacle.
For information on service tools or shop supplies, contact Caterpillar Service Technology Group on:
Caterpillar Service Technology501 S.W. Jefferson Ave.
Peoria, Illinois 61630-2184
1-800-542-8665 (USA)
1-800-541-8665 (Illinois)
1-800-523-8665 (Canada)
404435 (Telex)
1-309-675-6650 (Fax)
or
Caterpillar Service TechnologyCaterpillar Overseas S.A.
P.O. Box 6000
1211 Geneva 6
Switzerland
+41 (22) 849 40 56 (Geneva Phone)
+41 (22) 849 49 29 (Geneva Fax)
36CSTG (COSA E-Mail Address)