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Electronics Troubleshooting ILT

Connectors
Module 3 - TEXT REFERENCE

SERV1877

Electronics Troubleshooting ILT

Module 3 - Connectors
Text Reference

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© 2010 Caterpillar Inc.

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The purpose of a connector is to pass current from one wire to another. In order to
accomplish this, the connector must have two mating halves (plug or receptacle).
One half houses a pin and the other half houses a socket. When the two halves are
joined, current is allowed to pass.

With the increased use of electronic systems on Cat machines, servicing connectors
has become a critical task. With increased usage comes an increase in maintenance
on the wiring, connectors, pins, and sockets. Another important factor contributing
to increased repair is the harsh environment in which the connectors operate.
Connectors must operate in extremes of heat, cold, dirt, dust, moisture, chemicals,
etc.

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CONNECTORS
No Asperity Asperity
Pin Contacts Socket Contact No Contact

Condition of Asperity

Contact No Contact

Electrons
Converging
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Pins and sockets have resistance and offer some opposition to current flow. Since
the surface of the pins and sockets are not smooth (contain peaks and valleys), a
condition known as asperity (roughness of surface) exists. When the mating halves
are connected, approximately one percent of the surfaces actually contact each
other.

The electrons are forced to converge at the peaks, thereby creating a resistance
between the contact halves. Although this process seems rather insignificant to the
operation of an electronic control, a resistance across the connector could create a
malfunction in electronic controls.

In order to achieve a minimum resistance in the pins and contacts, we need to be

concerned with the finish, pressure, and metal used in the construction of the pins
and contacts. Tin is soft enough to allow for “film wiping”, but it has high resistivity.
Copper has low resistivity, but it is hard. So in striving for minimum resistance and
the reduction of asperity, low resistance copper contacts are often plated with tin.

Film wiping occurs when pins and contacts are plated with tin, and when they are
mated together, they have a tendency to “wipe” together and actually smooth out
some of the peaks and valleys created by the asperity condition. Other metals, such
as gold and silver, are excellent plating materials, but are too costly to use.

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Inform the participants that
connector service procedures can
be found in the appropriate Special
Instruction.
Show Video SEVN3197 (Basic Wire
Maintenance) if time allows.
-4- Module 3 - Connectors
Contaminants
Contaminants are another factor that contribute to resistance in connectors. Some
harsh conditions that employ chemicals, etc. can cause malfunctions due to increased
resistance.
NOTE: Connectors can and do cause many diagnostic problems. It may
be necessary to measure the resistance between connector halves when
diagnosing electronic control malfunctions. Also, disconnecting and reconnecting
connectors during the troubleshooting process can give misleading diagnostic
information. Additionally, use breakout cables sparingly when troubleshooting
intermittent electrical problems.
Types of Connectors
Several types of connectors are used throughout the electrical and electronic systems
on Cat machines. Each type differs in the manner in which they are serviced or
repaired.
The following types of connectors will be discussed in detail:
• Vehicular Environmental (VE) Connectors
• Sure Seal Connectors
• Deutsch Connectors (HD10, DT, CE, and DRC Series)
• Ampseal Connectors
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VE Connectors

• VE stands for Vehicular The VE connector was used primarily on earlier Cat machine electrical harnesses
Enviornments where high temperatures, larger number of contacts, or higher current carrying
capacities were needed.

The connector required a special metal release tool for removing the contacts that
could damage the connector lock mechanism if the tool was turned during release
of the retaining clip.

NOTE: The metal release tools for this connector are no longer available as
they have been replaced with plastic release tools. Metal release tools (listed
in SEHS8038) may still be used if you have them, but may not be used for any
other type of electrical connector.

Specific information relating to the process required for installing VE connector

contacts (pins and sockets) is contained in Special Instruction--Use of VE Connector
Tool Group (Form SEHS8038).

This type of connector is no longer used on current product, but may still require
servicing by a field/shop technician.

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• Typically found on Machines
• Up to 10 contacts (wires)
• Require the use of a special tool
6V3008 for installing contacts
• Each end includes BOTH pins
and sockets
• Different style pins and sockets
(open barrel type)
• Part numbers contained in
Special Instruction--Use of
6V3000 Sure Seal Repair Kit
(Form SMHS7531)
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Sure Seal Connectors
Sure Seal connectors used to be used extensively on Cat machines. These connector
housings have provisions for accurately mating between the two halves, but instead
of using guide keys or keyways, the connector bodies are molded such that they will
not mate incorrectly.
Sure Seal Connectors are limited to a capacity of 10 contacts (pins and sockets).
NOTE: Part numbers for spare plug and receptacle housings and contacts are
contained in Special Instruction–Use of 6V3000 Sure Seal Repair Kit (Form
SMHS7531).
Use special tool (6V3001) for crimping contacts and stripping wires.
Sure Seal Connectors require the use of a special tool 6V3008 for installing contacts.
Use denatured alcohol as a lubricant when installing contacts. Special tooling is not
required for removing pin contacts.
Any holes in the housings not used for contact assemblies should be filled with a
9G3695 Sealing Plug. The sealing plug will help prevent moisture from entering the
housings.
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• Cylindrical connector
• 3-, 5-, 6-, 9-pin models available
• Typically used for datalink wires
(9 pin)
• Plug has sockets, Receptacle
has pins
• Disassemble with Wire Removal
Tool
• Repair kit: 190-8900
• Deutsch Crimp Tool, P/N 1U5805
• No soldering
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Deutsch Heavy Duty (HD10) Series Connectors
The HD10 connector is a thermoplastic cylindrical connector utilizing crimp-type
contacts that are quickly and easily removed. The thermoplastic shells are available
in non-threaded and threaded configurations using insert arrangements of 3, 5, 6,
and 9 contacts. The contact size is #16 and accepts #14, #16, and #18 AWG wire.
The HD10 uses crimp-type, solid copper alloy contacts (size #16) that feature an ability
to carry continuous high operating current loads without overheating. The contacts
are crimp terminated using a Deutsch Crimp Tool, Cat part number 1U5805.
Deutsch termination procedures recommend NO SOLDERING after properly crimped
contacts are completed.
The procedure for preparing a wire and crimping a contact is the same for all
Deutsch connectors and is explained in Special Instruction–Servicing DT Connectors
(SEHS9615). The removal procedure differs from connector to connector and will be
explained in each section.
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• 2-, 3-, 4-, 6-, 8-, 12-pin
configuration
• Typically used on engine and
machine harnesses/sensors
• Receptacles have pins, Plugs
have sockets
• Each end has wedges that must
be in place
• Repair kit: 175-3700
• Deutsch Crimp Tool, P/N 1U5805
• No soldering
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Deutsch Transportation (DT) Series Connectors
The DT connector is a thermoplastic connector utilizing crimp-type contacts that are
quickly and easily removed and require no special tooling. The thermoplastic
housings are available in configurations using insert arrangements of 2, 3, 4, 6, 8,
and 12 contacts. The contact size is #16 and accepts #14, #16, and #18 AWG
wire.
The DT uses crimp-type, solid copper alloy contacts (size #16) that feature an ability
to carry continuous high operating current loads without overheating. Stamped
and formed contacts are usually used during manufacturing and initial assembly
of harnesses using DT connectors. The crimp-type contacts are crimped using a
Deutsch Crimp Tool, Cat part number 1U5804.
The DT connector differs from other Deutsch connectors in both appearance
and construction. The DT is either rectangular or triangular shaped and contains
serviceable plug wedges, receptacle wedges, and silicone seals.
The recommended cleaning solvent for all Deutsch contacts is denatured alcohol.
NOTE: For a more detailed explanation on servicing the DT connector, consult
Special Instruction–Servicing DT Connectors (SEHS9615).
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Cat Environmental Connectors (CE)

The CE connector is a special application connector. The CE Series connector can

accommodate between 7 and 37 contacts, with the 37 contact connector being used
on various electronic control modules.

The CE connector uses two different crimping tools. The crimping tool for #4 - #10
size contacts is a 4C4075 Hand Crimp Tool Assembly. The tool for #12 - #18 contacts
is the same tool as used on the HD and DT Series connectors (1U5804).

NOTE: For a more detailed explanation on servicing the CE connectors, refer to

Special Instruction–Use of CE/VE Connector Tools (SEHS9065).

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• Rectangular thermoplastic
housing
• 24-, 40-, 70-pin models available
• Typically used on ADEM 2 ECMs
• Keyed for proper orientation
• Plug has sockets, Receptacle
has pins
• No soldering
• Disassemble with Wire Removal
Tool
• Deutsch Crimp Tool, P/N 1U5805
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Deutsch Rectangular Connector (DRC)
The DRC connector features a rectangular thermoplastic housing and is completely
environmentally sealed. The DRC is best suited for use with external and internal
electronic control modules.
The connector is designed with a higher number of terminals. The insert arrangements
available are 24, 40, and 70 contact terminations. The contact size is #16 and
accepts #16 and #18 AWG wire.
The connector uses crimp-type, copper alloy contacts (size #16) that feature an
ability to carry continuous high operating current loads without overheating. Stamped
and formed contacts are usually used during manufacturing and initial assembly of
harnesses using DRC connectors. The crimp-type contacts are crimped using a
Deutsch Crimp Tool, Cat part number 1U5804.
The connector contains a “clocking” key for correct orientation and is properly
secured by a stainless steel jackscrew. A 4 mm (5/32 in.) HEX key is required to
mate the connector halves. The recommended torque for tightening the jackscrew
is 25 inch pounds.
NOTE: The DRC uses the same installation and removal procedures as the
HD10 series.
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• Newer style. Highway Truck
started using in 2006
• Used same pin/sockets as
Deutsch
• 2-, 3-, 4-, 6-, 8-, 12-pin models
available
• Connector Position Assurance
(CPA) and Terminal Position
Assurance (TPA)
• Plug has sockets, Receptacle
has pins
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Ampseal 16 Connector
The Ampseal connector features a thermoplastic housing with silicone rubber seals,
ensuring an environmentally sealed connection that is able to withstand harsh, wet
conditions. Three color coded styles, each with a unique key pattern, ensure
successful mating of the connectors.
Plug and receptacle assemblies feature a color coded terminal position assurance
(TPA) cover that locks the pins or sockets in place. The TPAs are keyed according
to their respective color code:
• Red: Key 1
• Gray: Key 2
• Yellow: Key 3
• Green: Key 4
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• Repair kit: 270-5051
• Deutsch Crimp Tool, P/N 1U5805
• No soldering
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Plug assemblies also feature a connector position assurance (CPA) lock that prevents
the unintended separation of plug and receptacle connections.
The connector is designed for a maximum of 12 pins. Connector arrangements are
available in 2-, 3-, 4-, 6-, 8-, and 12-pin versions. Connectors accept #14, #16, and
#18 AWG wire. The contacts are crimp terminated using a Deutsch Crimp Tool, Cat
part number 1U5804.
NOTE: Plug and receptacles will only accept wires with a specific range of
insulation diameters. Although contacts will accept other gauge wires with a
wider range of insulation diameters, only #14, #16, and #18 AWG wires with
recommended insulation diameters should be used. See REHS2556 for more
information regarding recommended insulation diameters, as well as a more
detailed explanation of servicing Ampseal connectors.
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• Stress that in Deutsch
connectors, the plugs get
sockets only and the receptacles
get pins only.
• In Sure Seal connectors, plugs
and receptacles each have both
pins and sockets.
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1 2
3 4
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Connector Schematic Symbol
The illustration above shows a typical schematic symbol of a connector. It is important
to understand what each part of this symbol represents in order to properly identify
connectors and related components.
• 1- Receptacle
• 2- Plug
• 3 - Pin
• 4- Socket
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