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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 ofcurrent electric connectors like X and SWP connectors.As compared with conventional connectors, new ones are provided with higher reliability, water-proof capability, electrical property, and other performance. By using them, you can easily repairharnesses like replacement of connectors or terminals. On some of our models, they are alreadyused. Komatsu will adopt them to future models to be introduced onto the market. By using theserepair kits, you can replace the current connectors with new ones.

1. FEATURES OF NEW CONNECTORS1) 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 rubbertogether with the terminal.

� The terminal has no protrusion, not damag-ing the shielding rubber when attaching anddetaching.

5) Durability of the terminal was improved.� The terminal is nickel-plated, improving the

durability when connecting and disconnect-ing the connectors.

� The contact part of the terminal is providedwith high precision, not allowing poor con-tact to occur.

2. BASIC PERFORMANCEParticularly, the waterproof capability was im-proved, increasing reliability.

Working temperature: –55 to 125°C(X connector: –50 to 120°C)

Waterproof capability:No water enters even if it is put one meter belowwater surface for four hours. No water enters evenif water of 8 to 10 megapascal is sprayed on theconnector from a position 100mm away.(X connector: Spray test level)

DT connector

HD30 connector

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— Contents —Page

1. Features of New Connectors ......................................................................... 1

2. Basic Performance ........................................................................................ 1

3. General Description of Connector ................................................................. 33-1 DT connector ............................................................................................... 33-2 HD30 connector ........................................................................................... 33-3 Pin Number Arrangement .......................................................................... 43-3-1 Pin Number Arrangement of DT connector .............................................. 43-3-2 Insert Arrangement of HD30 connector (Viewed from the pin terminal) .. 5

4. General Description of Kit .............................................................................. 64-1 Outline of the kits ......................................................................................... 64-1-1 Repair kit (A) ............................................................................................ 64-1-2 Repair kit (B) ............................................................................................ 64-2 Types and identification of pins and sockets <Reference> ......................... 74-2-1 Pin terminal .............................................................................................. 74-2-2 Socket terminal ........................................................................................ 74-2-3 Identifying sealing plug ............................................................................. 7

5. List of Repair Kit Components ..................................................................... 85-1 Repair kit (A) component list (Part No.: 790-222-4000) .............................. 85-2 Repair kit (B) component list (Part No.: 790-222-4100) ............................ 10

6. Replacement of Connectors and Terminals ................................................ 116-1 Pulling out and fitting in the DT connector terminal .................................... 116-1-1 Tools required .......................................................................................... 116-1-2 Pulling out the terminal ........................................................................... 126-1-3 Fitting in the terminal .............................................................................. 126-2 Pulling out and fitting in the HD30 connector terminal .............................. 146-2-1 Tools required ......................................................................................... 146-2-2 Pulling out the terminal ........................................................................... 146-2-3 Fitting in the terminal .............................................................................. 15

7. Crimp of Terminal ........................................................................................ 167-1 Tools required ............................................................................................ 167-2 Selecting pin and socket terminals ............................................................ 167-3 Crimping the terminal ................................................................................ 16

8. Replacement of machine-mounted connectorswith DEUTSCH connectors ........................................................................... 18

9. Part No. List of HD30 Connector Body ........................................................ 209-1 Part No. List of HD30 Connector Body (Without adaptor) ......................... 209-2 Part No. List of HD30 Connector Body (With adaptor) .............................. 219-3 Connector mounting nut and washer ........................................................ 22

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Pin contact

or

Socket contact

Socket contact

or

Pin contact

Sealing plug

3. GENERAL DESCRIPTION OF CONNECTOR3-1 DT connectorAs DT connectors, DT2-, 3-, 4-, 6-, 8-, and 12-ways types and DTHD 1-ways and DTM 2-waystypes are provided. Regarding the DTHD connector, three types are available depending on thesize of electric wire to be connected, each of which is given a different Part No.

<Configuration of DT connector>

3-2 HD30 connectorTwo sizes of connectors (shell size: 18 and 24) and also connectors with different nine pinconfigurations are provided. This type connector is mountable on a housing of either the pin orsocket terminal type. (The housing Part No. is different according to whether it is a pin-terminal-mounted connector or socket-terminal-mounted connector.)Other than, various kinds of combinations are available. Be careful to place an order by specifyinga correct Part No.

<Configuration of HD30 connector>

Pin contact

Receptacle body

Receptacle wedge Plug wedge

Plug body

Socket contact

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3-3 Pin Number Arrangement3-3-1 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 fourdifferent colors: grey, black, green, and brown. You cannot connect different colorconnectors.

Note 2: As DT connector bodies, two types are provided; one for nominal diameter 0.5 of electricwire and another for 0.85, 1.25 and 2. One with a small shielding rubber hole is for 0.5and 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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Shell size and Insert Arrangement Shell size and Insert Arrangementinsert layout insert layout18–8 24–9

18–14 24–16

18–20 24–21

18–21 24–23

24–31

3-3-2 Insert Arrangement of HD30 connector (Viewed from the pin terminal)

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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 (PartNo.: 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 orderseparately 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 kits4-1-1 Repair kit (A)For repair of connectors at repair shop. All parts of DT connector and required tools are includedin 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 ifnecessary.

� Case (Option)Large size: Part No. 799-601-7910Size: 410 x 240 x 325mmWeight: 6.0KgMedium size: Part No. 799-601-7920Size: 550 x 325 x 365mmWeight: 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-waysDT connectors are available as a compact kit. Like the repair kit (A), the repair kit (B) alsoincludes a terminal crimp tool and terminal pull-out tool. Therefore, it is well serviceable in thefield. Regarding the components list, refer to 5-2. This kit does not include a case (P/N: 799-601-7910 and 7920), either. Obtain one if necessary.

Photo of entire repair kit (B)Photo of entire repair kit (A)

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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 themon site. When you need to identify them on site, refer to the following tables. The DT connectoris serviceable with terminals with * only. The DTM connector is serviceable with terminals with ** only.

4-2-1 Pin terminal

4-2-2 Socket terminal

Part No. How to identifyUpper row: Nickel-plated Length of pin terminal (A) Dia. of pin terminal (B) How to identifyLower row: Gold-plated (mm) ± 0.4 (mm) ± 0.208191–05310 (**) 18.1 1.0 Measure the diameter08191–07310 (**) and length of the pin.

08191–05320 (*) • Measure the diameter

08191–07320 (*) 20.6 1.6 and length of the pin.• Without a green bar

08191–05330 (*) • Measure the diameter

08191–07330 (*) 20.6 1.6 and length of the pin.• With a green bar

08191–05340 20.6 2.4 Measure the diameterand length of the pin.

08191–05350 26.2 3.6 Measure the diameterand length of the pin.

08191–05360 26.2 5.7 Measure the diameterand length of the pin.

4-2-3 Identifying sealing plug

Part No. How to identifyUpper row: Nickel-plated Length of socket terminal (A) Dia. of socket terminal (B) How to identifyLower row: Gold-plated (mm) ± 0.4 (mm) ± 0.208191–05410 (**) 16.4 1.9 Measure the diameter08191–07410 (**) and length of the socket.

08191–05420 (*) • Measure the diameter

08191–07420 (*) 19.0 2.8 and length of the socket.• Without a green bar

08191–05430 (*) • Measure the diameter

08191–07430 (*) 19.0 2.8 and length of the socket.• With a green bar

08191–05440 19.3 4.0 Measure the diameterand length of the socket.

08191–05450 24.8 6.6 Measure the diameterand length of the socket.

08191–05460 24.8 8.5 Measure the diameterand length of the socket.

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

(A) (A)

(B)

Green bar

Part No. Color for identification08191–00710 Red08191–00770 White08191–00750 White08191–00760 Brown

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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 Q’ty Remarks

1 08191–05310 Pin (Nickel-plated) 100 (#20)2 08191–05320 Pin (Nickel-plated) 50 (#16: AWG16–20)3 08191–05330 Pin (Nickel-plated) 50 (#16: AWG14–16)4 08191–05340 Pin (Nickel-plated) 20 (#12)5 08191–05350 Pin (Nickel-plated) 10 (#8)6 08191–05360 Pin (Nickel-plated) 10 (#4)7 08191–07310 Pin (Gold-plated) 10 (#20)8 08191–07320 Pin (Gold-plated) 5 (#16: AWG16–20)9 08191–07330 Pin (Gold-plated) 5 (#16: AWG14–16)

10 08191–05410 Socket (Nickel-plated) 100 (#20)11 08191–05420 Socket (Nickel-plated) 50 (#16: AWG16–20)12 08191–05430 Socket (Nickel-plated) 50 (#16: AWG14–16)13 08191–05440 Socket (Nickel-plated) 20 (#12)14 08191–05450 Socket (Nickel-plated) 10 (#8)15 08191–05460 Socket (Nickel-plated) 10 (#4)16 08191–07410 Socket (Gold-plated) 10 (#20)17 08191–07420 Socket (Gold-plated) 5 (#16: AWG16–20)18 08191–07430 Socket (Gold-plated) 5 (#16: AWG14–16)19 08192–02100 Connector (Receptacle) 3 (DTM)20 08192–12100 Connector (Receptacle) 3 (DT2)21 08192–13100 Connector (Receptacle) 3 (DT3)22 08192–14100 Connector (Receptacle) 3 (DT4)23 08192–16100 Connector (Receptacle) 3 (DT6)24 08192–18101 Connector (Receptacle) 1 (DT8) Grey25 08192–18102 Connector (Receptacle) 3 (DT8) Black, standard26 08192–18103 Connector (Receptacle) 1 (DT8) Green27 08192–18104 Connector (Receptacle) 1 (DT8) Brown28 08192–19101 Connector (Receptacle) 1 (DT12) Grey29 08192–19102 Connector (Receptacle) 3 (DT12) Black, standard30 08192–19103 Connector (Receptacle) 1 (DT12) Green31 08192–19104 Connector (Receptacle) 1 (DT12) Brown32 08192–31100 Connector (Receptacle) 1 DTHD #1233 08192–41100 Connector (Receptacle) 1 DTHD #834 08192–51100 Connector (Receptacle) 1 DTHD #435 08192–02200 Connector (Plug) 3 (DTM)36 08192–12200 Connector (Plug) 3 (DT2)37 08192–13200 Connector (Plug) 3 (DT3)38 08192–14200 Connector (Plug) 3 (DT4)39 08192–16200 Connector (Plug) 3 (DT6)40 08192–18201 Connector (Plug) 1 (DT8) Grey41 08192–18202 Connector (Plug) 3 (DT8) Black, standard

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No. Part No. Part name Q’ty Remarks42 08192–18203 Connector (Plug) 1 (DT8) Green43 08192–18204 Connector (Plug) 1 (DT8) Brown44 08192–19201 Connector (Plug) 1 (DT12) Grey45 08192–19202 Connector (Plug) 3 (DT12) Black, standard46 08192–19203 Connector (Plug) 1 (DT12) Green47 08192–19204 Connector (Plug) 1 (DT12) Brown48 08192–31200 Connector (Plug) 1 DTHD#1249 08192–41200 Connector (Plug) 1 DTHD#850 08192–51200 Connector (Plug) 1 DTHD#451 08192–22100 Connector (Receptacle: For AEX, AVS0.5) 3 (DT2)52 08192–23100 Connector (Receptacle: For AEX, AVS0.5) 3 (DT3)53 08192–24100 Connector (Receptacle: For AEX, AVS0.5) 3 (DT4)54 08192–26100 Connector (Receptacle: For AEX, AVS0.5) 3 (DT6)55 08192–28101 Connector (Receptacle: For AEX, AVS0.5) 1 (DT8) Grey56 08192–28102 Connector (Receptacle: For AEX, AVS0.5) 3 (DT8) Black, standard57 08192–28103 Connector (Receptacle: For AEX, AVS0.5) 1 (DT8) Green58 08192–28104 Connector (Receptacle: For AEX, AVS0.5) 1 (DT8) Brown59 08192–29101 Connector (Receptacle: For AEX, AVS0.5) 1 (DT12) Grey60 08192–29102 Connector (Receptacle: For AEX, AVS0.5) 3 (DT12) Black, standard61 08192–29103 Connector (Receptacle: For AEX, AVS0.5) 1 (DT12) Green62 08192–29104 Connector (Receptacle: For AEX, AVS0.5) 1 (DT12) Brown63 08192–22200 Connector (Plug: For AEX, AVS0.5) 3 (DT2)64 08192–23200 Connector (Plug: For AEX, AVS0.5) 3 (DT3)65 08192–24200 Connector (Plug: For AEX, AVS0.5) 3 (DT4)66 08192–26200 Connector (Plug: For AEX, AVS0.5) 3 (DT6)67 08192–28201 Connector (Plug: For AEX, AVS0.5) 1 (DT8) Grey68 08192–28202 Connector (Plug: For AEX, AVS0.5) 3 (DT8) Black, standard69 08192–28203 Connector (Plug: For AEX, AVS0.5) 1 (DT8) Green70 08192–28204 Connector (Plug: For AEX, AVS0.5) 1 (DT8) Brown71 08192–29201 Connector (Plug: For AEX, AVS0.5) 1 (DT12) Grey72 08192–29202 Connector (Plug: For AEX, AVS0.5) 3 (DT12) Black, standard73 08192–29203 Connector (Plug: For AEX, AVS0.5) 1 (DT12) Green74 08192–29204 Connector (Plug: For AEX, AVS0.5) 1 (DT12) Brown75 08192–02300 Wedge (Receptacle) 5 (DTM)76 08192–12300 Wedge (Receptacle) 5 (DT2)77 08192–13300 Wedge (Receptacle) 5 (DT3)78 08192–14300 Wedge (Receptacle) 5 (DT4)79 08192–16300 Wedge (Receptacle) 5 (DT6)80 08192–18300 Wedge (Receptacle) 5 (DT8)81 08192–19300 Wedge (Receptacle) 5 (DT12)82 08192–02400 Wedge (Plug) 5 (DTM)83 08192–12400 Wedge (Plug) 5 (DT2)84 08192–13400 Wedge (Plug) 5 (DT3)

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5-2 Repair kit (B) component list (Part No.: 790-222-4100)

No. Part No. Part name Q’ty Remarks85 08192–14400 Wedge (Plug) 5 (DT4)86 08192–16400 Wedge (Plug) 5 (DT6)87 08192–18400 Wedge (Plug) 5 (DT8)88 08192–19400 Wedge (Plug) 5 (DT12)89 08191–00710 Sealing plug 10 (#20)90 08191–00770 Sealing plug 10 (#12, #16)91 08191–00750 Sealing plug 5 (#8)92 08191–00760 Sealing plug 5 (#4)93 08193–20012 Clamp 594 08193–30012 Clamp 3 Applicable to 8-ways type only95 799–601–7810 Tool 1 Terminal crimp tool96 799–601–7820 Tool 3 HD connector pin pull-out tool97 799–601–7830 Tool 3 HD connector pin pull-out tool98 799–601–7840 Tool 3 HD connector pin pull-out tool99 799–601–7850 Tool 3 HD connector pin pull-out tool

100 799–601–7860 Tool 1 HD connector pin pull-out tool101 799–601–7870 Tool 1 HD connector pin pull-out tool102 799–601–7880 Tool 1 DT connector pin pull-out tool103 799–601–7930 Operation Manual 1

No. Part No. Part name Q’ty Remarks1 08191–05310 Pin (Nickel-plated) 100 (#20)2 08191–05320 Pin (Nickel-plated) 50 (#16: AWG16–20)3 08191–05330 Pin (Nickel-plated) 50 (#16: AWG14–16)4 08191–05410 Socket (Nickel-plated) 100 (#20)5 08191–05420 Socket (Nickel-plated) 50 (#16: AWG16–20)6 08191–05430 Socket (Nickel-plated) 50 (#16: AWG14–16)7 08192–02100 Connector (Receptacle) 3 (DTM)8 08192–12100 Connector (Receptacle) 3 (DT2)9 08192–13100 Connector (Receptacle) 3 (DT3)

10 08192–14100 Connector (Receptacle) 3 (DT4)11 08192–16100 Connector (Receptacle) 3 (DT6)12 08192–02200 Connector (Plug) 3 (DTM)13 08192–12200 Connector (Plug) 3 (DT2)14 08192–13200 Connector (Plug) 3 (DT3)15 08192–14200 Connector (Plug) 3 (DT4)16 08192–16200 Connector (Plug) 3 (DT6)17 08192–22100 Connector (Receptacle:For AEX, AVS0.5) 3 (DT2)18 08192–23100 Connector (Receptacle:For AEX, AVS0.5) 3 (DT3)19 08192–24100 Connector (Receptacle:For AEX, AVS0.5) 3 (DT4)20 08192–26100 Connector (Receptacle:For AEX, AVS0.5) 3 (DT6)21 08192–22200 Connector (Plug:For AEX, AVS0.5) 3 (DT2)22 08192–23200 Connector (Plug:For AEX, AVS0.5) 3 (DT3)23 08192–24200 Connector (Plug:For AEX, AVS0.5) 3 (DT4)

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No. Part No. Part name Q’ty Remarks24 08192–26200 Connector (Plug:For AEX, AVS0.5) 3 (DT6)25 08192–02300 Wedge (Receptacle) (For male connector) 5 (DTM)26 08192–12300 Wedge (Receptacle) (For male connector) 5 (DT2)27 08192–13300 Wedge (Receptacle) (For male connector) 5 (DT3)28 08192–14300 Wedge (Receptacle) (For male connector) 5 (DT4)29 08192–16300 Wedge (Receptacle) (For male connector) 5 (DT6)30 08192–02400 Wedge (Plug) (For female connector) 5 (DTM)31 08192–12400 Wedge (Plug) (For female connector) 5 (DT2)32 08192–13400 Wedge (Plug) (For female connector) 5 (DT3)33 08192–14400 Wedge (Plug) (For female connector) 5 (DT4)34 08192–16400 Wedge (Plug) (For female connector) 5 (DT6)35 08191–00710 Sealing plug 10 (#20)36 08191–00770 Sealing plug 10 (#12, #16)37 08193–20012 Clamp 538 799–601–7810 Tool 1 Terminal crimp tool39 799–601–7820 Tool 3 To pull out HD connector terminal40 799–601–7830 Tool 3 To pull out HD connector terminal41 799–601–7840 Tool 3 To pull out HD connector terminal42 799–601–7850 Tool 3 To pull out HD connector terminal43 799–601–7860 Tool 1 To pull out HD connector terminal44 799–601–7870 Tool 1 To pull out HD connector terminal45 799–601–7880 Tool 1 To pull out DT connector pin46 799–601–7930 Operation Manual 1

6. REPLACEMENT OF CONNECTORS AND TERMINALS(Reference: The connector attached at the power supply side is usually a socket (socketcontact)).

6-1 Pulling out and fitting in the DT connector terminal6-1-1 Tools required1) 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 terminal1) By using a pair of needle nose pliers, twee-

zers, or a pull-out tool, pull out the wedge(1).

1

2

3 4

2) Find the contact fixing lug (2) in the connec-tor. While pulling it out with a pull-out toolor a pair of tweezers, slightly pull out theelectric wire to release the fixing lug.

3) While holding the shielding rubber (3), pullout the electric wire (4).When it is very difficult to pull it out, retrythe Step 2).

6-1-3 Fitting in the terminal1) 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 thefixing lug) and you feel that the contacttouches the back wall.

� Slightly pull the electric wire in the pull-out direction to check that the contact onthe electric wire’s end is not detached.

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� If the electric wire bends when you tryfitting it in and therefore, it cannot go in,attach a tool of Part No. 799-601-7830or -7840 on the terminal’s back-end andthen, fit it in.

799�601�7830, �7840

Fit this side ofthe wedge inthe connector.

2) After fitting in all electric wires, mount thewedge (1).

� When mounting the wedge to a 2-waysconnector, refer to the figure to the right.

� When mounting the wedge to a 3-ways pinconnector, place the wedge with its arrowdesignation toward the fitting part of theconnector housing, and then, mount it.

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6-2 Pulling out and fitting in the HD30 connector terminal6-2-1 Tools required

Pin/socket pull-out tool

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

1 799–601–7820 08191–05310 08191–05410 White or Red08191–07310 08191–07410

2 799–601–7830 08191–05320 08191–05420 Light blue08191–07320 08191–07420

3 799–601–7840 08191–05330 08191–05330 Blue08191–07330 08191–074304 799–601–7850 08191–05340 08191–05440 Yellow5 799–601–7860 08191–05350 08191–05450 Green6 799–601–7870 08191–05360 08191–05460 White

6-2-2 Pulling out the terminal1) 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.

6 5 4 3 2 1

Nominal No. Electric wire Part No. given byof connector size or Pin No. Part No. of pull-out tool manufacture Tool color

(Given on actual tool)18–8 2, 3 799–601–7850 114010 Yellow18–14 0.5 799–601–7830 0411–310–1605 Light blue

0.85, 1.25 799–601–7840 0411–204–1605 Blue18–20 0.5 799–601–7820 0411–240–2005 White or Red

0.85, 1.25 799–601–7840 0411–204–1605 Blue18–21 0.5 799–601–7820 0411–240–2005 White or Red24–9 15 799–601–7870 114009 White

8 799–601–7860 114008 Green2, 3 799–601–7850 114010 Yellow

24–16 2, 3 799–601–7850 114010 Yellow24–21 2, 3 799–601–7850 114010 Yellow

0.5 799–601–7830 0411–310–1605 Light blue0.85, 1.25 799–601–7840 0411–204–1605 Blue

24–23 0.5 799–601–7830 0411–310–1605 Light blue0.85, 1.25 799–601–7840 0411–204–1605 Blue

24–31 0.5 799–601–7830 0411–310–1605 Light blue0.85, 1.25 799–601–7840 0411–204–1605 Blue

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2) Attach the chosen pull-out tool (X1) to theelectric wire of pin and socket you will re-move.� Do not use a metallic screwdriver; it

damages a shielding rubber.

3) Slide the pull-out tool into a clearance be-tween the electric wire and the connectorshielding rubber, and then, push it in as faras it will go. (Be sure not to push it inforcedly to prevent the tool from being dam-aged.)

4) Pull out the electric wire with the pull-outtool.

6-2-3 Fitting in the terminal1) Grasp wire behind the contact barrel.

2) Fit the terminal into the hole and push it inuntil you hear a click.

� Push it in until you hear a click (which oc-curs when the contact passes by the fixinglug) and you feel that the contact touchesthe back wall.

� If the electric wire bends when you try fittingit in and therefore, it cannot go in, attach atool of Part No. 799-601-7830 or -7840 tothe terminal’s back-end and then, fit it in.

3) Slightly pull the electric wire in the pull-outdirection to check that the contact on theelectric wire’s end is not detached.

X1

799�601�7830, �7840

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7. CRIMP OF TERMINAL

7-1 Tools required

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

7-2 Selecting pin and socket terminalsWhen 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.

Universal hand crimp tool: 799–601–7810

7-3 Crimping the terminal1) By using a stripper, strip insulation from wire.

★ Regarding a removing distance, refer to thetable below.

Pin terminal Electric wire

The strand wireshould be seenthrough the hole onthe terminal sidesurface.

The end face of theinsulation shouldtouch the end faceof the terminal.

Part No. Removing Knob’sPin terminal Socket distance set valueterminal (mm)

08191–05310 08191–05410 5 408191–07310 08191–0741008191–05320 08191–05420 7 508191–07320 08191–0742008191–05330 08191–05430 7 608191–07330 08191–0742008191–05340 08191–05440 7 8

This crimp tool is a hand tool and therefore, you canuse it for the terminals described above. Regardingthicker terminals, you need a power tool for a manu-facturer.

To check if the striped insulation distance is correct,fit the electric wire into the terminal and look throughthe hole on the terminal side surface. If you can seethe strand wire through it and also the end face ofthe insulation touches the end face of the terminal,the distance is correct.

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2) Remove the pin (1) of Universal Hand CrimpTool.

1

2

43

Rotate the adjustment screw with theterminal pressed in.

6

3) Referring to the Table in the Step 1), pull up theknob (2) and rotate it to an appropriate set value.

4) Loosen the lock nut (3) and rotate the adjust-ment screw (4).

5) Fit the terminal in the Universal Hand CrimpTool.

6) Rotate the adjustment screw until the top-end ofthe terminal is aligned with the top-end of thetool 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.

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8. REPLACEMENT OF MACHINE-MOUNTED CONNECTORSWITH DEUTSCH CONNECTORS

This section describes how to replace a 2-ways X connector to a 2-ways DT connector.

1) Disconnecting the mounted connectorBy using a nipper or a pair of needle nose pli-ers, cut the electric wire off the connector.

5

Rotate the adjustment screw withthe terminal pressed in.

4

3

2) Strip insulation of wire 7mm.(Use a commercially available tool.)

3) Adjust the knob of the universal hand crimp toolto 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 universalhand crimp tool and loosen the lock nut (3).After that, rotate the adjustment screw (4).

5) Rotate the adjustment screw until the top-end ofthe terminal is aligned with the top-end of thehole of the tool. After that, tighten the lock nut.

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6) Set the terminal on the universal hand crimp tooland 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.

Clamp

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 connectorswith new ones and attach the clamp

11) Fit the connector into the clamp.

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9. PART NO. LIST OF HD30 CONNECTOR BODY9-1 Part No. List of HD30 Connector Body (Without adaptor)

No. Part No. Remarks1 08191–13101 Receptacle: Pin (Male) Normal type 18–82 08191–14101 Receptacle: Socket (Female) Normal type 18–83 08191–13105 Receptacle: Pin (Male) Extra-Thin type 18–84 08191–14105 Receptacle: Socket (Female) Extra-Thin type 18–85 08191–12201 Plug: Socket (Female) Normal type 18–86 08191–11201 Plug: Pin (Male) Normal type 18–87 08191–12205 Plug: Socket (Female) Extra-Thin type 18–88 08191–11205 Plug: Pin (Male) Extra-Thin type 18–89 08191–23101 Receptacle: Pin (Male) Normal type 18–14

10 08191–24101 Receptacle: Socket (Female) Normal type 18–1411 08191–23105 Receptacle: Pin (Male) Extra-Thin type 18–1412 08191–24105 Receptacle: Socket (Female) Extra-Thin type 18–1413 08191–22201 Plug: Socket (Female) Normal type 18–1414 08191–21201 Plug: Pin (Male) Normal type 18–1415 08191–22205 Plug: Socket (Female) Extra-Thin type 18–1416 08191–21205 Plug: Pin (Male) Extra-Thin type 18–1417 08191–33101 Receptacle: Pin (Male) Normal type 18–2018 08191–34101 Receptacle: Socket (Female) Normal type 18–2019 08191–32201 Plug: Socket (Female) Normal type 18–2020 08191–31201 Plug: Pin (Male) Normal type 18–2021 08191–43101 Receptacle: Pin (Male) Normal type 18–2122 08191–44101 Receptacle: Socket (Female) Normal type 18–2123 08191–42201 Plug: Socket (Female) Normal type 18–2124 08191–41201 Plug: Pin (Male) Normal type 18–2125 08191–53101 Receptacle: Pin (Male) Normal type 24–926 08191–54101 Receptacle: Socket (Female) Normal type 24–927 08191–52201 Plug: Socket (Female) Normal type 24–928 08191–51201 Plug: Pin (Male) Normal type 24–929 08191–63101 Receptacle: Pin (Male) Normal type 24–1630 08191–64101 Receptacle: Socket (Female) Normal type 24–1631 08191–63105 Receptacle: Pin (Male) Extra-Thin type 24–1632 08191–64105 Receptacle: Socket (Female) Extra-Thin type 24–1633 08191–62201 Plug: Socket (Female) Normal type 24–1634 08191–61201 Plug: Pin (Male) Normal type 24–1635 08191–62205 Plug: Socket (Female) Extra-Thin type 24–1636 08191–61205 Plug: Pin (Male) Extra-Thin type 24–1637 08191–73101 Receptacle: Pin (Male) Normal type 24–2138 08191–74101 Receptacle: Socket (Female) Normal type 24–2139 08191–73105 Receptacle: Pin (Male) Extra-Thin type 24–2140 08191–74105 Receptacle: Socket (Female) Extra-Thin type 24–2141 08191–72201 Plug: Socket (Female) Normal type 24–2142 08191–71201 Plug: Pin (Male) Normal type 24–2143 08191–72205 Plug: Socket (Female) Extra-Thin type 24–2144 08191–71205 Plug: Pin (Male) Extra-Thin type 24–2145 08191–83101 Receptacle: Pin (Male) Normal type 24–2346 08191–84101 Receptacle: Socket (Female) Normal type 24–23

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No. Part No. Remarks1 08191–13102 Receptacle: Pin (Male) Normal type 18–82 08191–14102 Receptacle: Socket (Female) Normal type 18–83 08191–13106 Receptacle: Pin (Male) Extra-Thin type 18–84 08191–14106 Receptacle: Socket (Female) Extra-Thin type 18–85 08191–12202 Plug: Socket (Female) Normal type 18–86 08191–11202 Plug: Pin (Male) Normal type 18–87 08191–12206 Plug: Socket (Female) Extra-Thin type 18–88 08191–11206 Plug: Pin (Male) Extra-Thin type 18–89 08191–23102 Receptacle: Pin (Male) Normal type 18–14

10 08191–24102 Receptacle: Socket (Female) Normal type 18–1411 08191–23106 Receptacle: Pin (Male) Extra-Thin type 18–1412 08191–24106 Receptacle: Socket (Female) Extra-Thin type 18–1413 08191–22202 Plug: Socket (Female) Normal type 18–1414 08191–21202 Plug: Pin (Male) Normal type 18–1415 08191–22206 Plug: Socket (Female) Extra-Thin type 18–1416 08191–21206 Plug: Pin (Male) Extra-Thin type 18–1417 08191–33102 Receptacle: Pin (Male) Normal type 18–2018 08191–34102 Receptacle: Socket (Female) Normal type 18–2019 08191–32202 Plug: Socket (Female) Normal type 18–2020 08191–31202 Plug: Pin (Male) Normal type 18–2021 08191–43102 Receptacle: Pin (Male) Normal type 18–2122 08191–44102 Receptacle: Socket (Female) Normal type 18–2123 08191–42202 Plug: Socket (Female) Normal type 18–2124 08191–41202 Plug: Pin (Male) Normal type 18–2125 08191–53102 Receptacle: Pin (Male) Normal type 24–926 08191–54102 Receptacle: Socket (Female) Normal type 24–9

No. Part No. Remarks47 08191–83103 Receptacle: Pin (Male) Thin type 24–2348 08191–84103 Receptacle: Socket (Female) Thin type 24–2349 08191–83105 Receptacle: Pin (Male) Extra-Thin type 24–2350 08191–84105 Receptacle: Socket (Female) Extra-Thin type 24–2351 08191–82201 Plug: Socket (Female) Normal type 24–2352 08191–81201 Plug: Pin (Male) Normal type 24–2353 08191–82203 Plug: Socket (Female) Thin type 24–2354 08191–81203 Plug: Pin (Male) Thin type 24–2355 08191–82205 Plug: Socket (Female) Extra-Thin type 24–2356 08191–81205 Plug: Pin (Male) Extra-Thin type 24–2357 08191–93103 Receptacle: Pin (Male) Thin type 24–3158 08191–94103 Receptacle: Socket (Female) Thin type 24–3159 08191–93105 Receptacle: Pin (Male) Extra-Thin type 24–3160 08191–94105 Receptacle: Socket (Female) Extra-Thin type 24–3161 08191–92203 Plug: Socket (Female) Thin type 24–3162 08191–91203 Plug: Pin (Male) Thin type 24–3163 08191–92205 Plug: Socket (Female) Extra-Thin type 24–3164 08191–91205 Plug: Pin (Male) Extra-Thin type 24–31

9-2 Part No. List of HD30 Connector Body (With adaptor)

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No. Part No. Remarks27 08191–52202 Plug: Socket (Female) Normal type 24–928 08191–51202 Plug: Pin (Male) Normal type 24–929 08191–63102 Receptacle: Pin (Male) Normal type 24–1630 08191–64102 Receptacle: Socket (Female) Normal type 24–1631 08191–63106 Receptacle: Pin (Male) Extra-Thin type 24–1632 08191–64106 Receptacle: Socket (Female) Extra-Thin type 24–1633 08191–62202 Plug: Socket (Female) Normal type 24–1634 08191–61202 Plug: Pin (Male) Normal type 24–1635 08191–62206 Plug: Socket (Female) Extra-Thin type 24–1636 08191–61206 Plug: Pin (Male) Extra-Thin type 24–1637 08191–73102 Receptacle: Pin (Male) Normal type 24–2138 08191–74102 Receptacle: Socket (Female) Normal type 24–2139 08191–73106 Receptacle: Pin (Male) Extra-Thin type 24–2140 08191–74106 Receptacle: Socket (Female) Extra-Thin type 24–2141 08191–72202 Plug: Socket (Female) Normal type 24–2142 08191–71202 Plug: Pin (Male) Normal type 24–2143 08191–72206 Plug: Socket (Female) Extra-Thin type 24–2144 08191–71206 Plug: Pin (Male) Extra-Thin type 24–2145 08191–83102 Receptacle: Pin (Male) Normal type 24–2346 08191–84102 Receptacle: Socket (Female) Normal type 24–2347 08191–83104 Receptacle: Pin (Male) Thin type 24–2348 08191–84104 Receptacle: Socket (Female) Thin type 24–2349 08191–83106 Receptacle: Pin (Male) Extra-Thin type 24–2350 08191–84106 Receptacle: Socket (Female) Extra-Thin type 24–2351 08191–82202 Plug: Socket (Female) Normal type 24–2352 08191–81202 Plug: Pin (Male) Normal type 24–2353 08191–82204 Plug: Socket (Female) Thin type 24–2354 08191–81204 Plug: Pin (Male) Thin type 24–2355 08191–82206 Plug: Socket (Female) Extra-Thin type 24–2356 08191–81206 Plug: Pin (Male) Extra-Thin type 24–2357 08191–93104 Receptacle: Pin (Male) Thin type 24–3158 08191–94104 Receptacle: Socket (Female) Thin type 24–3159 08191–93106 Receptacle: Pin (Male) Extra-Thin type 24–3160 08191–94106 Receptacle: Socket (Female) Extra-Thin type 24–3161 08191–92204 Plug: Socket (Female) Thin type 24–3162 08191–91204 Plug: Pin (Male) Thin type 24–3163 08191–92206 Plug: Socket (Female) Extra-Thin type 24–3164 08191–91206 Plug: Pin (Male) Extra-Thin type 24–31

9-3 Connector mounting nut and washerNo. Part No. Remarks

1 08191–10808 Nut for connectors 18–8, 18–14, 18–20, and 18–21(Tightening torque: 4.8kg·cm)

2 08191–50808 Nut for connectors 24–9, 24–16, 24–21, 24–23 and 24–31(Tightening torque: 6.5kg·cm)

3 08191–10809 Washer for connectors 18–8, 18–14, 18–20, and 18–214 08191–50809 Washer for connectors 24–9, 24–16, 24–21, 24–23, and 24–31

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May 2000

Customer Support Division