SEKN50031 of 23 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 125°C (X connector: –50 to 120°C) 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 SEKN5003 2 of 23 — 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 various kinds of combinations are available. three types are available depending on the size of electric wire to be connected. DT2-.SEKN5003 3 of 23 3. (The housing Part No. This type connector is mountable on a housing of either the pin or socket terminal type. 6-. 3-. is different according to whether it is a pin-terminalmounted connector or socket-terminal-mounted connector. <Configuration of HD30 connector> Pin contact Socket contact Sealing plug or or Socket contact Pin contact . and 12-ways types and DTHD 1-ways and DTM 2-ways types are provided.) Other than. <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. 4-. Be careful to place an order by specifying a correct Part No. each of which is given a different Part No. Regarding the DTHD connector. GENERAL DESCRIPTION OF CONNECTOR 3-1 DT connector As DT connectors. 8-. 25.5 of electric wire and another for 0.5 and one with a large hole is for 0.85. the 8. 1. black. one for nominal diameter 0. Note 2: As DT connector bodies.and 12-ways DT connector bodies are given four different colors: grey.25 and 2. One with a small shielding rubber hole is for 0. 1. two types are provided.85. The hole is large The hole is small . You cannot connect different color connectors.SEKN5003 4 of 23 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. and brown. green. and 2. SEKN5003 5 of 23 3-3-2 Insert Arrangement of HD30 connector (Viewed from the pin terminal) Shell size and insert layout 18–8 Insert Arrangement Shell size and insert layout 24–9 18–14 24–16 18–20 24–21 18–21 24–23 24–31 Insert Arrangement . As for HD30 connector bodies. 799-601-7910 Size: 410 x 240 x 325mm Weight: 6. All parts of DT connector and required tools are included in a kit. refer to 5-1. Separately get a HD30 connector body only and the kit is applicable to every connector.: 790-222-4000) and the repair kit (B) for 2-. refer to 5-2.0Kg Medium size: Part No. Therefore. Obtain one if necessary. Photo of entire repair kit (A) Photo of entire repair kit (B) Case (Option) Large size: Part No. 3-. and 6-ways connectors frequently used (Part No.: 790-222-4100). the repair kit (B) also includes a terminal crimp tool and terminal pull-out tool. For this reason. 799-601-7920 Size: 550 x 325 x 365mm Weight: 2. Like the repair kit (A).9Kg 4-1-2 Repair kit (B) For repair of connectors in the field. 3-. 4-.) Also. refer to 9.SEKN5003 6 of 23 4. . components of this kit are also selectively available. either. Regarding the components list. more than 100 types are provided and not used very frequently. 4-. no repair kit is available for the HD30 connector bodies. (Regarding the list of HD30 connector bodies. 4-1 Outline of the kits 4-1-1 Repair kit (A) For repair of connectors at repair shop. You must place an order separately when you need it. Regarding the components list. and 6-ways DT connectors are available as a compact kit. Mainly the parts of frequently used 2-. it is well serviceable in the field. GENERAL DESCRIPTION OF KIT Two types of repair kits are provided: the repair kit (A) for all connectors in DT Series (Part No. Obtain one if necessary. This kit does not include a case. This kit does not include a case (P/N: 799-6017910 and 7920). 08191–05320 (*) 08191–07320 (*) 20. refer to the following tables.2 How to identify 08191–05310 (**) 08191–07310 (**) 18.6 2. 08191–05460 24.0 2.2 How to identify 08191–05410 (**) 08191–07410 (**) 16. 4-2-3 Identifying sealing plug Part No.2 5.6 • Measure the diameter and length of the pin.6 Measure the diameter and length of the socket. The DTM connector is serviceable with terminals with ** only. 4-2-1 Pin terminal Part No.8 6.5 Measure the diameter and length of the socket.6 • Measure the diameter and length of the pin. of pin terminal (B) (mm) ± 0.4 (mm) ± 0. • With a green bar 08191–05440 19. you cannot identify them on site.6 1. Upper row: Nickel-plated Length of pin terminal (A) Lower row: Gold-plated (mm) ± 0. Therefore. Color for identification 08191–00710 Red 08191–00770 White 08191–00750 White 08191–00760 Brown (A) (A) (B) Green bar .8 • Measure the diameter and length of the socket. The DT connector is serviceable with terminals with * only.3 4.SEKN5003 7 of 23 4-2 Types and identification of pins and sockets <Reference> Pin and socket terminals have no engraved Part No. and ID mark.4 How to identify Dia.4 1.0 2.9 Measure the diameter and length of the socket.2 3. When you need to identify them on site.7 Measure the diameter and length of the pin.8 • Measure the diameter and length of the socket. Note: The gold-plated socket terminal has a crimped part of gold color.0 Measure the diameter and length of the socket. 4-2-2 Socket terminal How to identify Part No.4 Measure the diameter and length of the pin.0 Measure the diameter and length of the pin. 08191–05420 (*) 08191–07420 (*) 19. 08191–05450 24. • With a green bar 08191–05340 20.1 1.8 8. 08191–05350 26. • Without a green bar 08191–05330 (*) 08191–07330 (*) 20. 08191–05360 26.6 Measure the diameter and length of the pin. Upper row: Nickel-plated Length of socket terminal (A) Dia. • Without a green bar 08191–05430 (*) 08191–07430 (*) 19. of socket terminal (B) Lower row: Gold-plated (mm) ± 0.6 1. standard 26 08192–18103 Connector (Receptacle) 1 (DT8) Green 27 08192–18104 Connector (Receptacle) 1 (DT8) Brown 28 08192–19101 Connector (Receptacle) 1 (DT12) Grey 29 08192–19102 Connector (Receptacle) 3 (DT12) Black. Part No.: 790-222-4000) No.SEKN5003 8 of 23 5. standard (#20) . 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 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) Grey 25 08192–18102 Connector (Receptacle) 3 (DT8) Black. LIST OF REPAIR KIT COMPONENTS 5-1 Repair kit (A) component list (Part No. standard 30 08192–19103 Connector (Receptacle) 1 (DT12) Green 31 08192–19104 Connector (Receptacle) 1 (DT12) Brown 32 08192–31100 Connector (Receptacle) 1 DTHD #12 33 08192–41100 Connector (Receptacle) 1 DTHD #8 34 08192–51100 Connector (Receptacle) 1 DTHD #4 35 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) Grey 41 08192–18202 Connector (Plug) 3 (DT8) Black. 5) 3 (DT6) 55 08192–28101 Connector (Receptacle: For AEX. AVS0. standard 73 08192–29203 Connector (Plug: For AEX.5) 1 (DT12) Green 62 08192–29104 Connector (Receptacle: For AEX. AVS0.5) 3 (DT4) 66 08192–26200 Connector (Plug: For AEX.5) 1 (DT8) Grey 56 08192–28102 Connector (Receptacle: For AEX. AVS0. AVS0.5) 3 (DT3) 53 08192–24100 Connector (Receptacle: For AEX. AVS0. AVS0.5) 3 (DT6) 67 08192–28201 Connector (Plug: For AEX.5) 1 (DT8) Brown 71 08192–29201 Connector (Plug: For AEX.5) 1 (DT8) Green 70 08192–28204 Connector (Plug: For AEX. AVS0.5) 3 (DT12) Black.5) 1 (DT12) Grey 72 08192–29202 Connector (Plug: For AEX.5) 3 (DT3) 65 08192–24200 Connector (Plug: For AEX. AVS0. standard 69 08192–28203 Connector (Plug: For AEX.5) 1 (DT12) Brown 63 08192–22200 Connector (Plug: For AEX.5) 1 (DT8) Brown 59 08192–29101 Connector (Receptacle: For AEX.5) 3 (DT8) Black.SEKN5003 9 of 23 No. AVS0. AVS0. AVS0.5) 3 (DT12) Black. AVS0. Part name Q’ty Remarks 42 08192–18203 Connector (Plug) 1 (DT8) Green 43 08192–18204 Connector (Plug) 1 (DT8) Brown 44 08192–19201 Connector (Plug) 1 (DT12) Grey 45 08192–19202 Connector (Plug) 3 (DT12) Black.5) 3 (DT2) 64 08192–23200 Connector (Plug: For AEX. AVS0. AVS0. standard 61 08192–29103 Connector (Receptacle: For AEX. AVS0.5) 1 (DT8) Grey 68 08192–28202 Connector (Plug: For AEX. standard 46 08192–19203 Connector (Plug) 1 (DT12) Green 47 08192–19204 Connector (Plug) 1 (DT12) Brown 48 08192–31200 Connector (Plug) 1 DTHD#12 49 08192–41200 Connector (Plug) 1 DTHD#8 50 08192–51200 Connector (Plug) 1 DTHD#4 51 08192–22100 Connector (Receptacle: For AEX. AVS0.5) 1 (DT12) Brown 75 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) .5) 1 (DT12) Grey 60 08192–29102 Connector (Receptacle: For AEX.5) 3 (DT4) 54 08192–26100 Connector (Receptacle: For AEX. AVS0. AVS0.5) 1 (DT12) Green 74 08192–29204 Connector (Plug: For AEX. Part No. AVS0. standard 57 08192–28103 Connector (Receptacle: For AEX. AVS0.5) 3 (DT8) Black. AVS0.5) 1 (DT8) Green 58 08192–28104 Connector (Receptacle: For AEX. AVS0.5) 3 (DT2) 52 08192–23100 Connector (Receptacle: For AEX. AVS0. AVS0. 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 08191–05410 Socket (Nickel-plated) 100 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. Part name Q’ty Remarks 85 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. AVS0.5) 3 (DT3) 23 08192–24200 Connector (Plug:For AEX. AVS0. AVS0. Part No.5) 3 (DT4) (#20) .5) 3 (DT3) 19 08192–24100 Connector (Receptacle:For AEX. AVS0. AVS0. AVS0. AVS0. Part No.5) 3 (DT4) 20 08192–26100 Connector (Receptacle:For AEX.SEKN5003 10 of 23 5-2 No. #16) 91 08191–00750 Sealing plug 5 (#8) 92 08191–00760 Sealing plug 5 (#4) 93 08193–20012 Clamp 5 94 08193–30012 Clamp 3 Applicable to 8-ways type only 95 799–601–7810 Tool 1 Terminal crimp tool 96 799–601–7820 Tool 3 HD connector pin pull-out tool 97 799–601–7830 Tool 3 HD connector pin pull-out tool 98 799–601–7840 Tool 3 HD connector pin pull-out tool 99 799–601–7850 Tool 3 HD connector pin pull-out tool 100 799–601–7860 Tool 1 HD connector pin pull-out tool 101 799–601–7870 Tool 1 HD connector pin pull-out tool 102 799–601–7880 Tool 1 DT connector pin pull-out tool 103 799–601–7930 Operation Manual 1 Repair kit (B) component list (Part No.5) 3 (DT2) 18 08192–23100 Connector (Receptacle:For AEX.: 790-222-4100) No.5) 3 (DT2) 22 08192–23200 Connector (Plug:For AEX.5) 3 (DT6) 21 08192–22200 Connector (Plug:For AEX. Part No. etc.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. 2) Needle nose pliers (general tool). Part name Q’ty Remarks 24 08192–26200 Connector (Plug:For AEX. 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. AVS0. tweezers. REPLACEMENT OF CONNECTORS AND TERMINALS (Reference: The connector attached at the power supply side is usually a socket (socket contact)). .SEKN5003 11 of 23 No. #16) 37 08193–20012 Clamp 5 38 799–601–7810 Tool 1 Terminal crimp tool 39 799–601–7820 Tool 3 To pull out HD connector terminal 40 799–601–7830 Tool 3 To pull out HD connector terminal 41 799–601–7840 Tool 3 To pull out HD connector terminal 42 799–601–7850 Tool 3 To pull out HD connector terminal 43 799–601–7860 Tool 1 To pull out HD connector terminal 44 799–601–7870 Tool 1 To pull out HD connector terminal 45 799–601–7880 Tool 1 To pull out DT connector pin 46 799–601–7930 Operation Manual 1 6. When it is very difficult to pull it out. 1 2) Find the contact fixing lug (2) in the connector. 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. While pulling it out with a pull-out tool or a pair of tweezers. 4 . tweezers. slightly pull out the electric wire to release the fixing lug. 2 3) While holding the shielding rubber (3). pull out the electric wire (4). Slightly pull the electric wire in the pullout direction to check that the contact on the electric wire’s end is not detached. 3 6-1-3 Fitting in the terminal 1) Pick up the caulked part of the terminal and fit it into the hole. or a pull-out tool. Fit it in straight until you hear a click. pull out the wedge (1). retry the Step 2).SEKN5003 12 of 23 6-1-2 Pulling out the terminal 1) By using a pair of needle nose pliers. Fit this side of the wedge in the connector. fit it in. 7840 2) After fitting in all electric wires. attach a tool of Part No. When mounting the wedge to a 2-ways connector.SEKN5003 13 of 23 If the electric wire bends when you try fitting it in and therefore. mount it. 7996017830. place the wedge with its arrow designation toward the fitting part of the connector housing. it cannot go in. When mounting the wedge to a 3-ways pin connector. mount the wedge (1). and then. . refer to the figure to the right. 799-601-7830 or -7840 on the terminal’s back-end and then. Nominal No.5 799–601–7820 0411–240–2005 White or Red 24–9 15 799–601–7870 114009 White 8 799–601–7860 114008 Green 2.25 799–601–7840 0411–204–1605 Blue 18–20 24–23 24–31 Yellow .85.85.5 799–601–7830 0411–310–1605 Light blue 0. 3 799–601–7850 114010 18–14 0.25 799–601–7840 0411–204–1605 Blue 0.5 799–601–7820 0411–240–2005 White or Red 0.5 799–601–7830 0411–310–1605 Light blue 0. Part No. of tool 1 799–601–7820 08191–05310 08191–07310 08191–05410 08191–07410 White or Red 2 799–601–7830 08191–05320 08191–07320 08191–05420 08191–07420 Light blue 3 799–601–7840 08191–05330 08191–07330 08191–05330 08191–07430 Blue 4 799–601–7850 08191–05340 08191–05440 Yellow 5 799–601–7860 08191–05350 08191–05450 Green 6 799–601–7870 08191–05360 08191–05460 White 6 Part No. of pin terminal Part No. given by manufacture (Given on actual tool) Tool color 18–8 2. 1. 1. 1. of pull-out tool Part No.85. of socket terminal Tool color 5 4 3 2 1 6-2-2 Pulling out the terminal 1) In case of the HD30 Series. 3 799–601–7850 114010 Yellow 24–21 2. 1. Part No.5 799–601–7830 0411–310–1605 Light blue 0. Choose an appropriate pull-out tool in accordance with the table below.25 799–601–7840 0411–204–1605 Blue 0.25 799–601–7840 0411–204–1605 Blue 18–21 0.SEKN5003 14 of 23 6-2 6-2-1 Pulling out and fitting in the HD30 connector terminal Tools required Pin/socket pull-out tool No. Electric wire of connector size or Pin No.25 799–601–7840 0411–204–1605 Blue 0. 3 799–601–7850 114010 Yellow 0.5 799–601–7830 0411–310–1605 Light blue 0. 1.85. 3 799–601–7850 114010 Yellow 24–16 2. the sizes of pins and sockets to use are different depending on the connector type.85. push it in as far as it will go. (Be sure not to push it in forcedly to prevent the tool from being damaged. 7840 . Do not use a metallic screwdriver. 7996017830. X1 3) Slide the pull-out tool into a clearance between the electric wire and the connector shielding rubber. 3) Slightly pull the electric wire in the pull-out direction to check that the contact on the electric wire’s end is not detached. fit it in. 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. it damages a shielding rubber. 6-2-3 Fitting in the terminal 1) Grasp wire behind the contact barrel. and then. 799-601-7830 or -7840 to the terminal’s back-end and then. it cannot go in. If the electric wire bends when you try fitting it in and therefore.SEKN5003 15 of 23 2) Attach the chosen pull-out tool (X1) to the electric wire of pin and socket you will remove. 2) Fit the terminal into the hole and push it in until you hear a click. attach a tool of Part No.) 4) Pull out the electric wire with the pull-out tool. you can use it for the terminals described above. you need a power tool for a manufacturer. 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: 799–601–7810 7-2 Selecting pin and socket terminals When replacing pin and socket terminals. refer to 4-2. Regarding thicker terminals. be sure to use same types as ones previously used. . The end face of the insulation should touch the end face of the terminal. Part No. ★ Regarding a removing distance. To check if the striped insulation distance is correct. If you can see the strand wire through it and also the end face of the insulation touches the end face of the terminal. 7-3 Crimping the terminal 1) By using a stripper. Removing Knob’s distance set value (mm) Pin terminal Socket terminal 08191–05310 08191–07310 08191–05410 08191–07410 5 4 08191–05320 08191–07320 08191–05420 08191–07420 7 5 08191–05330 08191–07330 08191–05430 08191–07420 7 6 08191–05340 08191–05440 7 8 Pin terminal Electric wire This crimp tool is a hand tool and therefore. refer to the table below. fit the electric wire into the terminal and look through the hole on the terminal side surface. strip insulation from wire. The strand wire should be seen through the hole on the terminal side surface. the distance is correct. If you are confused about which ones to use.SEKN5003 16 of 23 7. 4 3 Rotate the adjustment screw with the terminal pressed in. 6 .SEKN5003 17 of 23 2) Remove the pin (1) of Universal Hand Crimp Tool. 5) Fit the terminal in the Universal Hand Crimp Tool. pull up the knob (2) and rotate it to an appropriate set value. 2 4) Loosen the lock nut (3) and rotate the adjustment screw (4). tighten the lock nut. 7) Fit the electric wire (6) in the terminal. the handle opens. 1 3) Referring to the Table in the Step 1). 6) Rotate the adjustment screw until the top-end of the terminal is aligned with the top-end of the tool hole. 8) Grip the handle and crimp the contact. Solder should not be added. Do not twist the wire strand. When you operate the handle up to the stroke end. Then. Be careful the wire strands not entering the contact barrel. 1). After that. rotate the adjustment screw (4). After that. of a terminal to use. the appropriate set value is different. For more information. tighten the lock nut. (Use a commercially available tool. 2) Strip insulation of wire 7mm. Depending on the Part No. 5 4) Fit the terminal into the hole of the universal hand crimp tool and loosen the lock nut (3). 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. cut the electric wire off the connector. . 4 3 Rotate the adjustment screw with the terminal pressed in.SEKN5003 18 of 23 8. refer to 7-3. 1) Disconnecting the mounted connector By using a nipper or a pair of needle nose pliers.) 3) Adjust the knob of the universal hand crimp tool to 5. 5) Rotate the adjustment screw until the top-end of the terminal is aligned with the top-end of the hole of the tool. 9) One all contacts are in place. Do not twist the strand wire. 10) Replace both the male and female connectors with new ones and attach the clamp 11) Fit the connector into the clamp. 8) Attach the terminal to a new connector. The wedge will snap into place. Clamp .SEKN5003 19 of 23 6) Set the terminal on the universal hand crimp tool and fit the electric wire into the terminal. 7) Grip the handle and caulk the contact. When you operate the handle up to the stroke end. the handle opens. insert the wedge. SEKN5003 20 of 23 9. Part No. 1 08191–13101 Receptacle: Pin (Male) Remarks Normal type 18–8 2 08191–14101 Receptacle: Socket (Female) Normal type 18–8 3 08191–13105 Receptacle: Pin (Male) Extra-Thin type 18–8 4 08191–14105 Receptacle: Socket (Female) Extra-Thin type 18–8 5 08191–12201 Plug: Socket (Female) Normal type 18–8 6 08191–11201 Plug: Pin (Male) Normal type 18–8 7 08191–12205 Plug: Socket (Female) Extra-Thin type 18–8 8 08191–11205 Plug: Pin (Male) Extra-Thin type 18–8 9 08191–23101 Receptacle: Pin (Male) Normal type 18–14 10 08191–24101 Receptacle: Socket (Female) Normal type 18–14 11 08191–23105 Receptacle: Pin (Male) Extra-Thin type 18–14 12 08191–24105 Receptacle: Socket (Female) Extra-Thin type 18–14 13 08191–22201 Plug: Socket (Female) Normal type 18–14 14 08191–21201 Plug: Pin (Male) Normal type 18–14 15 08191–22205 Plug: Socket (Female) Extra-Thin type 18–14 16 08191–21205 Plug: Pin (Male) Extra-Thin type 18–14 17 08191–33101 Receptacle: Pin (Male) Normal type 18–20 18 08191–34101 Receptacle: Socket (Female) Normal type 18–20 19 08191–32201 Plug: Socket (Female) Normal type 18–20 20 08191–31201 Plug: Pin (Male) Normal type 18–20 21 08191–43101 Receptacle: Pin (Male) Normal type 18–21 22 08191–44101 Receptacle: Socket (Female) Normal type 18–21 23 08191–42201 Plug: Socket (Female) Normal type 18–21 24 08191–41201 Plug: Pin (Male) Normal type 18–21 25 08191–53101 Receptacle: Pin (Male) Normal type 24–9 26 08191–54101 Receptacle: Socket (Female) Normal type 24–9 27 08191–52201 Plug: Socket (Female) Normal type 24–9 28 08191–51201 Plug: Pin (Male) Normal type 24–9 29 08191–63101 Receptacle: Pin (Male) Normal type 24–16 30 08191–64101 Receptacle: Socket (Female) Normal type 24–16 31 08191–63105 Receptacle: Pin (Male) Extra-Thin type 24–16 32 08191–64105 Receptacle: Socket (Female) Extra-Thin type 24–16 33 08191–62201 Plug: Socket (Female) Normal type 24–16 34 08191–61201 Plug: Pin (Male) Normal type 24–16 35 08191–62205 Plug: Socket (Female) Extra-Thin type 24–16 36 08191–61205 Plug: Pin (Male) Extra-Thin type 24–16 37 08191–73101 Receptacle: Pin (Male) Normal type 24–21 38 08191–74101 Receptacle: Socket (Female) Normal type 24–21 39 08191–73105 Receptacle: Pin (Male) Extra-Thin type 24–21 40 08191–74105 Receptacle: Socket (Female) Extra-Thin type 24–21 41 08191–72201 Plug: Socket (Female) Normal type 24–21 42 08191–71201 Plug: Pin (Male) Normal type 24–21 43 08191–72205 Plug: Socket (Female) Extra-Thin type 24–21 44 08191–71205 Plug: Pin (Male) Extra-Thin type 24–21 45 08191–83101 Receptacle: Pin (Male) Normal type 24–23 46 08191–84101 Receptacle: Socket (Female) Normal type 24–23 . PART NO. LIST OF HD30 CONNECTOR BODY 9-1 Part No. List of HD30 Connector Body (Without adaptor) No. Remarks 1 08191–13102 Receptacle: Pin (Male) Normal type 18–8 2 08191–14102 Receptacle: Socket (Female) Normal type 18–8 3 08191–13106 Receptacle: Pin (Male) Extra-Thin type 18–8 4 08191–14106 Receptacle: Socket (Female) Extra-Thin type 18–8 5 08191–12202 Plug: Socket (Female) Normal type 18–8 6 08191–11202 Plug: Pin (Male) Normal type 18–8 7 08191–12206 Plug: Socket (Female) Extra-Thin type 18–8 8 08191–11206 Plug: Pin (Male) Extra-Thin type 18–8 9 08191–23102 Receptacle: Pin (Male) Normal type 18–14 10 08191–24102 Receptacle: Socket (Female) Normal type 18–14 11 08191–23106 Receptacle: Pin (Male) Extra-Thin type 18–14 12 08191–24106 Receptacle: Socket (Female) Extra-Thin type 18–14 13 08191–22202 Plug: Socket (Female) Normal type 18–14 14 08191–21202 Plug: Pin (Male) Normal type 18–14 15 08191–22206 Plug: Socket (Female) Extra-Thin type 18–14 16 08191–21206 Plug: Pin (Male) Extra-Thin type 18–14 17 08191–33102 Receptacle: Pin (Male) Normal type 18–20 18 08191–34102 Receptacle: Socket (Female) Normal type 18–20 19 08191–32202 Plug: Socket (Female) Normal type 18–20 20 08191–31202 Plug: Pin (Male) Normal type 18–20 21 08191–43102 Receptacle: Pin (Male) Normal type 18–21 22 08191–44102 Receptacle: Socket (Female) Normal type 18–21 23 08191–42202 Plug: Socket (Female) Normal type 18–21 24 08191–41202 Plug: Pin (Male) Normal type 18–21 25 08191–53102 Receptacle: Pin (Male) Normal type 24–9 26 08191–54102 Receptacle: Socket (Female) Normal type 24–9 . List of HD30 Connector Body (With adaptor) No. Part No. Part No. Remarks 47 08191–83103 Receptacle: Pin (Male) Thin type 24–23 48 08191–84103 Receptacle: Socket (Female) Thin type 24–23 49 08191–83105 Receptacle: Pin (Male) Extra-Thin type 24–23 50 08191–84105 Receptacle: Socket (Female) Extra-Thin type 24–23 51 08191–82201 Plug: Socket (Female) Normal type 24–23 52 08191–81201 Plug: Pin (Male) Normal type 24–23 53 08191–82203 Plug: Socket (Female) Thin type 24–23 54 08191–81203 Plug: Pin (Male) Thin type 24–23 55 08191–82205 Plug: Socket (Female) Extra-Thin type 24–23 56 08191–81205 Plug: Pin (Male) Extra-Thin type 24–23 57 08191–93103 Receptacle: Pin (Male) Thin type 24–31 58 08191–94103 Receptacle: Socket (Female) Thin type 24–31 59 08191–93105 Receptacle: Pin (Male) Extra-Thin type 24–31 60 08191–94105 Receptacle: Socket (Female) Extra-Thin type 24–31 61 08191–92203 Plug: Socket (Female) Thin type 24–31 62 08191–91203 Plug: Pin (Male) Thin type 24–31 63 08191–92205 Plug: Socket (Female) Extra-Thin type 24–31 64 08191–91205 Plug: Pin (Male) Extra-Thin type 24–31 Part No.SEKN5003 21 of 23 9-2 No. SEKN5003 22 of 23 9-3 No. Part No. 24–23 and 24–31 (Tightening torque: 6. and 18–21 4 08191–50809 Washer for connectors 24–9. 18–14. 24–16. 18–14. 24–23. and 24–31 . Remarks 1 08191–10808 Nut for connectors 18–8. 24–21. 24–16. 18–20. 24–21. Remarks 27 08191–52202 Plug: Socket (Female) Normal type 24–9 28 08191–51202 Plug: Pin (Male) Normal type 24–9 29 08191–63102 Receptacle: Pin (Male) Normal type 24–16 30 08191–64102 Receptacle: Socket (Female) Normal type 24–16 31 08191–63106 Receptacle: Pin (Male) Extra-Thin type 24–16 32 08191–64106 Receptacle: Socket (Female) Extra-Thin type 24–16 33 08191–62202 Plug: Socket (Female) Normal type 24–16 34 08191–61202 Plug: Pin (Male) Normal type 24–16 35 08191–62206 Plug: Socket (Female) Extra-Thin type 24–16 36 08191–61206 Plug: Pin (Male) Extra-Thin type 24–16 37 08191–73102 Receptacle: Pin (Male) Normal type 24–21 38 08191–74102 Receptacle: Socket (Female) Normal type 24–21 39 08191–73106 Receptacle: Pin (Male) Extra-Thin type 24–21 40 08191–74106 Receptacle: Socket (Female) Extra-Thin type 24–21 41 08191–72202 Plug: Socket (Female) Normal type 24–21 42 08191–71202 Plug: Pin (Male) Normal type 24–21 43 08191–72206 Plug: Socket (Female) Extra-Thin type 24–21 44 08191–71206 Plug: Pin (Male) Extra-Thin type 24–21 45 08191–83102 Receptacle: Pin (Male) Normal type 24–23 46 08191–84102 Receptacle: Socket (Female) Normal type 24–23 47 08191–83104 Receptacle: Pin (Male) Thin type 24–23 48 08191–84104 Receptacle: Socket (Female) Thin type 24–23 49 08191–83106 Receptacle: Pin (Male) Extra-Thin type 24–23 50 08191–84106 Receptacle: Socket (Female) Extra-Thin type 24–23 51 08191–82202 Plug: Socket (Female) Normal type 24–23 52 08191–81202 Plug: Pin (Male) Normal type 24–23 53 08191–82204 Plug: Socket (Female) Thin type 24–23 54 08191–81204 Plug: Pin (Male) Thin type 24–23 55 08191–82206 Plug: Socket (Female) Extra-Thin type 24–23 56 08191–81206 Plug: Pin (Male) Extra-Thin type 24–23 57 08191–93104 Receptacle: Pin (Male) Thin type 24–31 58 08191–94104 Receptacle: Socket (Female) Thin type 24–31 59 08191–93106 Receptacle: Pin (Male) Extra-Thin type 24–31 60 08191–94106 Receptacle: Socket (Female) Extra-Thin type 24–31 61 08191–92204 Plug: Socket (Female) Thin type 24–31 62 08191–91204 Plug: Pin (Male) Thin type 24–31 63 08191–92206 Plug: Socket (Female) Extra-Thin type 24–31 64 08191–91206 Plug: Pin (Male) Extra-Thin type 24–31 Connector mounting nut and washer No.8kg·cm) 2 08191–50808 Nut for connectors 24–9. 18–20.5kg·cm) 3 08191–10809 Washer for connectors 18–8. and 18–21 (Tightening torque: 4. Part No. SEKN5003 23 of 23 May 2000 Customer Support Division .