Professional Documents
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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
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.
Serviceable Parts
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Service Kits
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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.
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.
(4) Gray (GY) Plug Mated With Black (BL) Receptacle. Green Wedge (GR) And Orange Wedge (OR).
Receptacle
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Plug
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).
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.
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NOTICE
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.
NOTICE
When removing the wedge, insert the removal tool along the
side of the wedge, not the corners, which could cause damage
Receptacle Housing
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.
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 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.
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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).
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:
b. Raise selector knob (J) and rotate it until the arrow is aligned with the wire size to be crimped.
4. Loosen locknut (K) and turn adjusting screw (L) in until it stops.
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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).
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.
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.
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Connector Cleaning
Connectors that have been unmated for service purposes must be cleaned before reconnecting.
NOTICE
The interior mating surfaces of the connector (i.e. terminals, seals, and insulators) should be cleaned using a cotton swab and denatured alcohol.
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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
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.
For information on service tools or shop supplies, contact Caterpillar Service Technology Group on:
1-800-542-8665 (USA)
1-800-541-8665 (Illinois)
1-800-523-8665 (Canada)
404435 (Telex)
1-309-675-6650 (Fax)
or
Switzerland
PSP-000501D1
2022/04/25
21:05:00+10:00
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SEHS96150001
© 2022 Caterpillar Inc.
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