Service Training SEGV3003

Course Module July 1997

TECHNICAL PRESENTATION

TRUE RMS MULTIMETER

FLUKE 87
AUTO DC

0 0 00
0 1 2 3 4 5 6 7 8 9 0
V

± 4
CATERPILLAR
MIN MAX RANGE HOLD

REL ∆

MACHINE
Hz
Peak Min Max

Ω
---
mV

---
V mA
A
ELECTRONICS
~V
µA

OFF
COURSE
A mA µA COM V-Ω

400mA MAX
FUSED

10A MAX 1000V MAX

FUSED

MODULE THREE: WIRE MAINTENANCE

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TABLE OF CONTENTS

COURSE DESCRIPTION............................................................................................................3

MODULE DESCRIPTION/OBJECTIVES..................................................................................4

LESSON PLAN ............................................................................................................................5

WIRE MAINTENANCE ..............................................................................................................6

CONNECTORS ..........................................................................................................................10

DEUTSCH CROSS REFERENCE LIST ...................................................................................21

MODULE THREE QUIZ ...........................................................................................................27

SURE-SEAL CONNECTOR EXERCISE .................................................................................28

DEUTSCH CONNECTOR EXERCISE.....................................................................................29

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COURSE DESCRIPTION

This module is a review of the basic electrical and electronic principles needed by a technician to
understand and maintain the complex machine systems installed in Caterpillar products. The modules
do not teach specific machine systems unless otherwise stated in the lesson description.

Each module contains a quiz/skill test to measure the student's electrical/electronic skills and
knowledge. It is recommended that the pretest be completed prior to scheduling training. The pretest is
designed to evaluate each module of the course and may be used as a "skills/knowledge inventory" for
the evaluation of each student.

Suggest the following procedure:

Pretest
• Administer the pretest.
• Do not answer questions regarding pretest content.
• Collect pretest, do not review or discuss test with students.
• Grade the pretest, but do not pass out scores.
• Use the pretest to evaluate each students knowledge prior to receiving instruction.

Posttest
• Each module lesson quiz/skill test will serve as a posttest for the individual modules.
• Have students exchange tests and review and discuss each question.
• Have students mark the incorrect responses.
• Collect all copies of the quizzes/skill tests and file for future reference.

The course is designed as several modules. The current modules are:

Module 1: Basic Electrical and Electronic Principles (SEGV3001)

Module 2: Electronic Components (SEGV3002)
Module 3: Wire Maintenance (SEGV3003)
Module 4: Electrical Schematics (SEGV3004)
Module 5: Machine Electrical and Electronic Systems, Diagnostic Tooling and Troubleshooting
Procedures (SEGV3005)
Additional Support Information:
List of Acronyms and Glossary of Electrical/Electronic Terms (SEKV3001)
Machine Electronic Course Pretest (SEBV3001)
Machine Electronic Course Pretest Answers (SEEV3001)

Each module contains the following:

A module description
A module objective
A module plan
A list of reference materials or job aids needed to present the module
A student handout section (if applicable)
A student quiz and a master copy of the quiz for the instructor (with answers)
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Module Three MODULE THREE: WIRE MAINTENANCE

Time: 2 Hours Module Three Description

The wire maintenance module provides the student with the necessary
information needed to understand and perform the tasks associated with
installing and maintaining electrical connectors and other related wire
maintenance tasks. This module will discuss wire maintenance
applications and some of the more common connectors used on
Caterpillar product.

Presentation Methods Lecture and Demonstration

Module Three Objective

Given Sure-Seal and Deutsch connector kits, demonstrate an ability to

install contacts, remove contacts, and service connectors used on
Caterpillar product.

Module Three Reference Materials and Job Aids

Show Video Prior to conducting Module Three have students view video "Basic Wire
Maintenance"--SEVN3197

Special Tooling required to demonstrate connectors:

6V3000 Sure-Seal Repair Kit
6V3001 Crimping Tool
6V3008 Insertion Tool
4C3406 Deutsch Connector Kit
9U7246 Deutsch Connector Kit
1U5804 Deutsch Connector Crimp Tool
9U7560 Field Soldering Iron Group (optional)
4C9024 Battery Group (optional)

Order Literature Service Literature required:

Special Instruction--Use of VE Connector Tool Group.......SEHS8038
Special Instruction--Use of 6V3000 Sure Seal Kit..............SMHS7531
Special Instruction--Use of CE Connector Tools.................SEHS9065
Special Instruction--Servicing DT Connectors....................SEHS9615
Video--Basic Wire Maintenance..........................................SEVN3197
Tool Operating Manual--9U7560 Field Soldering Iron
Group....................................................................................NEHS0601

Miscellaneous Items:
Small bottle of denatured alcohol.
Duplicate Handouts Student Handouts (Deutsch cross reference list) located at the end of the
presentation section.
Module Three Quiz located at end of Deutsch cross reference list.
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Module Three Module Lesson Plan

Lecture Note: Decide whether to conduct the lab exercises prior to the
presentation or at the end. See note below.

Slide Presentation (Slides 1 through 11)

A. Wire Maintenance (Slides 1 through 4)

1. Introduction to Module
2. Conductors
Video, Lecture and 3. Wire Sizing
Demonstration 4. Connectors

Show video "Basic Wire Maintenance"-- SEVN3197

B. Types of Connectors (Slides 5 through 11)

1. VE Connectors
2. Sure-Seal Connectors
3. Deutsch Connectors
a. HD10 Series
b. DT Series
c. CE Series
d. DRC Series
Lab Exercises
(Optional) C. Administer Quiz

D. Sure-Seal and Deutsch Connector Student Exercises located at

end of module. (Optional--Instructor Discretion)

Note: The two student exercises may be administered prior to the slide
presentation or afterwards. If the exercises are conducted prior to the
classroom instruction they provide instant feedback on the technicians
knowledge and experience in the area of wire maintenance. If they are
conducted after the video and slide presentation they do not reflect the
students past experiences, but measure the most recent demonstration.
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WIRE
MAINTENANCE

Wire Maintenance

With increased use of electronic systems on Caterpillar machines a much

stronger emphasis needs to be placed on the servicing of the various types
of connectors. 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.
SEGV3003 -7- Module Three
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RΩ
A.
2XRΩ

RΩ
B. RΩ 2
6Ω

Resistance
C. 5Ω

80°F 125°F
Temperature

Conductors

Most metals are good conductors, and copper is the most common metal
used for conductors (wires) in Caterpillar electrical systems.
Engineering selects the copper conductor (based on an acceptable amount
of resistance) that meets the need of a specific circuit. For a copper wire,
the resistance depends upon:

• the length of the wire

• the cross-sectional area of the wire
• the temperature of the wire

If the length of wire is doubled (Example A), the total resistance of the
wire is doubled. The longer the wire, the greater the resistance between
the two ends.

If the cross-sectional area (Example B) is reduced by half, the resistance

for any given length is doubled.

➥
SEGV3003 -8- Module Three
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Also, As temperature rises (Example C) in a copper wire, the resistance

increases.

Excessive resistance in a conductor from normal heat can adversely affect

the performance of electrical and electronic components. If the conductor
gets too hot, the insulation protecting the conductor will be damaged.

In most circuits, the smallest wire that will not create too much voltage
drop is normally used to reduce manufacturing costs.
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WIRE SIZING
AWG DIAMETER (mils) OHMS PER 1000 FT
10 102.9 .9989
12 80.8 1.588
14 64.1 2.525
16 50.8 4.016
18 40.3 6.385
20 32.0 10.15
22 25.4 16.14
30 10.0 103.2
40 3.10 1049.0

Wire sizing

Electrical and electronic circuits are engineered with specific size and
length conductors to provide paths for current flow. When repairing or
replacing machine wiring it is necessary to use the correct size and length
conductors. This slide illustrates the typical resistances for various size
conductors.

Use the chart on the Use the difference between a 14 AWG wire and a 18 AWG wire to make
slide to demonstrate a point. The 14 AWG wire has approximately 2.5 ohms per 1000 feet
the difference. and a 18 AWG wire which is approximately 36% smaller in diameter has
approximately 6.4 ohms per 1000 feet.
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CONNECTORS
No Asperity Asperity
Pin Contacts Socket Contact No Contact

ASPERITY IN
PIN CONTACTS

SOCKET PIN
Condition of Asperity

Contact No Contact

Electrons
Converging

Connectors

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 haves are joined, current is allowed to pass.

Asperity

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.

➥
SEGV3003 - 11 - Module Three
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Plating

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
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.

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.

Technicians need to be aware that 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, technicians need to be aware that disconnecting
and reconnecting connectors during the troubleshooting process can
give misleading diagnostic information. Additionally, advise students to
use breakout cables sparingly when troubleshooting intermittent type
electrical problems.
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TYPES OF
CONNECTORS

D
L

EU
EN R
TA
M A

TS
N L
O CU

C
H
IR I
V EH
EN V

SURE-SEAL

Types of Connectors

Several types of connectors are used throughout the electrical and

electronic systems on Caterpillar machines. Each type differs in the
manner in which they are serviced or repaired. Consult the appropriate
Special Instruction for the correct procedures.

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)

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VE (Vehicular Environmental) Connector

Special Instruction Used primarily on earlier Caterpillar machine electrical harnesses where
SEHS8038 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.

Do not use metal release tools (listed in SEHS8038) for any other type
of electrical connector.

After crimping a wire to the contact it is recommended that the contact be

soldered to provide for a good electrical contact. Use only rosin core
solder on any electrical connection.

Specific information relating to the process required for installing VE

connectors contacts (pins and sockets) is contained in Special Instruction-
-Use of 6V4810 VE Connector Tool Group (Form SEHS8038-01).

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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Sure-Seal Connectors

Special Instruction This type of connector is used extensively on Caterpillar machines. These
SMHS7531 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). Part numbers for spare plug and receptacle housings and
contacts are contained in Special Instruction--Use of 6V3000 Sure-Seal
Repair Kit (Form SMHS7531-01).

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.

Optional student lab exercise located at end of lesson.

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Deutsch Connectors

HD10 "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, Caterpillar 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.

➥
SEGV3003 - 16 - Module Three
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Inserting Contacts

Demonstrate to class Step #1: Grasp the contact-wire assembly between the thumb and
forefinger on the wire approximately one inch behind the
Materials needed contact crimp barrel.
1. Wire with contact
crimped.
Step #2: Hold the connector (shell) with the rear grommet facing you.
2. HD10 shell
Step #3: Push the contact straight into the connector grommet until a
positive stop is felt. The retaining fingers in the connector will
snap behind the shoulder of the contact and lock into place. A
slight tug will confirm that the contact is properly sealed.

INSERTING LOCKED

Draw on Board

Removing Contacts

Step #1: With the rear of the insert toward you. Snap the appropriate
size plastic removal tool over the wire of the contact to be
removed.

Step #2: Slide the removal tool along the wire into the insert cavity until
it engages the contact and a resistance is felt. The contact
retaining clip will now be in the unlocked position.

Step #3: Pull the contact wire assembly out of the connector.

Release locks Remove Contact

Tool

Draw on Board

Must use appropriate sized tool for contact removal. For a more
detailed explanation on the insertion and removal of a Deutsch contact,
consult Special Instruction--Use of CE Connector Tools (SEHS9065).
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DT Series

DT "Deutsch The DT connector is a thermoplastic connector utilizing crimp type

Transportation" 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 or stamped and formed contacts (less costly). The contacts
are crimp terminated using a Deutsch Crimp Tool, Caterpillar 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.

For a more detailed explanation on servicing the DT connector, consult

Special Instruction--Servicing DT Connectors (SEHS9615).

➥
SEGV3003 - 18 - Module Three
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Terminal Removal Procedure

Demonstrate to class Demonstrate the following tasks (Consult SEHS9615):

1. Terminal Removal Removal from Plug Housing

Step #1: Remove wedge from plug housing using screwdriver.

Step #2: Release locking finger using screwdriver.

Step #3: Pull wire and contact out of connector housing.

Removal from Receptacle Housing

Step #1: Remove wedge using long nose pliers.

Step #2: Remove wedge using 9U7247 Wedge Removal Tool.

Step #3: Release locking finger using screwdriver.

Step #4: Pull wire and contact out of connector housing.

2. Terminal Crimping
Terminal Crimping Procedure

Demonstrate the following tasks (Consult SEHS9615):

Step #1: Strip wire.

Step #2: Insert wire into the socket terminal end (the end with the
inspection hole).

Step #3: Using Wire Crimp Tool 1U5804, set tool to correct wire
size.

Step #4: Insert terminal into the tool and adjust tool until terminal is
flush with tool face.

Step #5: Insert wire into terminal and squeeze crimping tool.

Step #6: Release handles, remove terminal and perform an inspection

of the crimp.

Inserting the terminal in the connector housing is the same procedure

used for the HD10 connector, and does not need to be demonstrated for
the DT connector.
SEGV3003 - 19 - Module Three
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10

CE "Caterpillar CE Series
Environmental"
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, and
the tool for #12 - #18 contacts is the same tool as used on the HD and DT
Series connectors (1U5804).
SEGV3003 - 20 - Module Three
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11

DRC "Deutsch DRC Series

Rectangular
Connector"
The DRC connector features a rectangular thermoplastic housing and is
completely environmentally sealed. The DRC is best suited to be
compatible 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 or stamped and formed contacts (less costly). The contacts
are crimp terminated using a Deutsch Crimp Tool, Caterpillar part number
1U5805.

The connector contains a "clocking" key for correct orientation and is

properly secured by a stainless steel jackscrew. A 4mm (5/32 in.) HEX
wrench is required to mate the connector halves. The recommended
torque for tightening the jackscrew is 25 inch pounds.

The contact installation and removal procedures are the same as those
used for the HD10 series and will not be repeated.

Optional student lab exercise located at end of lesson.

SEGV3003 - 21 - Module Three
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Deutsch Connector Cross Reference List

DESCRIPTION OF PRODUCT DEUTSCH P/N CATERPILLAR P/N

Contacts

#14 Socket Contact 0462-209-16141 9W0844

#14 Pin Contact 0460-215-16141 9W0852
#16 /# 18 Pin Contact 0460-202-16141 8T8729
#16 / #18 Socket Contact 0462-201-16141 8T8730
#18 Pin Contact (Stamped &Formed) 1060-16-0122 3E3390
#18 Socket Contact (S & F) 1062-16-0122 3E3391
#16 / #14 Pin Contact (S & F) 1060-14-0122 106-9615
#16 / #14 Socket Contact (S & F) 1062-14-0122 106-9618
#16 / #18 Pin Contact (Extended) 0460-247-16141 7T9742
#16 / #18 Pin Contact (Gold) 0460-202-1631 9X3401
#16 / #18 Socket Contact (Gold) 0462-201-1631 9X3402
#12 / #14 Socket Contact (Gold) 0462-210-1231 3E5226

DT Connectors

2 Pin Plug DT06-2S-PO04 3E3360

2 Pin Plug W/Cap DT06-2S-EP04 3E3361
2 Pin Plug Wedge W2S 3E3362
2 Pin Receptacle DT04-2P-PO04 3E3363
2 Pin Receptacle W/Cap DT04-2P-EP04 3E3364
2 Pin Receptacle Wedge W2P 3E3365
2 Pin Receptacle (90 Degree) DT04-2P-NO06 9X0352
3 Pin Plug DT06-3S-PO04 3X3366
3 Pin Plug W/Cap 3E3367
3 Pin Plug W/Protective Cap DT06-3S-EP05 104-2921
3 Pin Plug Wedge W3S 3E3368
3 Pin Receptacle DT04-3P-PO04 3E3369
3 Pin Receptacle W/CaP DT04-3P-EP04 3E3370
3 Pin Receptacle Wedge W3P 3E3371
4 Pin Plug DT06-4S-P004 3E3372
4 Pin Plug W/Cap DT06-4S-EP04 3E3373
4 Pin Plug Wedge W4S 3E3374
4 Pin Receptacle DT04-4P-PO04 3E3375
4 Pin Receptacle W/Cap DT04-4P-EP04 3E3376
4 Pin Receptacle Wedge W4P 3E3377
4 Pin Receptacle, Inside Mt. (Experimental) DT04-4P-LE02 100-6655
6 Pin Plug DT06-6S-PO04 3E3378
6 Pin Plug W/Cap DT06-6S-EP04 3E3379
6 Pin Plug Wedge W6S 3E3380
6 Pin Receptacle DT04-6P-PO04 3E3381
6 Pin Receptacle W/Cap DT04-6P-EP04 3E3382
6 Pin Receptacle Wedge W6P 3E3383
8 Pin Plug DT06-08SA-PO04 3E3384
SEGV3003 - 22 - Module Three
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8 Pin Plug W/Cap DT06-08SA-EP04 3E3385

8 Pin Plug Wedge W8S 3E3386
8 Pin Receptacle DT04-08PA-PO04 3E3387
8 Pin Receptacle W/Cap DT04-08PA-EP04 3E3388
8 Pin Receptacle Wedge W8P 3E3389
12 Pin Plug DT06-12SA-PO04 3E5175
12 Pin Plug W/Cap DT06-12SA-EP04 3E5176
12 Pin Plug Wedge W12S 3E5177
12 Pin Receptacle DT04-12PA-PO04 3E5178
12 Pin Receptacle W/Cap DT04-12PA-EP04 3E5179
12 Pin Receptacle Wedge W12P 3E5180
12 Pin Receptacle, Inside Mount DT04-12PA-LE01 3E7990
12 Pin Receptacle, Outside Mount DT04-12PA-LE03 3EB969

HD10'S

3 Pin Plug (2 Pin Grommet) HD16-9-96S-CO11 9X563

3 Pin Receptacle (2 Pin Grommet) HD10-9-96P-BCO11 9X5635
3 Pin Receptacle (13 Bulkhead. No Thread) HD10-3-96P-BO09 7X6200
3 Pin Receptacle HD14-3-96P 8T8732
3 Pin Plug HD16-3-96S 8T8731
3 Pin Receptacle (Bulkhead) HD10-3-96P 9X4813
5 Pin Receptacle (Not for New Design) HDl4-5-16P 8T8734
5 Pin Plug (Not for New Design) HD16-5-16S 8T8733
5 Pin Receptacle (Bulkhead Special) NFND HDl0-5-16P-BO09 3E5394
6 Pin Receptacle HD14-6-96P 7T3272
6 Pin Plug HD16-6-96P 803654
6 Pin Plug (Date Link) HD16-6-12S 3E5225
6 Pin Receptacle (Bulkhead) HD10-6-96P 9X4814
9 Pin Receptacle HDl4-9-96P 8T8736
9 Pin Receptacle (Bulkhead, Old Insert Ar.) HD10-9-16P-BO09 7X6195
9 Pin Receptacle (Bulkhead-Special) HD10-9-96P-BO09 9W1951
9 Pin Receptacle (In Line, Old Insert Ar.) HD14-9-16P 7X6217
9 Pin Plug HD16-9-96S BT8735
9 Pin Plug (Old Insert Arrangement) HD16-9-16S 9W0847

DRC'S

24 Pin Receptacle, Outside Mt., Solder Cup A DRC10-24PA 7X6221

24 Pin Receptacle, Outside Mt., Solder Cup B DRC10-24PB 3E5312
24 Pin Receptacle, Outside Mt., PC Pin A DRC10-24PA-AO04 3E8826
24 Pin Receptacle, Flange Mt., Serviceable A DRC12-24PA 9X0145
24 Pin Receptacle, Flange Mt., Serviceable B DRC12-24PB 9X7143
24 Pin Receptacle, Flange Mt., Serviceable C DRC12-24PO 9X7145
24 Pin Receptacle, In-line, Serviceable A DRC14-24PA 9X0146
24 Pin Plug A DRC16-24SA 7X6222
24 Pin Plug B DRC16-24SB 9X7144
24 Pin Plug C DRC16-24SC 9X7146
SEGV3003 - 23 - Module Three
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40 Pin Receptacle, Outside Mt. Solder Cup DRC10-40P 8T9833

40 Pin Receptacle, Outside Mt., PC Pin DRC10-40P-AO04 3E9399
40 Pin Receptacle, Flange Mt., Serviceable A DRC12-40PA 9Xl343
40 Pin Receptacle, Flange Mt., Serviceable B DRC12-40PB 9X7148
40 Pin Receptacle, In-Line, Serviceable A DRC14-40PA 9X1339
40 Pin Plug DRC16-40S 8T9834
40 Pin Plug, Keyed A DRC18-40SA 9X0141
40 Pin Plug, Keyed B DRC18-40SB 9X7147
40 Pin Plug, Keyed A (ADEM) AEC16-40SA 3E6286
40 Pin Plug, Keyed B (ADEM) AEC16-40SB 3E6287
40 Pin Plug, Keyed C (ADEM) AEC16-40SC 101-0204
40 Pin Plug, Keyed D (ADEM) AEC16-40SD 101-0205
40 Pin Plug, Keyed Universal (ADEM) AEC16-40SU 105-2081
40 Pin Receptacle, Inside Mt., A (ADEM) AEC13-40PA 3E6156
40 Pin Receptacle, lnside Mt., B (ADEM) AEC13-40PB 3E6157
40 Pin Receptacle, Inside Mt., C (ADEM) AEC13-40SC 101-0206
40 Pin Receptacle, Inside Mt., D (ADEM) AEC13-40SD 101-0207
40 Pin Receptacle, In-Line, Serv- AB (ADEM) AEC13-40PAB 104-9655
70 Pin Receptacle, Inside Mt., A DRC13-70PA 3E0059
70 Pin Receptacle, Inside Mt., B DRC13-70PB 9X0348
70 Pin Receptacle, Inside Mt., D DRC13-70PO 3E6447
70 Pin Receptacle, Flange Mt., Serviceable A DRC12-70PA 103-0213
70 Pin Plug A DRC16-70SA 9X4391
70 Pin Plug B DRC16-70SB 9X0347
70 Pin Plug C DRC16-70SD 3E6448

Sealing

Sealing Plug #14, #16, #18 114017 8TB73

Seal 24 Pin (Flange) 0510-014-2406 9Xl365
Seal 40 Pin (Flange) 8C6024
Seal O-Ring 70 Pin (Flange) 9X7739
Seal 40 Pin ADEM (Flange) 3E6158
Seal 24 Pin (interface) 0673-009-2406 9X3265
Seal 40 Pin (interface) Non-Keyed 0510-003-0006 9x3l32
Seal 40 Pin (interface) Keyed 0513-010-4006 9X3490
Seal 40 Pin ADEM (interface) 0613-012-4006 3E6285
Seal 70 Pin (Interface) 0513-011-7006 9X5615
Seal 12 Pin DT (Outside Mt. Flange) 1013-003-1206 6V0128
Seal 2 Pin DT (interface) 1010-009-0206 102-8812
Seal 3 Pin DT (interface) 1010-002-0306 102-8813
Seal 4 Pin DT (interface) 1010-016-0406 102-8814
Seal 6 Pin DT (interface) 1010-017-0606 102-8815
Seal 8 Pin DT (interface) 1010-007-0806 102-8816
Seal 12 Pin OT (interface) 1010-020-1206 102-8817
SEGV3003 - 24 - Module Three
7/97 Student Handout

Service Tools

#14 Size Removal Tool (Green), HD10 Only 0411-291-1405 1U5805

#16 Size Removal Tool (Blue) 0411-204-1605 8T5318
CE Removal Tool Kit: #6, #8, #12, #16 HDT-10-RT 8T5319
HD10 Service Tool Kit W/Hand Crimp Tool HDT-48-04 4C3406
DT Service Kit W/Hand Crimp Tool 9U7250
DT Service Kit W/0 Hand Crimp Tool 9U7246
Hand Crimp Tool HDT-48-00 1U5804
(DT/HD10/DRC/CE #l2, #14, #16AWG)
Hand Crimp Tool HDT-04-10 4C4075
(CE #4, #6, #8, #10 AWG)

DT Service Kits

2 Pin Plug Kit HDT-06-2S-EP04 102-8807

2 Pin Receptacle Kit HDT-04-2P-EP04 102-8802
3 Pin Plug Kit HDT-06-3S-EP05 102-8808
3 Pin Receptacle Kit HDT-04-3P-EP04 102-8803
4 Pin Plug Kit HDT-06-4S-EP04 102-8809
4 Pin Receptacle Kit HDT-04-4P-EP04 102-8804
6 Pin Plug Kit HDT-06-6S-EP04 102-8810
6 Pin Receptacle HDT-04-6P-EP04 102-8805
8 Pin Plug Kit HDT-06-OBSA-EP04 102-8811
8 Pin Receptacle Kit HDT-04-08PA-EP04 102-8806
12 Pin Plug Kit HDT-06-12SA-EP04 102-8800
12 Pin Receptacle Kit HDT-04-12PA-EP04 102-8801
12 Pin Receptacle Kit (Inside Mount) HDT-04-12PA-LE01 103-8133
12 Pin Receptacle Kit (Outside Mount) HDT-04-12PA-LE03 103-8134

Hardware

Bolt, 40 & 24 Pin Bulkhead, Outside Mt. 8T3998

Washer, 40 & 24 Pin Bulkhead, Outside Mt. 8C9660
Screw, DRC Inside Mount 9X8280
Clip Assembly (3 Pin) 9X3495
Clip, DT (2, 3, 4, 6, 12) 3E6445
Bolt, Jackscrew (40, 70 DRC) 0526-001-00221 3E8557
Bolt, Jackscrew (24 DRC) 0526-004-00221 3E8558
Bolt Kit, Jackscrew (40 AEC 90) 0526-005-00221 6V6703
Bolt Kit, Jackscrew (40 AEC In-line) 0534-002-0001 106-4155
Ring, Retaining (Jackscrew) 3E4367
Cover O-Ring (70 Pin Flange) 9X9917
SEGV3003 - 25 - Module Three
7/97 Quiz
Instructor Copy

Endbells

Endbell 3 Pin HD-18-003 7X6198

Endbell 6 Pin HD-18-006 7X6199
Endbell 9 Pin HD-18-009 7X6197

Caps

Cap 3 Pin Plug HDC-14-3 9X3467

Cap 3 Pin Receptacle HDC-16-3 100-5805
Cap 6 Pin Plug HDC-14-6 9X4404
Cap 6 Pin Receptacle HDC-16-6 9X4405
Cap 9 Pin Plug HDC-14-9 8C6353
Cap 9 Pin Receptacle HDC-16-9 8C6354
Cap 24 Pin Receptacle 0515-004-2405 9X4713
Cap 24 Pin Plug 0515-005-2405 9X4714
Cap 40 Pin Receptacle 0515-002-4005 9X4711
Cap 40 Pin Plug 0515-001-4005 9X4712
Cap 40 Pin Receptacle (Shipping) 9X960l
Cap 40 Pin Receptacle (Sealed Shipping) 0504-001-4001 3E6443
Cap 40 Pin Receptacle (Sealed Ship-ADEM) 0504-002-4001 3E6446
SEGV3003 - 26 - Module Three
7/97 Quiz
Instructor Copy

Directions: Fill in the blanks and/or circle the correct answer.

1. What is the purpose of a connector? To Pass current from one wire to another.

2. What is asperity? Roughness or peaks and valleys on a surface which causes resistance.

3. Deutsch contacts should be soldered after crimping. True or False

4. Removing a pin contact from a Sure-Seal connector housing requires special tooling. True or False

5. Sure-Seal connectors are limited to a capacity of 10 pins and/or sockets contacts.

6. All unused holes in a connector housing require sealing plugs. True or False

7. After crimping, all contacts should be soldered using Rosin core solder. True or False

8. What is the suggested lubrication for installing contacts in Sure-Seal connectors?

Denatured Alcohol

9. A special tool is required for inserting contacts in a Sure-Seal connector housing. True or False

10. HD10 Series connectors are rectangular or triangular in design. True or False

11. Removing a contact from a DT Series connector housing requires special tooling. True or False

12. What is the suggested lubrication for installing contacts in DRC Series connectors?
None Required

13. On Deutsch Contacts, the wire is inserted into the end with inspection hole. True or False

14. The recommended cleaning solvent for all Deutsch contacts is? Denatured Alcohol

15. When using a Deutsch Crimping Tool (1U5804) it is necessary to set the wire selector gauge knob
to the size of the wire being crimped. True or False
SEGV3003 - 27 - Module Three
7/97 Quiz
Student Copy

Directions: Fill in the blanks and/or circle the correct answer.

1. What is the purpose of a connector? _________________________________________________

2. What is asperity? _____________________________________________________________

3. Deutsch contacts should be soldered after crimping. True or False

4. Removing a pin contact from a Sure-Seal connector housing requires special tooling. True or False

5. Sure-Seal connectors are limited to a capacity of __________ pins and sockets contacts.

6. All unused holes in a connector housing require sealing plugs. True or False

7. After crimping, all contacts should be soldered using Rosin core solder. True or False

8. What is the suggested lubrication for installing contacts in Sure-Seal connectors? ____________

9. A special tool is required for inserting contacts in a Sure-Seal connector housing. True or False

10. HD10 Series connectors are rectangular or triangular in design. True or False

11. Removing a contact from a DT Series connector housing requires special tooling. True or False

12. What is the suggested lubrication for installing contacts in DRC Series connectors? ____________

13. On Deutsch Contacts, the wire is inserted into the end with inspection hole. True or False

14. The recommended cleaning solvent for all Deutsch contacts is? ________________________

15. When using a Deutsch Crimping Tool (1U5804) it is necessary to set the wire selector gauge knob
to the size of the wire being crimped. True or False
SEGV3003 - 28 - Module Three
7/97 Sure-Seal Connector Exercise

Exercise: Sure-Seal Connectors

This lesson allows you to become familiar with constructing Sure-Seal Connectors.

• Cut lengths of #16 AWG wire at least six inches long.

• Take one pin or socket from the Sure-Seal Repair Kit.

• Use either a 6V3001 (if available) or 9S9150 (if available) Crimp tools.

• Use a Sure-Seal connector from the repair kit and insert the contact into the connector.

Note: You will be inspected for the following for this lesson:
• Did you select the correct crimp tool?
• Was the wire stripped according to specification?
• Was the contact crimped according to specification?
• Was the contact (pin or socket) installed correctly in the connector body, using the
insertion tool and lubricant?
• If any of the above procedures were not within specification, have the student (using the
Special Instruction) repeat the procedure on the opposite end of the conductor.

6V3000 Repair Kit, Sure-Seal

6V3001 Crimping Tool (2 each, if available)
6V3008 Insertion Tool
1P2305 Terminal and Connector Assortment
9S9150 Crimping Tool (2 each, if available)
1 small bottle of denatured alcohol
#16 AWG wire ( enough for each student to have two pieces at least six inches long)
1-1U5804 Crimp Tool (Deutsch connectors)
Use of 6V3000 Sure-Seal Repair Kit...............................................................................SMHS7531
Video "Basic Wire Maintenance".....................................................................................SEVN3197
SEGV3003 - 29 - Module Three
7/97 Deutsch Connector Exercise

Exercise: Deutsch Connectors

This lesson allows you to become familiar with constructing Deutsch Connectors including CE
connectors.

• Cut lengths of #16 AWG wire at least six inches long.

• Take one pin or socket (#14/#16) from the Deutsch Repair Kit.

• Use a 1U5804 Crimp tool.

• Use a Deutsch connector from the repair kit and insert the contact into the connector.

Note: You will be inspected for the following for this lesson:
• Did you select the correct crimp tool?
• Was the wire stripped according to specification?
• Was the contact crimped according to specification?
• Was the contact (pin or socket) installed correctly in the connector body, using the
insertion tool and lubricant?
• If any of the above procedures were not within specification, have the student (using the
Special Instruction) repeat the procedure on the opposite end of the conductor.

1-9U7246/9U7250 Deutsch Connector Kit

1-1U5804 Crimp Tool (Deutsch connectors)
1 small bottle of denatured alcohol
1-1U5805 #14 wire removal tool (Green), HD10 Only
1-8T5318 #16 wire removal tool (Blue)
#16 AWG wire (enough for each student to have two pieces at least six inches long)
Use of CE Connector Tools..............................................................................................SEHS9065
Servicing DT Connectors ................................................................................................SEHS9615
Video "Basic Wire Maintenance".....................................................................................SEVN3197