Servicing Deutsch HD and DT Style Connectors (1408) : Tool Operating Manual

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Tool Operating Manual
Servicing Deutsch HD and DT style connectors{1408}
Media Number -SEHS9615-03 Publication Date -01/10/2001 Date Updated -20/07/2004

SEHS96150001
Servicing Deutsch HD and DT style connectors{1408}

SMCS - 1408
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
(1) And HD
(2) Style Connectors.
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.
https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 7/31/2014

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.
(1) Green Plug Wedge.
(2) Green Receptacle Wedge.
(3) Black Plug Housing.
(4) Black Receptacle Housing.
(5) Plug Seal.
(6) Gold Pin Terminal.
(7) Sealing Plug.

Illustration 5. Current HD Style Connector Nomenclature.
(1) Gray Plug Housing.
(2) Gray Receptacle Housing.

Illustration 6. Service Tools.
(1) 147-6456 Wedge Removal Tool.
(2) 151-6320 Pin/Socket Removal Tool.
(3) 1U-5804 Crimp Tool.
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.
(1) Black (BL) Plug Mated With Gray (GY) Receptacle.
(2) Gray (GY) Plug Mated With Gray (GY) Receptacle.
(3) Black (BL) Plug Mated With Black (BL) Receptacle.
(4) Gray (GY) Plug Mated With Black (BL) Receptacle. Green Wedge (GR) And Orange Wedge (OR).
Receptacle

Illustration 8. Receptacle Color Combinations.
(1) Gray Body With Orange Wedge.
(2) Gray Body With Green Wedge.
(3) Black Body with Orange Wedge.
(4) Black Body With Green Wedge.
Plug

Illustration 9. Plug Color Combinations.
(1) Black (BL) Body With Green (GR) Wedge.
(2) Gray (GY) Body With Orange (OR) Wedge.
Connector Unmating
No tools are required to unmate DT or HD style connectors.
NOTICE
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
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
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.
(N) Crimp Barrel Length.
(M) Inspection Hole.
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.
(G) Wire Selector Gauge.
(H) Lock Clip.
(J) Selector Knob.
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.
(K) Locknut.
(L) Adjusting Screw.
4. Loosen locknut (K) and turn adjusting screw (L) in until it stops.

Illustration 22. Insert Terminal (6) Into Crimping Tool.
(K) Locknut.
(L) Adjusting Screw.
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
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.
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.
(1) Alignment Marks.
For information on service tools or shop supplies, contact Caterpillar Service Technology Group on:
Caterpillar Service Technology

501 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 Technology

Caterpillar 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)
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Servicing Deutsch HD and DT Style Connectors (1408) : Tool Operating Manual

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Media Search - SEHS9615 - Servicing Deutsch HD and DT style connectors{1408} Page 1 of 16

Servicing Deutsch HD and DT style connectors{1408}

DT Style Connector Compatibility

Acceptable Color Combinations

HD Style Terminal Removal

Terminal Crimp Procedure

Caterpillar Service Technology

Caterpillar Service Technology

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