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Introduction to Repair Kit of New Connector


(DEUTSCH DT and HD30 Connectors)
Komatsu decided to adopt DEUTSCH DT and HD30 connectors to all our models, instead of
current electric connectors like X and SWP connectors.
As compared with conventional connectors, new ones are provided with higher reliability, waterproof capability, electrical property, and other performance. By using them, you can easily repair
harnesses like replacement of connectors or terminals. On some of our models, they are already
used. Komatsu will adopt them to future models to be introduced onto the market. By using these
repair kits, you can replace the current connectors with new ones.

1. FEATURES OF NEW CONNECTORS


1) All connectors are waterproofed.
2) A common terminal is used on both DT and
HD30 connectors.
3) One type of terminal crimp tool is provided,
which is common to both.
4) On-site terminal replacement is easy.
 There is no need to caulk a shielding rubber
together with the terminal.
 The terminal has no protrusion, not damaging the shielding rubber when attaching and
detaching.
5) Durability of the terminal was improved.
 The terminal is nickel-plated, improving the
durability when connecting and disconnecting the connectors.
 The contact part of the terminal is provided
with high precision, not allowing poor contact to occur.

DT connector

2. BASIC PERFORMANCE
Particularly, the waterproof capability was improved, increasing reliability.
Working temperature: 55 to 125C
(X connector: 50 to 120C)
Waterproof capability:
No water enters even if it is put one meter below
water surface for four hours. No water enters even
if water of 8 to 10 megapascal is sprayed on the
connector from a position 100mm away.
(X connector: Spray test level)

HD30 connector

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Contents
Page
1. Features of New Connectors ......................................................................... 1
2. Basic Performance ........................................................................................ 1
3. General Description of Connector .................................................................
3-1 DT connector ...............................................................................................
3-2 HD30 connector ...........................................................................................
3-3 Pin Number Arrangement ..........................................................................
3-3-1 Pin Number Arrangement of DT connector ..............................................
3-3-2 Insert Arrangement of HD30 connector (Viewed from the pin terminal) ..

3
3
3
4
4
5

4. General Description of Kit ..............................................................................


4-1 Outline of the kits .........................................................................................
4-1-1 Repair kit (A) ............................................................................................
4-1-2 Repair kit (B) ............................................................................................
4-2 Types and identification of pins and sockets <Reference> .........................
4-2-1 Pin terminal ..............................................................................................
4-2-2 Socket terminal ........................................................................................
4-2-3 Identifying sealing plug .............................................................................

6
6
6
6
7
7
7
7

5. List of Repair Kit Components ..................................................................... 8


5-1 Repair kit (A) component list (Part No.: 790-222-4000) .............................. 8
5-2 Repair kit (B) component list (Part No.: 790-222-4100) ............................ 10
6. Replacement of Connectors and Terminals ................................................ 11
6-1 Pulling out and fitting in the DT connector terminal .................................... 11
6-1-1 Tools required .......................................................................................... 11
6-1-2 Pulling out the terminal ........................................................................... 12
6-1-3 Fitting in the terminal .............................................................................. 12
6-2 Pulling out and fitting in the HD30 connector terminal .............................. 14
6-2-1 Tools required ......................................................................................... 14
6-2-2 Pulling out the terminal ........................................................................... 14
6-2-3 Fitting in the terminal .............................................................................. 15
7. Crimp of Terminal ........................................................................................
7-1 Tools required ............................................................................................
7-2 Selecting pin and socket terminals ............................................................
7-3 Crimping the terminal ................................................................................

16
16
16
16

8. Replacement of machine-mounted connectors


with DEUTSCH connectors ........................................................................... 18
9. Part No. List of HD30 Connector Body ........................................................
9-1 Part No. List of HD30 Connector Body (Without adaptor) .........................
9-2 Part No. List of HD30 Connector Body (With adaptor) ..............................
9-3 Connector mounting nut and washer ........................................................

20
20
21
22

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3. GENERAL DESCRIPTION OF CONNECTOR


3-1

DT connector

As DT connectors, DT2-, 3-, 4-, 6-, 8-, and 12-ways types and DTHD 1-ways and DTM 2-ways
types are provided. Regarding the DTHD connector, three types are available depending on the
size of electric wire to be connected, each of which is given a different Part No.
<Configuration of DT connector>

Pin contact
Socket contact
Plug body

Receptacle body
Receptacle wedge

Plug wedge

3-2 HD30 connector


Two sizes of connectors (shell size: 18 and 24) and also connectors with different nine pin
configurations are provided. This type connector is mountable on a housing of either the pin or
socket terminal type. (The housing Part No. is different according to whether it is a pin-terminalmounted connector or socket-terminal-mounted connector.)
Other than, various kinds of combinations are available. Be careful to place an order by specifying
a correct Part No.
<Configuration of HD30 connector>

Pin contact

Socket contact
Sealing plug

or
or

Socket contact

Pin contact

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3-3 Pin Number Arrangement


3-3-1 Pin Number Arrangement of DT connector
Pin Number Arrangement (Viewed from the fitting part)
Male (Receptacle)

Female (Plug)

Note 1: To prevent misconnection, the 8- and 12-ways DT connector bodies are given four
different colors: grey, black, green, and brown. You cannot connect different color
connectors.
Note 2: As DT connector bodies, two types are provided; one for nominal diameter 0.5 of electric
wire and another for 0.85, 1.25 and 2. One with a small shielding rubber hole is for 0.5
and one with a large hole is for 0.85, 1.25, and 2.

The hole is large

The hole is small

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3-3-2

Insert Arrangement of HD30 connector (Viewed from the pin terminal)

Shell size and


insert layout
188

Insert Arrangement

Shell size and


insert layout
249

1814

2416

1820

2421

1821

2423

2431

Insert Arrangement

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4. GENERAL DESCRIPTION OF KIT


Two types of repair kits are provided: the repair kit (A) for all connectors in DT Series (Part No.:
790-222-4000) and the repair kit (B) for 2-, 3-, 4-, and 6-ways connectors frequently used (Part
No.: 790-222-4100).
As for HD30 connector bodies, more than 100 types are provided and not used very frequently.
For this reason, no repair kit is available for the HD30 connector bodies. You must place an order
separately when you need it. (Regarding the list of HD30 connector bodies, refer to 9.) Also,
components of this kit are also selectively available.

4-1 Outline of the kits


4-1-1 Repair kit (A)
For repair of connectors at repair shop. All parts of DT connector and required tools are included
in a kit. Separately get a HD30 connector body only and the kit is applicable to every connector.
Regarding the components list, refer to 5-1. This kit does not include a case. Obtain one if
necessary.

Photo of entire repair kit (A)

Photo of entire repair kit (B)

Case (Option)
Large size:
Part No. 799-601-7910
Size:
410 x 240 x 325mm
Weight:
6.0Kg
Medium size: Part No. 799-601-7920
Size:
550 x 325 x 365mm
Weight:
2.9Kg

4-1-2 Repair kit (B)


For repair of connectors in the field. Mainly the parts of frequently used 2-, 3-, 4-, and 6-ways
DT connectors are available as a compact kit. Like the repair kit (A), the repair kit (B) also
includes a terminal crimp tool and terminal pull-out tool. Therefore, it is well serviceable in the
field. Regarding the components list, refer to 5-2. This kit does not include a case (P/N: 799-6017910 and 7920), either. Obtain one if necessary.

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4-2

Types and identification of pins and sockets <Reference>

Pin and socket terminals have no engraved Part No. and ID mark. Therefore, you cannot identify them
on site. When you need to identify them on site, refer to the following tables. The DT connector
is serviceable with terminals with * only. The DTM connector is serviceable with terminals with ** only.

4-2-1

Pin terminal

Part No.
Upper row: Nickel-plated Length of pin terminal (A)
Lower row: Gold-plated
(mm) 0.4

How to identify
Dia. of pin terminal (B)
(mm) 0.2

How to identify

0819105310 (**)
0819107310 (**)

18.1

1.0

Measure the diameter


and length of the pin.

0819105320 (*)
0819107320 (*)

20.6

1.6

Measure the diameter


and length of the pin.
Without a green bar

0819105330 (*)
0819107330 (*)

20.6

1.6

Measure the diameter


and length of the pin.
With a green bar

0819105340

20.6

2.4

Measure the diameter


and length of the pin.

0819105350

26.2

3.6

Measure the diameter


and length of the pin.

0819105360

26.2

5.7

Measure the diameter


and length of the pin.

4-2-2

Socket terminal

How to identify
Part No.
Upper row: Nickel-plated Length of socket terminal (A) Dia. of socket terminal (B)
Lower row: Gold-plated
(mm) 0.4
(mm) 0.2

How to identify

0819105410 (**)
0819107410 (**)

16.4

1.9

Measure the diameter


and length of the socket.

0819105420 (*)
0819107420 (*)

19.0

2.8

Measure the diameter


and length of the socket.
Without a green bar

0819105430 (*)
0819107430 (*)

19.0

2.8

Measure the diameter


and length of the socket.
With a green bar

0819105440

19.3

4.0

Measure the diameter


and length of the socket.

0819105450

24.8

6.6

Measure the diameter


and length of the socket.

0819105460

24.8

8.5

Measure the diameter


and length of the socket.

Note: The gold-plated socket terminal has a crimped part of gold color.

4-2-3

Identifying sealing plug


Part No.

Color for identification

0819100710

Red

0819100770

White

0819100750

White

0819100760

Brown

(A)

(A)
(B)

Green bar

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5. LIST OF REPAIR KIT COMPONENTS


5-1

Repair kit (A) component list (Part No.: 790-222-4000)


No.

Part No.

Part name

Qty

Remarks

0819105310

Pin (Nickel-plated)

100

(#20)

0819105320

Pin (Nickel-plated)

50

(#16: AWG1620)

0819105330

Pin (Nickel-plated)

50

(#16: AWG1416)

0819105340

Pin (Nickel-plated)

20

(#12)

0819105350

Pin (Nickel-plated)

10

(#8)

0819105360

Pin (Nickel-plated)

10

(#4)

0819107310

Pin (Gold-plated)

10

(#20)

0819107320

Pin (Gold-plated)

(#16: AWG1620)

0819107330

Pin (Gold-plated)

(#16: AWG1416)

10

0819105410

Socket (Nickel-plated)

100

11

0819105420

Socket (Nickel-plated)

50

(#16: AWG1620)

12

0819105430

Socket (Nickel-plated)

50

(#16: AWG1416)

13

0819105440

Socket (Nickel-plated)

20

(#12)

14

0819105450

Socket (Nickel-plated)

10

(#8)

15

0819105460

Socket (Nickel-plated)

10

(#4)

16

0819107410

Socket (Gold-plated)

10

(#20)

17

0819107420

Socket (Gold-plated)

(#16: AWG1620)

18

0819107430

Socket (Gold-plated)

(#16: AWG1416)

19

0819202100

Connector (Receptacle)

(DTM)

20

0819212100

Connector (Receptacle)

(DT2)

21

0819213100

Connector (Receptacle)

(DT3)

22

0819214100

Connector (Receptacle)

(DT4)

23

0819216100

Connector (Receptacle)

(DT6)

24

0819218101

Connector (Receptacle)

(DT8) Grey

25

0819218102

Connector (Receptacle)

(DT8) Black, standard

26

0819218103

Connector (Receptacle)

(DT8) Green

27

0819218104

Connector (Receptacle)

(DT8) Brown

28

0819219101

Connector (Receptacle)

(DT12) Grey

29

0819219102

Connector (Receptacle)

(DT12) Black, standard

30

0819219103

Connector (Receptacle)

(DT12) Green

31

0819219104

Connector (Receptacle)

(DT12) Brown

32

0819231100

Connector (Receptacle)

DTHD #12

33

0819241100

Connector (Receptacle)

DTHD #8

34

0819251100

Connector (Receptacle)

DTHD #4

35

0819202200

Connector (Plug)

(DTM)

36

0819212200

Connector (Plug)

(DT2)

37

0819213200

Connector (Plug)

(DT3)

38

0819214200

Connector (Plug)

(DT4)

39

0819216200

Connector (Plug)

(DT6)

40

0819218201

Connector (Plug)

(DT8) Grey

41

0819218202

Connector (Plug)

(DT8) Black, standard

(#20)

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No.

Part No.

Part name

Qty

Remarks

42

0819218203

Connector (Plug)

(DT8) Green

43

0819218204

Connector (Plug)

(DT8) Brown

44

0819219201

Connector (Plug)

(DT12) Grey

45

0819219202

Connector (Plug)

(DT12) Black, standard

46

0819219203

Connector (Plug)

(DT12) Green

47

0819219204

Connector (Plug)

(DT12) Brown

48

0819231200

Connector (Plug)

DTHD#12

49

0819241200

Connector (Plug)

DTHD#8

50

0819251200

Connector (Plug)

DTHD#4

51

0819222100

Connector (Receptacle: For AEX, AVS0.5)

(DT2)

52

0819223100

Connector (Receptacle: For AEX, AVS0.5)

(DT3)

53

0819224100

Connector (Receptacle: For AEX, AVS0.5)

(DT4)

54

0819226100

Connector (Receptacle: For AEX, AVS0.5)

(DT6)

55

0819228101

Connector (Receptacle: For AEX, AVS0.5)

(DT8) Grey

56

0819228102

Connector (Receptacle: For AEX, AVS0.5)

(DT8) Black, standard

57

0819228103

Connector (Receptacle: For AEX, AVS0.5)

(DT8) Green

58

0819228104

Connector (Receptacle: For AEX, AVS0.5)

(DT8) Brown

59

0819229101

Connector (Receptacle: For AEX, AVS0.5)

(DT12) Grey

60

0819229102

Connector (Receptacle: For AEX, AVS0.5)

(DT12) Black, standard

61

0819229103

Connector (Receptacle: For AEX, AVS0.5)

(DT12) Green

62

0819229104

Connector (Receptacle: For AEX, AVS0.5)

(DT12) Brown

63

0819222200

Connector (Plug: For AEX, AVS0.5)

(DT2)

64

0819223200

Connector (Plug: For AEX, AVS0.5)

(DT3)

65

0819224200

Connector (Plug: For AEX, AVS0.5)

(DT4)

66

0819226200

Connector (Plug: For AEX, AVS0.5)

(DT6)

67

0819228201

Connector (Plug: For AEX, AVS0.5)

(DT8) Grey

68

0819228202

Connector (Plug: For AEX, AVS0.5)

(DT8) Black, standard

69

0819228203

Connector (Plug: For AEX, AVS0.5)

(DT8) Green

70

0819228204

Connector (Plug: For AEX, AVS0.5)

(DT8) Brown

71

0819229201

Connector (Plug: For AEX, AVS0.5)

(DT12) Grey

72

0819229202

Connector (Plug: For AEX, AVS0.5)

(DT12) Black, standard

73

0819229203

Connector (Plug: For AEX, AVS0.5)

(DT12) Green

74

0819229204

Connector (Plug: For AEX, AVS0.5)

(DT12) Brown

75

0819202300

Wedge (Receptacle)

(DTM)

76

0819212300

Wedge (Receptacle)

(DT2)

77

0819213300

Wedge (Receptacle)

(DT3)

78

0819214300

Wedge (Receptacle)

(DT4)

79

0819216300

Wedge (Receptacle)

(DT6)

80

0819218300

Wedge (Receptacle)

(DT8)

81

0819219300

Wedge (Receptacle)

(DT12)

82

0819202400

Wedge (Plug)

(DTM)

83

0819212400

Wedge (Plug)

(DT2)

84

0819213400

Wedge (Plug)

(DT3)

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5-2

No.

Part No.

Part name

Qty

Remarks

85

0819214400

Wedge (Plug)

(DT4)

86

0819216400

Wedge (Plug)

(DT6)

87

0819218400

Wedge (Plug)

(DT8)

88

0819219400

Wedge (Plug)

(DT12)

89

0819100710

Sealing plug

10

(#20)

90

0819100770

Sealing plug

10

(#12, #16)

91

0819100750

Sealing plug

(#8)

92

0819100760

Sealing plug

(#4)

93

0819320012

Clamp

94

0819330012

Clamp

Applicable to 8-ways type only

95

7996017810

Tool

Terminal crimp tool

96

7996017820

Tool

HD connector pin pull-out tool

97

7996017830

Tool

HD connector pin pull-out tool

98

7996017840

Tool

HD connector pin pull-out tool

99

7996017850

Tool

HD connector pin pull-out tool

100

7996017860

Tool

HD connector pin pull-out tool

101

7996017870

Tool

HD connector pin pull-out tool

102

7996017880

Tool

DT connector pin pull-out tool

103

7996017930

Operation Manual

Repair kit (B) component list (Part No.: 790-222-4100)


No.

Part No.

Part name

Qty

Remarks

0819105310

Pin (Nickel-plated)

100

(#20)

0819105320

Pin (Nickel-plated)

50

(#16: AWG1620)

0819105330

Pin (Nickel-plated)

50

(#16: AWG1416)

0819105410

Socket (Nickel-plated)

100

0819105420

Socket (Nickel-plated)

50

(#16: AWG1620)

0819105430

Socket (Nickel-plated)

50

(#16: AWG1416)

0819202100

Connector (Receptacle)

(DTM)

0819212100

Connector (Receptacle)

(DT2)

0819213100

Connector (Receptacle)

(DT3)

10

0819214100

Connector (Receptacle)

(DT4)

11

0819216100

Connector (Receptacle)

(DT6)

12

0819202200

Connector (Plug)

(DTM)

13

0819212200

Connector (Plug)

(DT2)

14

0819213200

Connector (Plug)

(DT3)

15

0819214200

Connector (Plug)

(DT4)

16

0819216200

Connector (Plug)

(DT6)

17

0819222100

Connector (Receptacle:For AEX, AVS0.5)

(DT2)

18

0819223100

Connector (Receptacle:For AEX, AVS0.5)

(DT3)

19

0819224100

Connector (Receptacle:For AEX, AVS0.5)

(DT4)

20

0819226100

Connector (Receptacle:For AEX, AVS0.5)

(DT6)

21

0819222200

Connector (Plug:For AEX, AVS0.5)

(DT2)

22

0819223200

Connector (Plug:For AEX, AVS0.5)

(DT3)

23

0819224200

Connector (Plug:For AEX, AVS0.5)

(DT4)

(#20)

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No.

Part No.

Part name

Qty

Remarks

24

0819226200

Connector (Plug:For AEX, AVS0.5)

(DT6)

25

0819202300

Wedge (Receptacle) (For male connector)

(DTM)

26

0819212300

Wedge (Receptacle) (For male connector)

(DT2)

27

0819213300

Wedge (Receptacle) (For male connector)

(DT3)

28

0819214300

Wedge (Receptacle) (For male connector)

(DT4)

29

0819216300

Wedge (Receptacle) (For male connector)

(DT6)

30

0819202400

Wedge (Plug) (For female connector)

(DTM)

31

0819212400

Wedge (Plug) (For female connector)

(DT2)

32

0819213400

Wedge (Plug) (For female connector)

(DT3)

33

0819214400

Wedge (Plug) (For female connector)

(DT4)

34

0819216400

Wedge (Plug) (For female connector)

(DT6)

35

0819100710

Sealing plug

10

(#20)

36

0819100770

Sealing plug

10

(#12, #16)

37

0819320012

Clamp

38

7996017810

Tool

Terminal crimp tool

39

7996017820

Tool

To pull out HD connector terminal

40

7996017830

Tool

To pull out HD connector terminal

41

7996017840

Tool

To pull out HD connector terminal

42

7996017850

Tool

To pull out HD connector terminal

43

7996017860

Tool

To pull out HD connector terminal

44

7996017870

Tool

To pull out HD connector terminal

45

7996017880

Tool

To pull out DT connector pin

46

7996017930

Operation Manual

6. REPLACEMENT OF CONNECTORS AND TERMINALS


(Reference: The connector attached at the power supply side is usually a socket (socket
contact)).

6-1
6-1-1

Pulling out and fitting in the DT connector terminal


Tools required

1) Tool to pull out a terminal (X1): 799-601-7880


This tool is used to pull out the terminal and wedge of DT and DTM connectors.

2) Needle nose pliers (general tool), tweezers, etc.

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6-1-2 Pulling out the terminal
1) By using a pair of needle nose pliers, tweezers, or a pull-out tool, pull out the wedge
(1).

2) Find the contact fixing lug (2) in the connector. While pulling it out with a pull-out tool
or a pair of tweezers, slightly pull out the
electric wire to release the fixing lug.

3) While holding the shielding rubber (3), pull


out the electric wire (4).
When it is very difficult to pull it out, retry
the Step 2).

6-1-3 Fitting in the terminal


1) Pick up the caulked part of the terminal and
fit it into the hole.
 Fit it in straight until you hear a click.
 Push it in until you hear a click (which
occurs when the contact passes by the
fixing lug) and you feel that the contact
touches the back wall.
 Slightly pull the electric wire in the pullout direction to check that the contact on
the electric wires end is not detached.

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If the electric wire bends when you try


fitting it in and therefore, it cannot go in,
attach a tool of Part No. 799-601-7830
or -7840 on the terminals back-end and
then, fit it in.

7996017830, 7840

2) After fitting in all electric wires, mount the


wedge (1).

When mounting the wedge to a 2-ways


connector, refer to the figure to the right.

Fit this side of


the wedge in
the connector.

When mounting the wedge to a 3-ways pin


connector, place the wedge with its arrow
designation toward the fitting part of the
connector housing, and then, mount it.

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6-2
6-2-1

Pulling out and fitting in the HD30 connector terminal


Tools required
Pin/socket pull-out tool
No.

Part No. of tool

7996017820

0819105310
0819107310

0819105410
0819107410

White or Red

7996017830

0819105320
0819107320

0819105420
0819107420

Light blue

7996017840

0819105330
0819107330

0819105330
0819107430

Blue

7996017850

0819105340

0819105440

Yellow

7996017860

0819105350

0819105450

Green

7996017870

0819105360

0819105460

White

Part No. of pin terminal Part No. of socket terminal Tool color

6-2-2 Pulling out the terminal


1) In case of the HD30 Series, the sizes of pins and sockets to use are different depending on
the connector type. Choose an appropriate pull-out tool in accordance with the table below.
Nominal No.
Electric wire
of connector size or Pin No.

Part No. of pull-out tool

Part No. given by


manufacture
(Given on actual tool)

Tool color

188

2, 3

7996017850

114010

1814

0.5

7996017830

04113101605

Light blue

0.85, 1.25

7996017840

04112041605

Blue

0.5

7996017820

04112402005

White or Red

0.85, 1.25

7996017840

04112041605

Blue

1821

0.5

7996017820

04112402005

White or Red

249

15

7996017870

114009

White

7996017860

114008

Green

2, 3

7996017850

114010

Yellow

2416

2, 3

7996017850

114010

Yellow

2421

2, 3

7996017850

114010

Yellow

0.5

7996017830

04113101605

Light blue

0.85, 1.25

7996017840

04112041605

Blue

0.5

7996017830

04113101605

Light blue

0.85, 1.25

7996017840

04112041605

Blue

0.5

7996017830

04113101605

Light blue

0.85, 1.25

7996017840

04112041605

Blue

1820

2423
2431

Yellow

SEKN5003
15 of 23
2) Attach the chosen pull-out tool (X1) to the
electric wire of pin and socket you will remove.
 Do not use a metallic screwdriver; it
damages a shielding rubber.

X1

3) Slide the pull-out tool into a clearance between the electric wire and the connector
shielding rubber, and then, push it in as far
as it will go. (Be sure not to push it in
forcedly to prevent the tool from being damaged.)
4) Pull out the electric wire with the pull-out
tool.

6-2-3 Fitting in the terminal


1) Grasp wire behind the contact barrel.
2) Fit the terminal into the hole and push it in
until you hear a click.


Push it in until you hear a click (which occurs when the contact passes by the fixing
lug) and you feel that the contact touches
the back wall.
If the electric wire bends when you try fitting
it in and therefore, it cannot go in, attach a
tool of Part No. 799-601-7830 or -7840 to
the terminals back-end and then, fit it in.

3) Slightly pull the electric wire in the pull-out


direction to check that the contact on the
electric wires end is not detached.

7996017830, 7840

SEKN5003
16 of 23

7. CRIMP OF TERMINAL
7-1

Tools required
Universal hand crimp tool (X2): 799-601-7810
Stripper (General tool: To strip the insulation from wire)

Universal hand crimp tool: 7996017810

7-2

Selecting pin and socket terminals

When replacing pin and socket terminals, be sure to use same types as ones previously used.
If you are confused about which ones to use, refer to 4-2.

7-3

Crimping the terminal

1) By using a stripper, strip insulation from wire.


Regarding a removing distance, refer to the
table below.
Part No.

Removing Knobs
distance set value
(mm)

Pin terminal

Socket
terminal

0819105310
0819107310

0819105410
0819107410

0819105320
0819107320

0819105420
0819107420

0819105330
0819107330

0819105430
0819107420

0819105340

0819105440

Pin terminal

Electric wire

This crimp tool is a hand tool and therefore, you can


use it for the terminals described above. Regarding
thicker terminals, you need a power tool for a manufacturer.
To check if the striped insulation distance is correct,
fit the electric wire into the terminal and look through
the hole on the terminal side surface. If you can see
the strand wire through it and also the end face of
the insulation touches the end face of the terminal,
the distance is correct.

The strand wire


should be seen
through the hole on
the terminal side
surface.

The end face of the


insulation should
touch the end face
of the terminal.

SEKN5003
17 of 23
2) Remove the pin (1) of Universal Hand Crimp
Tool.

3) Referring to the Table in the Step 1), pull up the


knob (2) and rotate it to an appropriate set value.

4) Loosen the lock nut (3) and rotate the adjustment screw (4).
5) Fit the terminal in the Universal Hand Crimp
Tool.
6) Rotate the adjustment screw until the top-end of
the terminal is aligned with the top-end of the
tool hole. Then, tighten the lock nut.
7) Fit




the electric wire (6) in the terminal.


Do not twist the wire strand.
Solder should not be added.
Be careful the wire strands not entering the
contact barrel.

8) Grip the handle and crimp the contact.


 When you operate the handle up to the
stroke end, the handle opens.

Rotate the adjustment screw with the


terminal pressed in.

SEKN5003
18 of 23

8. REPLACEMENT OF MACHINE-MOUNTED CONNECTORS


WITH DEUTSCH CONNECTORS
This section describes how to replace a 2-ways X connector to a 2-ways DT connector.
1) Disconnecting the mounted connector
By using a nipper or a pair of needle nose pliers, cut the electric wire off the connector.

2) Strip insulation of wire 7mm.


(Use a commercially available tool.)

3) Adjust the knob of the universal hand crimp tool


to 5.
Depending on the Part No. of a terminal to use,
the appropriate set value is different.
For more information, refer to 7-3, 1).

4) Fit the terminal into the hole of the universal


hand crimp tool and loosen the lock nut (3).
After that, rotate the adjustment screw (4).
5) Rotate the adjustment screw until the top-end of
the terminal is aligned with the top-end of the
hole of the tool. After that, tighten the lock nut.

4
3
Rotate the adjustment screw with
the terminal pressed in.

SEKN5003
19 of 23
6) Set the terminal on the universal hand crimp tool
and fit the electric wire into the terminal.
 Do not twist the strand wire.
7) Grip the handle and caulk the contact.
 When you operate the handle up to the
stroke end, the handle opens.

8) Attach the terminal to a new connector.


9) One all contacts are in place, insert the wedge.
The wedge will snap into place.

10) Replace both the male and female connectors


with new ones and attach the clamp

11) Fit the connector into the clamp.

Clamp

SEKN5003
20 of 23

9. PART NO. LIST OF HD30 CONNECTOR BODY


9-1

Part No. List of HD30 Connector Body (Without adaptor)


No.

Part No.

0819113101

Receptacle: Pin (Male)

Remarks
Normal type

188

0819114101

Receptacle: Socket (Female)

Normal type

188

0819113105

Receptacle: Pin (Male)

Extra-Thin type

188

0819114105

Receptacle: Socket (Female)

Extra-Thin type

188

0819112201

Plug: Socket (Female)

Normal type

188

0819111201

Plug: Pin (Male)

Normal type

188

0819112205

Plug: Socket (Female)

Extra-Thin type

188

0819111205

Plug: Pin (Male)

Extra-Thin type

188

0819123101

Receptacle: Pin (Male)

Normal type

1814

10

0819124101

Receptacle: Socket (Female)

Normal type

1814

11

0819123105

Receptacle: Pin (Male)

Extra-Thin type

1814

12

0819124105

Receptacle: Socket (Female)

Extra-Thin type

1814

13

0819122201

Plug: Socket (Female)

Normal type

1814

14

0819121201

Plug: Pin (Male)

Normal type

1814

15

0819122205

Plug: Socket (Female)

Extra-Thin type

1814

16

0819121205

Plug: Pin (Male)

Extra-Thin type

1814

17

0819133101

Receptacle: Pin (Male)

Normal type

1820

18

0819134101

Receptacle: Socket (Female)

Normal type

1820

19

0819132201

Plug: Socket (Female)

Normal type

1820

20

0819131201

Plug: Pin (Male)

Normal type

1820

21

0819143101

Receptacle: Pin (Male)

Normal type

1821

22

0819144101

Receptacle: Socket (Female)

Normal type

1821

23

0819142201

Plug: Socket (Female)

Normal type

1821

24

0819141201

Plug: Pin (Male)

Normal type

1821

25

0819153101

Receptacle: Pin (Male)

Normal type

249

26

0819154101

Receptacle: Socket (Female)

Normal type

249

27

0819152201

Plug: Socket (Female)

Normal type

249

28

0819151201

Plug: Pin (Male)

Normal type

249

29

0819163101

Receptacle: Pin (Male)

Normal type

2416

30

0819164101

Receptacle: Socket (Female)

Normal type

2416

31

0819163105

Receptacle: Pin (Male)

Extra-Thin type

2416

32

0819164105

Receptacle: Socket (Female)

Extra-Thin type

2416

33

0819162201

Plug: Socket (Female)

Normal type

2416

34

0819161201

Plug: Pin (Male)

Normal type

2416

35

0819162205

Plug: Socket (Female)

Extra-Thin type

2416

36

0819161205

Plug: Pin (Male)

Extra-Thin type

2416

37

0819173101

Receptacle: Pin (Male)

Normal type

2421

38

0819174101

Receptacle: Socket (Female)

Normal type

2421

39

0819173105

Receptacle: Pin (Male)

Extra-Thin type

2421

40

0819174105

Receptacle: Socket (Female)

Extra-Thin type

2421

41

0819172201

Plug: Socket (Female)

Normal type

2421

42

0819171201

Plug: Pin (Male)

Normal type

2421

43

0819172205

Plug: Socket (Female)

Extra-Thin type

2421

44

0819171205

Plug: Pin (Male)

Extra-Thin type

2421

45

0819183101

Receptacle: Pin (Male)

Normal type

2423

46

0819184101

Receptacle: Socket (Female)

Normal type

2423

SEKN5003
21 of 23

9-2

No.

Part No.

Remarks

47

0819183103

Receptacle: Pin (Male)

Thin type

2423

48

0819184103

Receptacle: Socket (Female)

Thin type

2423

49

0819183105

Receptacle: Pin (Male)

Extra-Thin type

2423

50

0819184105

Receptacle: Socket (Female)

Extra-Thin type

2423

51

0819182201

Plug: Socket (Female)

Normal type

2423

52

0819181201

Plug: Pin (Male)

Normal type

2423

53

0819182203

Plug: Socket (Female)

Thin type

2423

54

0819181203

Plug: Pin (Male)

Thin type

2423

55

0819182205

Plug: Socket (Female)

Extra-Thin type

2423

56

0819181205

Plug: Pin (Male)

Extra-Thin type

2423

57

0819193103

Receptacle: Pin (Male)

Thin type

2431

58

0819194103

Receptacle: Socket (Female)

Thin type

2431

59

0819193105

Receptacle: Pin (Male)

Extra-Thin type

2431

60

0819194105

Receptacle: Socket (Female)

Extra-Thin type

2431

61

0819192203

Plug: Socket (Female)

Thin type

2431

62

0819191203

Plug: Pin (Male)

Thin type

2431

63

0819192205

Plug: Socket (Female)

Extra-Thin type

2431

64

0819191205

Plug: Pin (Male)

Extra-Thin type

2431

Part No. List of HD30 Connector Body (With adaptor)


No.

Part No.

Remarks

0819113102

Receptacle: Pin (Male)

Normal type

188

0819114102

Receptacle: Socket (Female)

Normal type

188

0819113106

Receptacle: Pin (Male)

Extra-Thin type

188

0819114106

Receptacle: Socket (Female)

Extra-Thin type

188

0819112202

Plug: Socket (Female)

Normal type

188

0819111202

Plug: Pin (Male)

Normal type

188

0819112206

Plug: Socket (Female)

Extra-Thin type

188

0819111206

Plug: Pin (Male)

Extra-Thin type

188

0819123102

Receptacle: Pin (Male)

Normal type

1814

10

0819124102

Receptacle: Socket (Female)

Normal type

1814

11

0819123106

Receptacle: Pin (Male)

Extra-Thin type

1814

12

0819124106

Receptacle: Socket (Female)

Extra-Thin type

1814

13

0819122202

Plug: Socket (Female)

Normal type

1814

14

0819121202

Plug: Pin (Male)

Normal type

1814

15

0819122206

Plug: Socket (Female)

Extra-Thin type

1814

16

0819121206

Plug: Pin (Male)

Extra-Thin type

1814

17

0819133102

Receptacle: Pin (Male)

Normal type

1820

18

0819134102

Receptacle: Socket (Female)

Normal type

1820

19

0819132202

Plug: Socket (Female)

Normal type

1820

20

0819131202

Plug: Pin (Male)

Normal type

1820

21

0819143102

Receptacle: Pin (Male)

Normal type

1821

22

0819144102

Receptacle: Socket (Female)

Normal type

1821

23

0819142202

Plug: Socket (Female)

Normal type

1821

24

0819141202

Plug: Pin (Male)

Normal type

1821

25

0819153102

Receptacle: Pin (Male)

Normal type

249

26

0819154102

Receptacle: Socket (Female)

Normal type

249

SEKN5003
22 of 23

9-3

No.

Part No.

Remarks

27

0819152202

Plug: Socket (Female)

Normal type

249

28

0819151202

Plug: Pin (Male)

Normal type

249

29

0819163102

Receptacle: Pin (Male)

Normal type

2416

30

0819164102

Receptacle: Socket (Female)

Normal type

2416

31

0819163106

Receptacle: Pin (Male)

Extra-Thin type

2416

32

0819164106

Receptacle: Socket (Female)

Extra-Thin type

2416

33

0819162202

Plug: Socket (Female)

Normal type

2416

34

0819161202

Plug: Pin (Male)

Normal type

2416

35

0819162206

Plug: Socket (Female)

Extra-Thin type

2416

36

0819161206

Plug: Pin (Male)

Extra-Thin type

2416

37

0819173102

Receptacle: Pin (Male)

Normal type

2421

38

0819174102

Receptacle: Socket (Female)

Normal type

2421

39

0819173106

Receptacle: Pin (Male)

Extra-Thin type

2421

40

0819174106

Receptacle: Socket (Female)

Extra-Thin type

2421

41

0819172202

Plug: Socket (Female)

Normal type

2421

42

0819171202

Plug: Pin (Male)

Normal type

2421

43

0819172206

Plug: Socket (Female)

Extra-Thin type

2421

44

0819171206

Plug: Pin (Male)

Extra-Thin type

2421

45

0819183102

Receptacle: Pin (Male)

Normal type

2423

46

0819184102

Receptacle: Socket (Female)

Normal type

2423

47

0819183104

Receptacle: Pin (Male)

Thin type

2423

48

0819184104

Receptacle: Socket (Female)

Thin type

2423

49

0819183106

Receptacle: Pin (Male)

Extra-Thin type

2423

50

0819184106

Receptacle: Socket (Female)

Extra-Thin type

2423

51

0819182202

Plug: Socket (Female)

Normal type

2423

52

0819181202

Plug: Pin (Male)

Normal type

2423

53

0819182204

Plug: Socket (Female)

Thin type

2423

54

0819181204

Plug: Pin (Male)

Thin type

2423

55

0819182206

Plug: Socket (Female)

Extra-Thin type

2423

56

0819181206

Plug: Pin (Male)

Extra-Thin type

2423

57

0819193104

Receptacle: Pin (Male)

Thin type

2431

58

0819194104

Receptacle: Socket (Female)

Thin type

2431

59

0819193106

Receptacle: Pin (Male)

Extra-Thin type

2431

60

0819194106

Receptacle: Socket (Female)

Extra-Thin type

2431

61

0819192204

Plug: Socket (Female)

Thin type

2431

62

0819191204

Plug: Pin (Male)

Thin type

2431

63

0819192206

Plug: Socket (Female)

Extra-Thin type

2431

64

0819191206

Plug: Pin (Male)

Extra-Thin type

2431

Connector mounting nut and washer


No.

Part No.

Remarks

0819110808

Nut for connectors 188, 1814, 1820, and 1821


(Tightening torque: 4.8kgcm)

0819150808

Nut for connectors 249, 2416, 2421, 2423 and 2431


(Tightening torque: 6.5kgcm)

0819110809

Washer for connectors 188, 1814, 1820, and 1821

0819150809

Washer for connectors 249, 2416, 2421, 2423, and 2431

SEKN5003
23 of 23

May 2000
Customer Support Division