D I S T R I B U T I O N a TE Connectivity Company TE Connectivity's Industrial & Commercial Transportation Products D I S T R I B U T I O N a TE Connectivity Company LADD specializes in the sales, marketing, distribution, and technical support of select TE Connectivity Industrial & Commercial Transportation electrical connectors and accessories. LADD is more than just a distributor. We haven't forgotten the importance of personal service. The Customer Service department can assist you with technical answers, pricing, orders, and more. TE Connectivity Industrial & Commercial Transportation Distribution LADD Distribution CANADA & UNITED STATES: LADD Distribution LLC Tel: +1-800-223-1236 Fax: +1-937-438-9755 ladd.us@te.com ladd.canada@te.com CHINA: LADD Distribution Deutsch Connectors Trading (Shanghai) Co., Ltd. Tel: +8621-33981423 ladd.china@te.com EUROPE, MIDDLE EAST, & AFRICA: LADD Distribution Tyco Electronics AMP GmbH Tel: +49-89-899157-0 Fax: +49-89-8574684 ladd.emea@te.com JAPAN: LADD Distribution Ltd. Tel: +81-3-5922-1345 ladd.japan@te.com Other TE Connectivity Locations ARGENTINA: Tyco Electronics Argentina S.A. Tel: +5411-4733-2200 Fax: +5411-4733-2213 AUSTRALIA: Tyco Electronics Pty Limited Tel: +1300-509-970 DeutschANZ@te.com BRAZIL: Tyco Electronics Brasil Ltda. Tel: +55-11-3404-6000 Fax: +55-11-3404-6091 INDIA: Deutsch India Power Connectors Ltd. Tel: +91-120-6794425 Fax: +91-120-6794413 ISRAEL: Deutsch Israel Ltd. Tel: +972-8-671-9020 KOREA: Tyco Electronics AMP Korea Limited Tel: +82-2-3415-4583 Fax: +82-2-3486-3595 SOUTH AFRICA: Tyco Electronics South Africa (Proprietary) Ltd. Tel: +2711-707-6300 Fax: +2711-466-3555 UNITED KINGDOM: Deutsch UK Tel: +01424-857148 Fax: +01424-855979 LADD Distribution | 800-223-1236 | laddinc.com Table of Contents General Information About TE Connectivity 2 STRIKE Series Connector Series Overview 8 Tooling Introduction to Connectors 3 Technical Specifications 5 Products 81 129 Specialty Products Bussing Options 85 Controller Area Networks 91 97 AEC Series 13 Diodes & Resistors AMPSEAL Connectors 17 Printed Circuit Board Connectors 101 AMPSEAL16 Connectors 23 Single Terminal 111 Contacts 115 DRB Series 29 DRC Series 37 DT Family HD10 Series HD30 & HDP20 Series Additional Resources Modification List 142 Standards 149 Glossary 150 Index 157 43 61 69 TE Connectivity About TE Connectivity TE Connectivity's Industrial & Commercial Transportation business unit - every connection counts TE Connectivity's products are in nearly every high-tech product imaginable. From consumer electronics, health care, energy supply, and communication networks, to the automotive and aviation industries, TE's extensive portfolio of over 500,000 products keep the world connected. TE Connectivity's intelligent and robust solutions and technologies carry over to the industrial and heavy duty vehicle markets. TE Connectivity offers products that work just as hard as the vehicles in which they are installed. Years ago, tractors, construction equipment, trucks, and boats had simple electrical systems that might have included electrical starting and a basic lighting package. Today, ECUs, joysticks, fuel-efficient engines, LED lights, and CAN systems are standard equipment. The need to protect sensitive electrical systems from vibration, moisture, dust, dirt, salt and airborne particles has never been greater. To support today's increasingly complex and sophisticated equipment and applications, TE Connectivity's Industrial & Commercial Transportation business unit was created. TE Connectivity's Industrial & Commercial Transportation business unit was formed in 2012, when TE acquired the Deutsch group of companies. For decades, DEUTSCH industrial electrical connectors have been counted on by industry leading manufacturers to maintain electrical connections and to keep equipment running. TE Connectivity has been among the world leaders in interconnector solutions for OEMs for over 50 years. Now together, establishing an unparalleled product portfolio with global presence, TE Connectivity's Industrial & Commercial Transportation business unit provides cutting-edge solutions to face the complex challenges of today's marketplace. From heavy duty trucks to construction equipment, mining vehicles to fire trucks, as well as boats, motorcycles, and tractors, leading manufacturers count on TE Connectivity's Industrial & Commercial Transportation business unit. 2 Introduction to Connectors Introduction to Connectors In heavy industries, electrical systems must stand up to rigorous conditions and all weather environments. Failure in an electrical system can be expensive to diagnose and down equipment can stop entire operations. As equipment becomes increasingly sophisticated and reliant on electronic packaging and diagnostics, design engineers know the importance of choosing environmentally sealed electrical connectors capable of holding up to extreme conditions. Many manufacturers count on TE Connectivity's Industrial & Commercial Transportation electrical connectors to maintain their electrical connections. Benefits of industrial connectors There are many different connectors for harsh environments and connector selection for each specific application is important. Once the questions of wire gauge and pin count have been addressed, the environmental challenges specific to each application must be identified, including if the electrical system will be exposed to heat, impact or vibration. Other elements that need to be addressed include if the connectors will be susceptible to moisture or chemicals and field serviceability. Developed with simplicity of design and ease of use in mind, TE Connectivity connectors offer a variety of innovative solutions to suit nearly any application and stand up to environmental challenges. Whether for a new application or a retrofit, connectors provide simplified design and wiring, and easy field repairs. Industrial & Commercial Transportation connector applications include ECUs, joysticks, industrial and marine engines, control boxes, lights and CAN systems, just to mention a few. TE Industrial & Commercial Transportation's connector series offer several features designed to combat environmental challenges. Connector features help protect electrical connections Connector bodies must be able to stand up to the environmental conditions. Rugged all-metal bodies and corrosion resistant thermoplastic shells are manufactured from high quality materials selected for their ability to withstand years of environmental exposure. Metal connectors are built to withstand the force and shock of hard impacts that connectors face in rough environments. High-grade thermoplastic connectors are lightweight and are engineered to be flame resistant and extremely chemical resistant. Different connector body materials are available 3 Introduction to Connectors to meet diverse application requirements. Proper contact alignment is another important aspect of environmentally sealed electrical connectors. Secondary locks snap into or onto the mating face of a connector to help make sure that the contacts slide together properly when the connectors are mated. Many of TE Connectivity's Industrial & Commercial Transportation connectors feature secondary locks that are commonly referred to as wedgelocks or terminal position assurance (TPA). Wedgelocks and TPAs provide additional stability to both the contact barrel and the mated connectors. A firm, secure locking mechanism that can withstand vibration and shock is critical to maintain a steadfast connector engagement in rugged applications. TE Connectivity's Industrial & Commercial Transportation connectors are held together by push-latches, threaded coupling rings, or tightened together by jackscrews. The locking mechanisms are easy to engage and disengage and give an audible or tactile signal when they are securely fastened. Once fastened, the locking mechanisms prevent disengagement due to vibration or impact. Since even a small degradation in electrical connections can be critical to industrial vehicles, manufacturers are turning to TE Connectivity's Industrial & Commercial Transportation's environmentally sealed electrical connectors to keep their equipment running. Connectors are increasingly needed as industrial equipment becomes more complex and reliant on electronic control units, CAN systems, and on-board communications systems. With a wide variety of industrial electrical connectors, manufacturers can find a connector for nearly any application. No matter the environment, TE Connectivity's industrial connectors provide the innovative solutions demanded by harsh conditions. TE Connectivity's dedication to quality and innovation has created a unique system of easy-to-use connectors to simplify processes from start to finish. 4 Technical Specifications Technical Specifications AMPSEAL Connector Performance Specifications Current Up to 17 amps gold, up to 8 amps tin Temperature Operating at temperatures -40 C to +125 C for gold plated, -40 C to +105 C for tin plated. Durability See note. Mate and unmate specimens for 10 cycles at maximum rate of 600 cycles per hour. Physical Shock No discontinuities of 1 microsecond or longer duration. TE Spec 109-26-1. Subject mated specimens to 50 G's half-sine shock pulses of 11 milliseconds duration. Three shocks in each direction applied along 3 mutually perpendicular planes, 18 total shocks. See Fig 5 in TE product document 1081329. Insulation Resistance 100 megohms minimum. TE Spec 109-28-4. Test between adjacent contacts of mated specimens. Immersion Leakage current not to exceed 50 micro-amperes at 48 volts DC. TE Spec 109-74-5. Immerse specimens to a depth of 100 mm in 5% salt water at a temperature of 23 5 C for 1 hour. Check between adjacent circuits and each surface to reference electrode. Random Vibration See note. TE Spec 109-21-7, Condition G, except 10500 Hz frequency range. Subject mated specimens to 10 Gs for 8 hours each plane. Voltage 250 volts AC Note: Shall meet visual requirements, show no physical damage and shall meet requirements of additional tests as specified in Test Sequence in Figure 3 of TE product document 108-1329. 5 Technical Specifications AMPSEAL 16 Connector Performance Specifications Current Up to 13 amps Immersion IP67 rating Temperature Operating at temperatures -40 C to +125 C. Random Vibration No discontinuities. See note. EIA-364-28 Subject mated specimens to 21 G's rms between 25 to 2000 Hz. Twenty hours in each of three mutually perpendicular planes. Durability See note. 50 cycles. Insulation Resistance 20 megohms minimum. SAE J2030 6.3. Insulation resistance at 1000 volts DC adjacent terminals measured after 60 seconds or until stabilization occurs. Voltage 250 volts DC Note: Shall meet visual requirements, show no physical damage, and meet requirements of additional tests as specified in the Product Qualification and Requalification Test Sequence in Figure 3 of TE product document 108-2184. DEUTSCH Connector Performance Specifications Temperature Operating at temperatures from -55 C to +125 C continuous at rated current. * DTMH Series: -55 C to +150 C Durability No electrical or mechanical defects after 100 cycles of engagement and disengagement. Vibration No unlocking or unmating and exhibits no mechanical or physical damage after sinusoidal vibration levels of 20 G's at 10 to 2000 Hz in each of the three mutually perpendicular planes. No electrical discontinuities longer than 1 microsecond. Physical Shock No unlocking, unmating, or other unsatisfactory result during or after 50 G's in each of three mutually perpendicular planes. No electrical discontinuities longer than 1 microsecond. MIL-STD 202, Method 213, Condition "C". Notice Please consult drawings for full specifications. 6 Fluid Resistance Connectors show no damage when exposed to most fluids used in industrial applications. Insulation Resistance 1000 megohms minimum at 25 C. Moisture Resistance Properly wired and mated connections will withstand immersion under three feet of water without loss of electronic qualities or leakage. * Moisture resistance does not apply to DTMN Series Dielectric Withstanding Voltage Current leakage less than 2 milliamps at 1500 VAC. Thermal Cycle No cracking, chipping or leaking after 20 test cycles from -55 C to +125 C. Technical Specifications Connector Material Specifications AEC Series Grommet: Silicone rubber Jackscrew: Steel Plug Threaded Inserts: Steel Shell: Thermoplastic AMPSEAL Wire Seal: Silicone rubber Mating Seal: Silicone rubber Cover: Glass filled PBT Locking Wedge: PBT AMPSEAL 16 Wire Seal: Silicone rubber Plug Peripheral Seal: Silicone rubber Housing: 15% Glass filled thermoplastic CPA: 15% Glass filled thermoplastic PLR: 15% Glass filled thermoplastic DRB Series Flange Body: Thermoplastic Flange Clip: Steel Grommet: Silicone rubber Jackscrew: Steel Receptacle Threaded Inserts: Steel Shell: Thermoplastic Wedgelocks: Thermoplastic DRC Series Grommet: Silicone rubber Insert Retainer: Thermoplastic Jackscrew: Steel Receptacle Threaded Inserts: Steel/Brass Shell: Thermoplastic DT Family (DT, DTM, DTMH, DTP, DTV) Grommet: Silicone rubber Insert Retainer: Thermoplastic Receptacle Interfacial Seal: Silicone rubber Shell: Thermoplastic Wedgelocks: Thermoplastic DTHD Series Grommet: Silicone rubber Shell: Thermoplastic HD10 Series Grommet: Silicone rubber Insert Retainer: Thermoplastic Receptacle Interfacial Seal: Silicone rubber Shell: Thermoplastic HDP20 Series Grommet: Silicone rubber Insert Retainer: Thermoplastic Plug Coupling Ring: Thermoplastic Shell: Thermoplastic HD30 Series Grommet: Silicone rubber Insert Retainer: Thermoplastic Plug Coupling Ring: Aluminum Shell: Aluminum STRIKE Series Flange Seal: Silicone rubber Plug Grommet: Silicone rubber Receptacle Threaded Inserts: Brass Shell: Thermoplastic TPA: Thermoplastic 7 Connector Series Overview Connector Series Overview Each connector series offers different design features to accommodate many design requirements. Below is an overview of each series that highlights the cavity count, wire gauge, material, and locking mechanism style. For complete series information, please see the series section of the catalog. TE Connectivity connectors offer different shapes, latching mechanisms, mounting styles, and materials to meet diverse application requirements and all DEUTSCH product lines offer accessories to further expand the series flexibility. AEC Series Key Features: * Accepts contact size 16 (13 amps) * 14-20 AWG * 40 cavity arrangement * In-line or PCB mount * Square, thermoplastic housing * Jackscrew for mating AMPSEAL Connectors Key Features: * Accepts contact size 1.3 mm (up to 17 amps gold, up to 8 amps tin) * 16-20 AWG * 8, 14, 23, and 35 cavity arrangements * PCB mount * Rectangular, thermoplastic housing * Integrated latch for mating * Integrated wedgelock confirms contact alignment and retention * Product specification documents: 108-1329 and 114-16016 AMPSEAL 16 Connectors Key Features: * Accepts contact size 16 (up to 13 amps) * 14-20 AWG * 2, 3, 4, 6, 8, and 12 cavity arrangements * In-line mount * Rectangular, thermoplastic housing * Integrated latch for mating * Integrated PLR confirms contact alignment and retention * Product specification documents: 108-2184, 114-13045, and 114-13065 8 Connector Series Overview DRB Series Key Features: * Accepts contact sizes 4 (100 amps), 8 (60 amps), 12 (25 amps), 16 (13 amps), and 20 (7.5 amps) * 6-22 AWG * 48, 60, 102, and 128 cavity arrangements * Flange mount * Rectangular, thermoplastic housing * Jackscrew for mating * Wedgelocks confirm contact alignment and retention DRC Series Key Features: * Accepts contact sizes 16 (13 amps) and 20 (7.5 amps) * 14-22 AWG * 24, 38, 40, 50, 60, 64, 70, and 76 cavity arrangements * In-line, flange, or PCB mount * Rectangular, thermoplastic housing * Jackscrew for mating DT Series Key Features: * Accepts contact size 16 (13 amps) * 14-20 AWG * 2, 3, 4, 6, 8, and 12 cavity arrangements * In-line, flange, or PCB mount * Rectangular, thermoplastic housing * Integrated latch for mating * Wedgelocks confirm contact alignment and retention DTHD Series Key Features: * Accepts contact sizes 4 (100 amps), 8 (60 amps), and 12 (25 amps) * 6-14 AWG * 1 cavity arrangement * In-line or flange mount * Circular, thermoplastic housing * Integrated latch for mating 9 Connector Series Overview DTM Series Key Features: * Accepts contact size 20 (7.5 amps) * 16-22 AWG * 2, 3, 4, 6, 8, and 12 cavity arrangements * In-line, flange, or PCB mount * Rectangular, thermoplastic housing * Integrated latch for mating * Wedgelocks confirm contact alignment and retention DTP Series Key Features: * Accepts contact size 12 (25 amps) * 10-14 AWG * 2 and 4 cavity arrangements * In-line, flange, or PCB mount * Rectangular, thermoplastic housing * Integrated latch for mating * Wedgelocks confirm contact alignment and retention DTV Series Key Features: * Accepts contact size 16 (13 amps) * 14-20 AWG * 18 cavity arrangement * Flange mount * Rectangular, thermoplastic housing * Integrated latch for mating * Wedgelocks confirm contact alignment and retention HD10 Series Key Features: * Accepts contact sizes 4 (100 amps), 12 (25 amps), and 16 (13 amps) * 6-20 AWG * 3, 4, 5, 6, and 9 cavity arrangements * In-line, flange, or PCB mount * Circular, thermoplastic housing * Coupling ring for mating 10 Connector Series Overview HD30 Series Key Features: * Accepts contact sizes 4 (100 amps), 8 (60 amps), 12 (25 amps), 16 (13 amps), and 20 (7.5 amps) * 6-22 AWG * 2, 6, 7, 8, 9, 14, 16, 18, 19, 20, 21, 23, 29, 31, 33, 35, and 47 cavity arrangements * In-line or flange mount * Circular, aluminum housing * Coupling ring for mating HDP20 Series Key Features: * Accepts contact sizes 4 (100 amps), 8 (60 amps), 12 (25 amps), 16 (13 amps), and 20 (7.5 amps) * 4-22 AWG * 2, 6, 7, 8, 9, 14, 16, 18, 19, 20, 21, 23, 29, 31, 33, 35, and 47 cavity arrangements * In-line or flange mount * Circular, thermoplastic housing * Coupling ring for mating STRIKE Series Key Features: * Accepts contact sizes 16 (13 amps) and 20 (7.5 amps) * 14-22 AWG * 32 and 64 cavity arrangements * In-line, flange, or PCB mount * Square, thermoplastic housing * Lever for mating * TPA confirms contact alignment and retention 11 AEC Series Contents AEC Series Overview 14 Part Numbering System 14 Dimensions 14 Configuration 15 Accessories 15 13 AEC Series AEC Series Overview The DEUTSCH AEC Series connectors are environmentally sealed, heavy duty electrical connectors that accept size 16 contacts. The AEC Series connectors are constructed of rugged thermoplastic and offer receptacles with either in-line or PCB mounting options. Part Numbering System AEC 14 - 40 P * * - XXXX Special Modifications Series Wire Seals Contact Size Blank = Standard Seal E = Extra Thin Wall Seal 1 = Size 16 Contacts Style 4 = In-line Receptacle 6 = Plug 7 = PCB Mount Receptacle Key A, B, C, D, or U Contacts Configuration P = Pin S = Socket Dimensions D A B E C AEC Plug Cavity Overall Length Overall Height A B 40 1.440 (36.58) 1.778 (45.16) Dimensions are for reference only. 14 F Overall Width C 1.894 (48.11) AEC Receptacle Overall Length Overall Height Overall Width D E F 1.642 (41.71) 1.944 (49.38) 1.828 (46.43) AEC Series Configuration Keying Options A = A key B = B key C = C key D = D key U = Universal key Insert Arrangement XX-XX X size XX X, X, X Part Number Number and Size of Cavities Notice Do not over torque jackscrew. The recommended torque rating for the AEC Series plug jackscrew when tightening is 25-28 IN-LB (2.86-3.16 N.M.). AEC1*-40*** 40 size 16 A, B, C, D, U Accessories Description Dust cap, 40 way receptacle, environmentally sealed Dust cap, 40 way receptacle, non-environmentally sealed Dust cap, 40 way plug, non-environmentally sealed Boot Part Number AEC40-BT-STPDWN Description Boot, 40 way plug or receptacle, black, step-down *Distorting the boots can lessen their longevity tio LAD D l u si v e t Dust Cap Part Number 0504-002-4001 0515-009-4005 0515-010-4005 n xc o E Dust caps and boots are available for use with the AEC Series. The dust caps are designed to provide protection to the connector interface when the connector halves are not mated. The boots are aesthetically appealing and provide increased protection from dirt, paint overspray, and pressure washing. D i s tr i b u 15 AMPSEAL Connectors Contents AMPSEAL Connector Overview 18 Product Documentation 18 Dimensions 18 Configurations 19 Part Numbers 19 Accessories 20 How To Instructions 20-21 17 AMPSEAL Connectors AMPSEAL Connector Overview AMPSEAL connectors provide rugged reliability and environmental sealing. They are available in cable plugs and PCB mount headers that are designed to stand up to high-temperature underhood applications. The pre-assembled receptacle housing connector features built-in contact sealing and an integral interfacial seal that protects mated connectors. Applicable Product Documentation Additional documentation is available for assistance with AMPSEAL products. The following TE Connectivity document numbers may be helpful: 1654285-2 (Catalog Section) 108-1329 (Product Specification) 114-16016 (Application Specification) 408-3229 (Instruction Sheet) 408-9592 (Instruction Sheet, Tooling) 408-9999 (Instruction Sheet, Tooling) Dimensions E B C Cavity 8 14 23 35 Overall Length A 1.32 (33.6) 1.32 (33.6) 1.32 (33.6) 1.32 (33.6) AMPSEAL Plug Overall Height B 1.36 (34.6) 1.36 (34.6) 1.36 (34.6) 1.36 (34.6) Dimensions are for reference only. 18 A Overall Width C 1.08 (27.4) 1.39 (35.4) 1.87 (47.4) 2.50 (63.4) E F Overall Length Straight D 1.35 (34.3) 1.35 (34.3) 1.35 (34.25) 1.35 (34.25) D F AMPSEAL Header Overall Overall Height Width E F 1.26 (32.1) 1.61 (40.8) 1.26 (32.1) 1.92 (48.8) 1.26 (32.1) 2.39 (60.8) 1.26 (32.1) 3.03 (76.9) G Overall Length 90 G 1.49 (37.9) 1.49 (37.9) 1.49 (37.9) 1.49 (37.9) AMPSEAL Connectors Configurations 8 Positions 8 size 1.3 mm 14 Positions 14 size 1.3 mm 23 Positions 23 size 1.3 mm 35 Positions 35 size 1.3 mm Part Numbers Keyed Position Housing Color Black 8 Natural Black Natural 14 Gray Blue Black Natural 23 Gray Blue Black Natural 35 Gray Blue Orange Contact Finish Tin plated Gold plated Tin plated Gold plated Tin plated Gold plated Tin plated Gold plated Tin plated Gold plated Tin plated Gold plated Tin plated Gold plated Tin plated Gold plated Tin plated Gold plated Tin plated Gold plated Tin plated Gold plated Tin plated Gold plated Tin plated Gold plated Tin plated Gold plated Gold plated Right-Angle PCB Header Receptacle Housing Without Seal With Seal (Plug) 776279-1 776280-1 776286-1 1-776279-1 1-776280-1 776279-2 776280-2 776286-2 1-776279-2 1-776280-2 776266-1 776267-1 776273-1 1-776266-1 1-776267-1 776266-2 776267-2 776273-2 1-776266-2 1-776267-2 776266-4 776267-4 776273-4 1-776266-4 1-776267-4 776266-5 776267-5 776273-5 1-776266-5 1-776267-5 770669-1 776087-1 770680-1 1-770669-1 1-776087-1 770669-2 776087-2 770680-2 1-770669-2 1-776087-2 770669-4 776087-4 770680-4 1-770669-4 1-776087-4 770669-5 776087-5 770680-5 1-770669-5 1-776087-5 776180-1 776163-1 776164-1 1-776180-1 1-776163-1 776180-2 776163-2 776164-2 1-776180-2 1-776163-2 776180-4 776163-4 776164-4 1-776180-4 1-776163-4 776180-5 776163-5 776164-5 1-776180-5 1-776163-5 776164-6 1-776180-6 1-776163-6 Vertical PCB Header Without Seal With Seal 776275-1 1-776275-1 776275-2 1-776275-2 776261-1 1-776261-1 776261-2 1-776261-2 776261-4 1-776261-4 776261-5 1-776261-5 776200-1 1-776200-1 776200-2 1-776200-2 776200-4 1-776200-4 776200-5 1-776200-5 776230-1 1-776230-1 776230-2 1-776230-2 776230-4 1-776230-4 776230-5 1-776230-5 - 776276-1 1-776276-1 776276-2 1-776276-2 776262-1 1-776262-1 776262-2 1-776262-2 776262-4 1-776262-4 776262-5 1-776262-5 776228-1 1-776228-1 776228-2 1-776228-2 776228-4 1-776228-4 776228-5 1-776228-5 776231-1 1-776231-1 776231-2 1-776231-2 776231-4 1-776231-4 776231-5 1-776231-5 1-776231-6 19 AMPSEAL Connectors Accessories Wire relief is available as an accessory for the AMPSEAL 23 and 35 position connectors. The wire relief offers a high level of protection and helps reduce strain from the wires. Wire Relief Positions 23 35 Part Number 776464-1 (one half, two halves required per receptacle housing) 776463-1 (one half, two halves required per receptacle housing) Description Vertical, sealed receptacle housing wire relief (accepts no. 4 self-tapping screw) Vertical, sealed receptacle housing wire relief (accepts no. 4 self-tapping screw) How To Instructions Contact Insertion Step 1: Grasp crimped contact approximately one inch behind the contact barrel. 20 Step 2: Check that the wedgelock of the plug assembly is in open position. Align the contact with the applicable cavity. Step 3: Insert the contact into the connector cavity until there is an audible or tactile click. A slight tug will verify the contact is locked in place. Step 4: After all the contacts have been inserted, close the wedgelock by simultaneously squeezing locking latches inward and pushing the wedgelock into the housing. AMPSEAL Connectors Contact Removal Step 1: Insert the tip of a screwdriver (2-5mm wide blade) between the edge of the plug assembly housing and one corner of the wedgelock. Step 2: Gently pry the edge of the wedgelock until it is released from (but not completely removed) the housing. Repeat these steps for the opposite corner of the wedge. 21 AMPSEAL 16 Connectors Contents AMPSEAL 16 Connector Overview 24 Product Documentation 24 Dimensions 24 Configurations 24 Part Numbers 25 Accessories 26 How To Instructions 27 23 AMPSEAL 16 Connectors AMPSEAL 16 Connector Overview The AMPSEAL 16 connector system is targeted for off-road, heavy duty industrial, recreational and agricultural applications. This wire-to-wire and wire-to-device connector line was designed to meet the rigorous demands of an industry that requires the highest standards in performance. The AMPSEAL 16 receptacle and pin housings offer a one-piece approach and come fully assembled. Applicable Product Documentation Additional documentation is available for assistance with AMPSEAL 16 products. The following TE Connectivity document numbers may be helpful: 1654281-2 (Catalog Section) 108-2184 (Product Specification) 114-13065 (Application Specification) 114-13045 (Application Specification, Contacts) 408-8623 (Instruction Sheet) Dimensions B E C Cavity 2 3 4 6 8 12 A F D AMPSEAL 16 Plug AMPSEAL 16 Cap Overall Length Overall Height Overall Width Overall Length Overall Height Overall Width A B C D E F 1.45 (36.75) .93 (23.5) .80 (20.33) 1.87 (47.55) .75 (18.93) .77 (19.60) 1.45 (36.80) .93 (23.5) .98 (24.83) 1.87 (47.55) .75 (19.15) .95 (24.10) 1.44 (36.70) 1.06 (26.8) 1.00 (25.33) 1.87 (47.55) .88 (22.45) .97 (24.60) 1.44 (36.60) 1.22 (31.0) 1.00 (25.33) 1.87 (47.55) 1.05 (26.65) .97 (24.60) 1.45 (36.80) 1.24 (31.5) 1.15 (29.33) 1.87 (47.55) 1.05 (26.65) 1.13 (28.60) 1.45 (36.80) 1.24 (31.5) 1.51 (38.33) 1.87 (47.55) 1.05 (26.65) 1.48 (37.60) Dimensions are for reference only. Configurations 2 Positions 2 size 1.58 mm 24 3 Positions 3 size 1.58 mm 4 Positions 4 size 1.58 mm 6 Positions 6 size 1.58 mm 8 Positions 8 size 1.58 mm 12 Positions 12 size 1.58 mm AMPSEAL 16 Connectors Part Numbers PLR Position Keying Color 2 3 4 6 8 12 Red Gray Yellow Green Red Gray Yellow Green Red Gray Yellow Green Red Gray Yellow Red Gray Yellow Green Red Gray Yellow Green Key A Key B Key C Key D Key A Key B Key C Key D Key A Key B Key C Key D Key A Key B Key C Key A Key B Key C Key D Key A Key B Key C Key D Receptacle Pin Housing Receptacle Pin Housing Housing (Plug) (Cap) Housing (Plug) (Cap) Standard Dia. Seal Standard Dia. Seal Reduced Dia. Seal Reduced Dia. Seal 776427-1 776428-1 776522-1 776534-1 776427-2 776428-2 776522-2 776534-2 776427-3 776428-3 776522-3 776534-3 776427-4 776428-4 776522-4 776534-4 776429-1 776430-1 776523-1 776535-1 776429-2 776430-2 776523-2 776535-2 776429-3 776430-3 776523-3 776535-3 776429-4 776430-4 776523-4 776535-4 776487-1 776488-1 776524-1 776536-1 776487-2 776488-2 776524-2 776536-2 776487-3 776488-3 776524-3 776536-3 776487-4 776488-4 776524-4 776536-4 776433-1 776434-1 776531-1 776537-1 776433-2 776434-2 776531-2 776537-2 776433-3 776434-3 776531-3 776537-3 776494-1 776495-1 776532-1 776538-1 776494-2 776495-2 776532-2 776538-2 776494-3 776495-3 776532-3 776538-3 776494-4 776495-4 776532-4 776538-4 776437-1 776438-1 776533-1 776539-1 776437-2 776438-2 776533-2 776539-2 776437-3 776438-3 776533-3 776539-3 776437-4 776438-4 776533-4 776539-4 Receptacle housing (plug) and pin housing (cap) PLR colors are mechanically keyed to mate only with identical colors. Part Number Suffix: -1 = A key (red PLR) -2 = B key (gray PLR) -3 = C key (yellow PLR) -4 = D key (green PLR) Pin Housing (Cap) CPA (Connector Position Assurance) Receptacle Housing (Plug) PLR (Primary Latch Reinforcement) 25 AMPSEAL 16 Connectors Accessories Mounting clips and backshells are accessory items available for use with AMPSEAL 16 connectors. These accessories cover design requirements by assisting with mounting, providing additional protection, and offering increased aesthetics. Mounting Clips Mounting Clip Part Number Description 1924487-1 Mounting clip without anti-rotational feature 1924487-2 Mounting clip with anti-rotational feature Backshells Number of Positions 2 3 4 6 8 12 26 Conduit Size NC08/NW7.5 NC12/NW10 NC08/NW7.5 NC12/NW10 NC08/NW7.5 NC12/NW10 NC16/NW13 NC08/NW7.5 NC12/NW10 NC16/NW13 NC12/NW10 NC16/NW13 NC12/NW10 NC16/NW13 NC20/NW17 Standard Straight 2035047-1 2035047-2 2035047-3 2035047-5 2035047-4 2035047-6 2035047-7 2035047-9 2035047-8 1-2035047-0 1-2035047-1 Part Numbers Standard Low Profile 90 90 Rec. Housing 2035048-1 2035366-1 2035366-3 2035048-5 2035048-2 2035366-2 2035366-4 2035048-6 2035048-3 2035366-7 2035048-7 2035366-9 1-2035366-1 2035366-8 1-2035366-0 1-2035366-2 2035047-9 - = Backshell available only with latch window. Can be used for cap assembly if desired. Low Profile 90 Pin Housing 2098436-1 2098436-3 2098436-2 2098436-4 2098436-7 2098436-9 1-2098436-1 2098436-8 1-2098436-0 1-2098436-2 - AMPSEAL 16 Connectors How To Instructions Contact Insertion Step 1: Grasp crimped contact approximately one inch behind the contact barrel. Step 2: Verify the PLR is in the pre-staged position, unlocked. Step 3: Align the contact with the desired circuit cavity at the rear of the housing assembly. Step 2: Insert the tool into the contact cavity and deflect the contact retention finger. Step 3: Gently pull the wire until the contact is free from the housing. Step 4: Push the contact straight into the connector cavity until the contact retention finger returns to its normal position behind the retention shoulder on the contact. A slight tug will verify the contact is locked in place. Step 5: When all of the required contacts have been inserted, push the PLR into the fully locked position. Contact Removal Step 1: Insert the removal tool into the PLR extraction slot and pull until the PLR is completely removed from the housing. 27 DRB Series Contents DRB Series Overview 30 Part Numbering System 30 Dimensions 30 Configurations 31 Required Components Accessories How To Instructions 32-33 33 34-35 29 DRB Series DRB Series Overview The DRB Series connectors are heavy duty connectors suitable for bulkhead applications. They are designed to accommodate multiple wire gauges and feature high pin counts, including 48, 60, 102, and 128 cavities. To increase the design flexibility, the DRB Series offers several mounting flange options and wire arrangements. The DRB Series is suited for on- and off-highway applications, marine, industrial, and agriculture markets in harsh environments. Part Numbering System DRB 16 - 60 S * E - **** Special Modifications Series L018 = Wire Router Style 16 = Plug 12 = Flange Mount Receptacle Wire Seals E = Environmental NE = Non-Environmental Configuration Key Contacts A, B, C, or D P = Pin S = Socket Dimensions A D B E C F DRB Plug DRB Receptacle Overall Length Overall Height Overall Width Overall Length Overall Height Overall Width A B C D E F 48 & 60 1.406 (35.71) 2.606 (66.19) 2.606 (66.19) 2.077 (52.76) 2.606 (66.19) 2.606 (66.19) 102 1.778 (45.16) 2.966 (75.34) 4.951 (125.76) 2.291 (58.19) 2.966 (75.34) 4.951 (125.76) 128 1.748 (44.40) 2.966 (75.34) 4.951 (125.76) 2.291 (58.19) 2.966 (75.34) 4.951 (125.76) Cavity Dimensions are for reference only. 30 DRB Series Configurations Insert Arrangement Keying Options A = A key B = B key C = C key D = D key DRB1*-48** 12 size 12 12 size 16 24 size 20 A, B, C, D DRB1*-102*** 2 size 4 4 size 8 16 size 12 80 size 16 A, B, C, D XX-XX X size XX X, X, X Part Number Number and Size of Cavities DRB1*-60** 12 size 16 48 size 20 A, B, C, D DRB1*-128*** 16 size 12 112 size 16 A, B, C, D 31 DRB Series Required Components Required Components A complete DRB assembly requires a wedgelock for each plug and receptacle and a mounting flange. There are several flange options to accommodate design requirements. The wedgelocks are required to confirm proper contact placement. Plug Plug Wedgelock(s) Flange Receptacle Wedgelock(s) Receptacle Flange Options Flange *A, B, C, D keying available 32 Part Number Accept Connectors Description DRBF-2* (1) DRB 48 or 60 Way Single mounting flange for one 48 or 60 way DRB plug and receptacle mated pair DRBF-3** (2) DRB 48 or 60 Ways Double mounting flange for any combination of two 48 or 60 way DRB plug and receptacle mated pairs DRBF-1* (1) DRB 102 Way Single mounting flange for the 102 or 128 way DRB or (1) DRB 128 Way plug and receptacle mated pair DRBM-3* Single mounting flange for the 102 or 128 way DRB (1) DRB 102 Way plug and receptacle mated pair, includes two 125 amp or (1) DRB 128 Way mounting posts DRB Series Secondary Wedgelocks DEUTSCH DRB electrical connectors require secondary wedgelocks which are sold separately. The wedgelocks confirm proper contact alignment and offer keying options within each connector. Secondary wedgelocks are assembled at the mating interfaces and click into place. Receptacle Plug WB-48P* Wedgelock for 48 way receptacle WB-48S* Wedgelock for 48 way plug WB-60P* Wedgelock for 60 way receptacle WB-60S* Wedgelock for 60 way plug WB-51P*L Left wedgelock for 102 way receptacle WB-51S*L Left wedgelock for 102 way plug WB-51P*R Right wedgelock for 102 way receptacle WB-51S*R Right wedgelock for 102 way plug WB-64P* Wedgelock for 128 way receptacle (requires two) WB-64S* Wedgelock for 128 way plug (requires two) *A, B, C, D keying available Accessories tio LAD D l u si v e t n xc o E Boots D i s tr i b u Boots provide a professional looking finishing touch for DEUTSCH DRB Series connectors. Made of durable plastisol, these slip-on boots are not only aesthetically appealing, but also provide increased protection from dirt, paint overspray, and pressure washing. The plastisol boots are rated from -20 F to +212 F and offer a slip-on design making installation quick and easy. Boot Part Number DRB48-60-BT DRB48-60-BT DRB102-BT DRB102-BT-90DEG Description 48 way plug or receptacle boot, black 60 way plug or receptacle boot, black 102/128 way plug or receptacle boot, black 102/128 way plug or receptacle boot, 90 bend, black *Distorting the boots can lessen their longevity 33 DRB Series How To Instructions Assembly Step 1: Wedgelocks should be pressed firmly in place, with only a slight gap showing between the wedgelock and connector. Step 2: If the wedgelock will not go all the way in, check to make sure all of the contacts are properly seated. Improper assembly can cause the jackscrew to be stripped during assembly. To prevent damage, the jackscrew will strip out before the threads in the connector are damaged. If the jackscrew becomes stripped, please replace the jackscrew and the push nut. Step 3: Contacts should be fully inserted into the connector, with the locking fingers in place under the shoulder of the contact. If a contact is not fully inserted, the retention finger will prevent the wedgelock from pressing into place. Step 4: When mating the plug with the receptacle, confirm that the plug is not being pulled into the receptacle at an angle by the jackscrew. Notice Do not over torque jackscrew. The recommended torque rating for the DRB Series plug jackscrew when tightening is 30-35 IN-LB (3.38-3.95 N.M.). Contact Insertion Step 1: Hold connector with rear grommet/wire router cap facing you. 34 Step 2: Push contact straight into contact cavity until a click is heard/felt. A slight tug will confirm the contact is inserted correctly. Step 3: Once all contacts are in place, insert wedgelock by lining up the keyway. The wedgelock will press into place. DRB Series Contact Removal Step 1: Remove wedgelock using a screwdriver. Pull wedgelock straight out. Step 2: To remove contacts, gently pull wire backwards, while at the same time releasing the locking finger by moving it away from the contact with a screwdriver. 35 DRC Series Contents DRC Series Overview 38 Part Numbering System 38 Connector Styles 38 Dimensions 39 Mating 39 Configurations 40 Accessories 41-42 37 DRC Series DRC Series Overview The environmentally sealed DRC Series is a rectangular connector series that offers insert arrangements of 24, 40, 50, 60, 64, 70, and 76 cavities and accepts size 12, 16, and 20 contacts. Several mounting options are available including in-line, flange mount, and PCB mount. Part Numbering System DRC 14 - 40 P * X - XXXX Special Modifications Series Wire Seals Contact Size Blank = Standard Seal T = Thin Wall Seal (Size 16 Only) E = Extra Thin Wall Seal (Size 16 Only) 1 = Size 16 Contacts 2 = Size 20 Contacts Style 0 = Molded in Contacts 2 = Flange Mount Receptacle 3 = 90 PCB Receptacle 4 = In-line Receptacle 6 = Plug 8 = Keyed Plug (40 Pin Size 16 Only) Key (if applicable) Contacts P = Pin S = Socket Configuration Connector Styles In-line Receptacle 38 Flange Mount Receptacle PCB Receptacle Standard Plug DRC Series Dimensions D A E B F C DRC Plug Cavity 24 (sz. 20) 24 (sz. 16) 38 40 (sz. 20) 40 (sz. 16) 50 60 64 70 76 Overall Overall Height Overall Width Length B C A 1.435 (36.45) 1.244 (31.60) 2.004 (50.90) 1.600 (40.64) 1.148 (29.16) 2.100 (53.34) 1.435 (36.45) 1.274 (32.36) 2.700 (68.58) 1.380 (35.05) 1.244 (31.60) 2.700 (68.58) 1.597 (40.56) 1.202 (30.53) 2.868 (72.85) 1.435 (36.45) 1.408 (35.76) 2.700 (68.58) 1.435 (36.45) 1.448 (36.78) 2.700 (68.58) ---1.643 (41.73) 1.421 (36.09) 4.094 (103.99) ---- DRC Receptacle Overall Length D 1.785 (45.34) 1.742 (44.25) -1.785 (45.34) 1.699 (43.15) --1.785 (45.34) 1.757 (44.63) 1.115 (28.32) Overall Height Overall Width E F 1.500 (38.10) 1.202 (30.53) -1.500 (38.10) 1.202 (30.53) 1.987 (50.47) 2.161 (54.89) 1.500 (38.10) 1.421 (36.09) 1.827 (46.41) 3.104 (78.84) 2.154 (54.71) -3.800 (96.52) 2.908 (73.86) 3.094 (78.59) 3.094 (78.59) 5.866 (149.00) 4.094 (103.99) 5.686 (144.42) Dimensions are for reference only. Mating Criteria The DEUTSCH DRC Series plugs are keyed to provide positive alignment and to prevent mis-mating. Jackscrew Key Note Notice Do not over torque jackscrew. The recommended torque rating for the DRC Series plug jackscrew when tightening is 25-28 IN-LB (2.83-3.16 N.M.). 39 DRC Series Configurations Insert Arrangement Connector Styles I = In-line F = Flange Mount Receptacle P = PCB Receptacle DRC2*-24** 24 size 20 I, F, P DRC2*-40** 40 size 20 F, P DRC2*-60** 60 size 20 P DRC1*-70** 70 size 16 I, F, P 40 Part Number Number and Size of Cavities XX-XX X size XX X, X, X DRC1*-24** 24 size 16 I, F, P DRC26-38** 34 size 20, 4 size 12 (Plug for DRC20-76P****) DRC1*-40** 40 size 16 I, F, P DRC2*-64** 64 size 20 P DRC20-76P**** 68 size 20, 8 size 12 P DRC2*-50** 50 size 20 P DRC Series Accessories Several accessory items are available to complement the connectors including boots, gaskets, backshells, and wire routers. Accessories are designed to complete the application and meet a wide array of design requirements such as providing additional protection and offering increased aesthetics. Backshells The DEUTSCH DRC Series backshells are designed to snap onto the back of the connectors and accept convoluted tubing. The rigid, durable backshells offer a high level of protection, provide strain relief, and improve aesthetics. Backshells and Wire Routers Connector Cavities Part Number 38 0528-003-3805 38 0528-004-3805 38 0528-005-3805 40 0515-015-4005 50 0528-001-5005 60 0528-002-6005 60 0528-007-6005 70 0515-029-7005 70 0515-031-7005 70 0528-006-7005 70 0528-012-7005 70 0525-013-7005 Description 90 backshell to the side, plug 90 backshell, plug 90 low profile backshell, plug Wire router, plug 90 backshell, plug 90 backshell, plug 90 backshell to the side, plug Straight wire router, plug Straight wire router, plug or receptacle, Straight backshell, plug or receptacle, requires two halves and wire router 90 backshell to the side, plug or receptacle, without tubing rib 90 backshell to the side, plug or receptacle, with tubing rib tio LAD D l u si v e t n xc o E Boots D i s tr i b u Boots provide a professional looking finishing touch for DEUTSCH DRC Series connectors. Made of durable plastisol, these slip-on boots are not only aesthetically appealing, but also provide increased protection from dirt, paint overspray, and pressure washing. The plastisol boots are rated from -20 F to +212 F and offer a slip-on design making installation quick and easy. Boot Part Number DRC24-BT DRC26-24BT DRC40-BT DRC40-BT-90DEG DRC26-40BT DRC70-BT Description 24 way boot, size 16 contact arrangements, black 24 way boot, size 20 contact arrangements, black 40 way boot, size 16 contact arrangements, black 40 way boot, size 16 contact arrangements, 90 bend, black 40 way boot, size 20 contact arrangements, black 70 way boot, size 16 contact arrangements, black *Distorting the boots can lessen their longevity 41 DRC Series tio LAD D l u si v e t n xc o E Gaskets D i s tr i b u Moisture, dirt, salt, sand, and road debris can all work their way into electrical panels through unsealed mounting flanges. Rated to operate in environments from -70F to +225F, these rugged high quality neoprene gaskets form a tight seal between the panel face and connector flange to help keep out destructive elements. The gaskets have a thickness of .125" and meet the UL-94-HBF, Mil-R-6130C, and FMVSS-302 flammability specifications. Gasket P/N DRC24-GKT DRC40-GKT DRC70-GKT 42 Connector P/N DRC12-24P** DRC12-40P** DRC12-70P** DT Family Contents DT Family Overview 44 Printed Circuit Board 55 Part Numbering System 44 DTV Series Dimensions 45 DTMH Series & High Temperature Modification Configurations 46 DTMN Series 59 How To Instructions 60 Required Components 47-48 Special Modifications 48-49 Accessories 50-54 43 56 57-58 DT Family DT Family Overview DEUTSCH DT, DTM, and DTP Series environmentally sealed connectors are designed specifically for cable to cable applications. The DT connectors are used in harsh environment applications where even a small degradation in connection may be critical. Thermoplastic housings offer a wide operating temperature range and silicone rear wire and interface seals allow the connectors to withstand conditions of extreme temperature and moisture. The connector may be populated with either solid or stamped & formed style contacts. Contact insertion and removal does not require any special tools. Contacts are retained in locked position by dielectric fingers which are molded as an integral part of the housing. Secondary wedgelocks are assembled at the mating interfaces to provide proper contact positioning. The DEUTSCH DT Series general purpose connectors will provide reliability and performance on the engine or transmission, under the hood, on the chassis, or in the cab. DT Series Overview DTM Series Overview DEUTSCH DT Series connectors offer field proven reliability and rugged quality. The DT design strengths include optional flange mounting, multi-pin arrangements, and design flexibility. The DT Series offers the designer the ability to use multiple size 16 contacts, each with 13 amp continuous capacity, within a single shell. DEUTSCH DTM Series connectors offer solutions to your smaller wire gauge applications. Building on the DT design strengths, the DTM connector line was developed to fill the need for lower amperage, multi-pin, inexpensive connectors. The DTM Series offers the designer the ability to use multiple size 20 contacts, each with 7.5 amp continuous capacity, within a single shell. DTP Series Overview DEUTSCH DTP Series connectors provide solutions for your power application requirements. Building on both the DT and DTM design strengths, the DTP connector line was developed to fill the need for higher amperage, multi-pin, inexpensive connectors. The DTP Series offers the designer the ability to use multiple size 12 contacts, each with 25 amp continuous capacity, within a single shell. The DTP connectors are currently available in two and four pin configurations. DT Family Part Numbering System DT* 06 - 2 S * - XXXX Series Blank = DT Series M = DTM Series P = DTP Series Style 44 04 = Receptacle 06 = Plug Special Modifications Key (if applicable) Contacts P = Pin S = Socket Configuration DT Family DT Series Dimensions E B C A D F DT Plug Cavity Overall Length Overall Height A B 2 1.118 (28.4) .628 (15.95) 3 1.118 (28.4) .934 (23.72) 4 1.218 (30.94) .724 (18.39) 6 1.218 (30.94) .891 (22.63) 8 1.217 (30.91) .776 (19.71) 12 1.218 (30.94) .716 (18.19) Overall Width C .591 (15.01) .718 (18.23) .716 (18.19) .716 (18.19) 1.465 (37.21) 1.597 (40.56) DT Receptacle Overall Length Overall Height D E 1.708 (43.38) .670 (17.02) 1.698 (43.13) .973 (24.71) 1.808 (45.92) .776 (19.71) 1.808 (45.92) .951 (24.16) 1.798 (45.67) 1.000 (25.40) 1.808 (45.92) .876 (22.25) Overall Width F .675 (17.15) .832 (21.13) .820 (20.83) .820 (20.83) 1.435 (36.45) 1.597 (40.56) Dimensions are for reference only. DTM Series Dimensions E B C A F DTM Plug Cavity Overall Length Overall Height A B 2 1.085 (27.56) .508 (12.90) 3 1.085 (27.56) .551 (14.00) 4 1.185 (30.10) .695 (17.65) 6 1.185 (30.10) .817 (20.75) 8 1.185 (30.10) .600 (15.24) 12 1.185 (30.10) .600 (15.24) Overall Width C .475 (12.07) .640 (16.26) .600 (15.24) .600 (15.24) 1.245 (31.62) 1.575 (40.01) D DTM Receptacle Overall Length Overall Height Overall Width D E F 1.620 (41.15) .638 (16.21) .651 (16.54) 1.620 (41.15) .638 (16.21) .861 (20.73) 1.720 (43.69) .772 (19.61) .756 (19.20) 1.720 (43.69) .937 (23.80) .756 (19.20) 1.720 (43.69) .796 (20.22) 1.245 (31.62) 1.720 (43.69) .796 (20.22) 1.575 (40.01) Dimensions are for reference only. DTP Series Dimensions E B C DTP Plug Cavity Overall Length Overall Height A B 2 1.364 (34.65) .711 (18.06) 4 1.364 (34.65) .960 (24.38) Dimensions are for reference only. D A F Overall Width C .732 (18.59) .868 (22.05) DTP Receptacle Overall Length Overall Height Overall Width D E F 1.861 (47.27) .869 (22.07) .972 (22.15) 1.861 (47.27) 1.069 (27.15) 1.060 (26.92) 45 DT Family DT Family Connector Configurations Insert Arrangement Keying Options A = A key B = B key C = C key D = D key Part Number Number and Size of Cavities DT04-4P 4 size 16 X, X, X DT Series Configurations DT0*-2* 2 size 16 DT0*-3* 3 size 16 DT0*-4* 4 size 16 DT0*-6* 6 size 16 DT0*-08** 8 size 16 A, B, C, D DT0*-12** 12 size 16 A, B, C, D DTM Series Configurations DTM0*-2* 2 size 20 DTM0*-3* 3 size 20 DTM0*-4* 4 size 20 DTP Series Configurations DTP0*-2* 2 size 12 46 DTP0*-4* 4 size 12 DTM0*-6* 6 size 20 DTM0*-08** 8 size 20 A, B, C, D DTM0*-12** 12 size 20 A, B, C, D DT Family Required Components Secondary Wedgelocks DEUTSCH DT style electrical connectors require secondary wedgelocks which are sold separately. The wedgelocks help ensure proper contact alignment within each connector. Secondary wedgelocks are assembled at the mating interface and click into place. If by chance the secondary wedgelocks are not properly seated during assembly, they will be pressed into locked position during the mating of the connector. Adding to the design flexibility of the DT Series, several wedgelocks offer keying options. Wedgelocks for enhanced seal retention plugs (P012) are also available. DT Series Wedgelocks Receptacle Plug W2P* Wedgelock for 2 way receptacle *A, B, C, D keying available W2S* Wedgelock for 2 way plug *A, B, C, D keying available W3P* Wedgelock for 3 way receptacle *J1939 keying available W3S* Wedgelock for 3 way plug *J1939 keying available W4P* Wedgelock for 4 way receptacle *A, B, C, D keying available W4S* Wedgelock for 4 way plug *A, B, C, D keying available W6P Wedgelock for 6 way receptacle W6S Wedgelock for 6 way plug W8P Wedgelock for 8 way receptacle W8S Wedgelock for 8 way plug W12P Wedgelock for 12 way receptacle W12S Wedgelock for 12 way plug Notice Wedgelocks for enhanced plugs (P012) are available. DTP Series Wedgelocks Receptacle Plug WP-2P Wedgelock for 2 way receptacle WP-2S Wedgelock for 2 way plug WP-4P Wedgelock for 4 way receptacle WP-4S Wedgelock for 4 way plug 47 DT Family DTM Series Wedgelocks Receptacle Plug WM-2P* Wedgelock for 2 way receptacle *A, B, C keying available WM-2S* Wedgelock for 2 way plug *A, B, C keying available WM-3P Wedgelock for 3 way receptacle WM-3S Wedgelock for 3 way plug WM-4P Wedgelock for 4 way receptacle WM-4S Wedgelock for 4 way plug WM-6P Wedgelock for 6 way receptacle WM-6S Wedgelock for 6 way plug WM-8P Wedgelock for 8 way receptacle WM-8S Wedgelock for 8 way plug WM-12S Wedgelock for 12 way plug WM-12P Wedgelock for 12 way receptacle Special Modifications The DT Series connectors offer several modifications to enhance the design flexibility and meet application specific needs. Options include enhanced seal retention, flanges, and connector body color just to mention a few. By combining the DT Series connectors with the available modifications and accessories, the design possibilities are immense. B016 Modification The B016 receptacle modification helps prevent mis-mating. The B016 is available for the DT 12 way connectors, DT13/15, and DTF13/15 PCB Series connectors. In addition to the four keying positions (A, B, C, or D) and color coding, the B016 enhancement gives the user both visual and tactile proof of correct mating, thus eliminating mis-mating opportunities during assembly. Please note the P012 plug is the required mate for the B016 receptacle to make the enhancement effective. P012 Modification The DT P012 plugs provide enhanced front seal retention resulting in an ultra tight environmental seal. The enhanced seal retention keeps the seal in place during mating and unmating. The P012 modification requires an enhanced P012 wedgelock. The DEUTSCH P012 modification is available in 2, 3, 4, 6, 8, and 12 cavity arrangements. P012 plugs have a black connector body except for the 8 and 12 cavity arrangements, where the color is based on the key. 48 DT Family E007 & E008 Modification Flange Modifications To meet the application requirements where wires need added protection, the DT (E008) and DTM (E007) Series may be supplied with shrink boot adapters. These adapters accept shrink tubing. Designed to simplify wire routing and assembly, DT Series receptacles are available in many mounting configurations and styles. Welded flange * Welded flange - BL04, BL08, CL03, L012, LE14 * Welded flange, end cap - LE07, LE11 * Welded flange, shrink boot adapter - LE08, LE12 Sealed flange * Sealed flange, end cap - CL09, LE01, LE05, LE06, LE09, LE10, LE17, LE21 * Sealed flange, shrink boot adapter - BL10, CL07 C015 Modification E003 Modification The C015 modification offers a reduced diameter insert cavity allowing for a proper seal with smaller wire insulation. The C015 modification is also referred to as an "E" seal. The E003 modification offers a protective end cap attached to the rear of the connector. There are holes in the cap to allow the contacts to be inserted. E004 Modification E005 Modification The E004 modification changes the connector body color to black. The E005 modification offers a protective end cap attached to the rear of the connector and has a black connector body. Notice Additional modifications are available, please contact your representative. 49 DT Family Accessories Several accessory items are available to complement the connectors including boots, backshells, gaskets, dust caps, and mounting clips. Accessory items cover a wide array of design requirements such as assisting with mounting, providing additional protection, and offering enhanced aesthetics. tio LAD D l u si v e t n xc o E Gaskets D i s tr i b u Moisture, dirt, salt, sand, and road debris can all work their way into electrical panels through unsealed mounting flanges. Rated to operate in environments from -70F to +225F, these rugged high quality neoprene gaskets form a tight seal between the panel face and connector flange to help keep out destructive elements. The gaskets have a thickness of .125" and meet the UL-94-HBF, Mil-R-6130C, and FMVSS-302 flammability specifications. Gasket P/N DT3P-L012-GKT DT4P-L012-GKT DTP4P-L012-GKT DT8P-L012-GKT DT12-L012-GKT Connector P/N DT04-3P-L012 DT04-4P-L012 DTP04-4P-L012 DT04-08P*-L012 DT04-12P*-L012 DTM04-12P*-L012 tio LAD D l u si v e t n xc o E Dust Caps D i s tr i b u The DT Series dust caps are made of either thermoplastic or durable plastisol and are designed to provide protection for the connector interface when the two halves are not mated. The plastisol caps, available for plugs and receptacles, are ideal for providing temporary protection from dirt, dust, and paint overspray. The thermoplastic caps provide an environmental seal for an unmated plug. Thermoplastic Dust Cap P/N 1011-344-0205 1011-345-0305 1011-346-0405 1011-347-0605 1011-348-0805 1011-349-1205 Plastisol Dust Cap P/N DTM3S-DC DT3P-DC DT4P-DC DT6P-DC DTM12P-DC DT12P-DC, DT12P-DC-BK DT12S-DC 50 Connector P/N DT06-2S DT06-3S DT06-4S DT06-6S DT06-08S* DT06-12S*, DT16-15S*, DT16-18S* Connector P/N DTM06-3S DT04-3P DT04-4P DT04-6P DTM04-12P* DT04-12P* DT06-12S* DT Family tio LAD D l u si v e t n xc o E Boots D i s tr i b u Boots provide a professional looking finishing touch for DEUTSCH DT family connectors. Made of durable plastisol, these slip-on boots are not only aesthetically appealing, but also provide increased protection from dirt, paint overspray, and pressure washing. The plastisol boots are rated from -20 F to +212 F and offer a slip-on design making installation quick and easy. Receptacle Boot Description 2 way receptacle boot, gray 2 way receptacle boot, black 3 way receptacle boot, gray 3 way receptacle boot, black 4 way receptacle boot, gray 4 way receptacle boot, gray, enhanced length 6 way receptacle boot, gray 6 way receptacle boot, black 8 way receptacle boot, gray 8 way receptacle boot, black 12 way receptacle boot, gray 12 way receptacle boot, black 12 way receptacle boot, gray, enhanced length Boot Part Number DT Series DTM Series DTP Series DT2P-BT DTM2P-BT DTP2P-BT DT2P-BT-BK DTM2P-BT-BK DTP2P-BT-BK DT3P-BT DTM3P-BT DT3P-BT-BK DTM3P-BT-BK DT4P-BT DTM4P-BT DTP4P-BT - - DTP4P-BT-EN DT6P-BT DT6P-BT-BK DT8P-BT DT8P-BT-BK DT12P-BT DT12P-BT-BK DTM6P-BT DTM8P-BT DTM8P-BT-BK DTM12P-BT DTM12P-BT-BK - DT12P-BT-EN - - *Distorting the boots can lessen their longevity Plug Boot Description 2 way plug boot, gray 2 way plug boot, black 3 way plug boot, gray 3 way plug boot, black 4 way plug boot, gray 4 way plug boot, gray, enhanced length 6 way plug boot, gray 6 way plug boot, black 8 way plug boot, gray 8 way plug boot, black 12 way plug boot, gray 12 way plug boot, black 12 way plug boot, gray, enhanced length 48 way plug boot, gray DT Series DT2S-BT DT2S-BT-BK DT3S-BT DT3S-BT-BK DT4S-BT DT6S-BT DT6S-BT-BK DT8S-BT DT8S-BT-BK DT12S-BT DT12S-BT-BK DT12S-BT-EN DT48S-BT Boot Part Number DTM Series DTP Series DTM2S-BT DTP2S-BT DTM2S-BT-BK DTM3S-BT DTM3S-BT-BK DTM4S-BT DTP4S-BT DTP4S-BT-EN DTM6S-BT DTM8S-BT DTM8S-BT-BK DTM12S-BT DTM12S-BT-BK - *Distorting the boots can lessen their longevity 51 DT Family Backshells The DEUTSCH DT and DTM Series backshells are designed to snap onto and mate with all standard (basic plug and receptacles without modifications that affect the rear of the connector) DT and DTM Series connectors. The rigid, durable backshells offer a high level of protection and allow convoluted tubing to nest within the rear of the backshell. Straight (180) and right angle (90) versions and backshells with strain relief for jacketed cable are also available. Since the backshells are designed to work with the standard DT and DTM connectors, tests should be conducted for fit and function of a backshell being used on any part with a modification. Receptacle Backshells Connector DT04-2P DTM*04-2P DT04-3P DT04-4P DTM*04-4P DT04-6P DT04-08P* DT04-12P* 52 Style 180 180 90 90 180 180 180 90 90 180 180 90 90 180 180 180 90 90 180 90 180 90 Strain Relief X X X X X X X X Tubing Size (mm) 6, 7.5, 8.5, and 10 6, 7.5, 8.5, and 10 6, 7.5, 8.5, and 10 6, 7.5, 8.5, and 10 7.5 and 8.5 6, 7.5, 8.5, and 10 6, 7.5, 8.5, and 10 6, 7.5, 8.5, and 10 6, 7.5, 8.5, and 10 6, 7.5, 8.5, and 10 6, 7.5, 8.5, and 10 6, 7.5, 8.5, and 10 6, 7.5, 8.5, and 10 8.5 8.5, 10, and 13 8.5, 10, and 13 8.5, 10, and 13 8.5, 10, and 13 8.5, 10, and 13 8.5, 10, and 13 10, 13, and 17 10, 13, and 17 P/N 1011-229-0205 1011-257-0205 1011-230-0205 1011-258-0205 1028-021-0205 1011-233-0305 1011-261-0305 1011-234-0305 1011-262-0305 1011-237-0405 1011-265-0405 1011-238-0405 1011-266-0405 1028-027-0405 1011-241-0605 1011-269-0605 1011-242-0605 1011-270-0605 1011-245-0805 1011-246-0805 1011-249-1205 1011-250-1205 DT Family Plug Backshells Connector Style 180 180 90 90 DTM06-2S 180 DTM*06-2S 180 DT06-3S 180 180 90 90 DT06-4S 180 180 90 90 DTM*06-4S 180 DT06-6S 180 180 90 90 DT06-08S* 180 90 DT06-12S* 180 90 DT06-12S*-**** 180 Strain Relief Tubing Size (mm) 6, 7.5, 8.5, and 10 6, 7.5, 8.5, and 10 6, 7.5, 8.5, and 10 6, 7.5, 8.5, and 10 7.5 and 8.5 8.5 6, 7.5, 8.5, and 10 6, 7.5, 8.5, and 10 6, 7.5, 8.5, and 10 6, 7.5, 8.5, and 10 6, 7.5, 8.5, and 10 6, 7.5, 8.5, and 10 6, 7.5, 8.5, and 10 6, 7.5, 8.5, and 10 8.5 8.5, 10, and 13 8.5, 10, and 13 8.5, 10, and 13 8.5, 10, and 13 8.5, 10, and 13 8.5, 10, and 13 10, 13, and 17 10, 13, and 17 13 and 17 DT06-2S X X X X X X X X P/N 1011-227-0205 1011-255-0205 1011-228-0205 1011-256-0205 1011-273-0205 1028-041-0205 1011-231-0305 1011-259-0305 1011-232-0305 1011-260-0305 1011-235-0405 1011-263-0405 1011-236-0405 1011-264-0405 1028-008-0405 1011-239-0605 1011-267-0605 1011-240-0605 1011-268-0605 1011-243-0805 1011-244-0805 1011-247-1205 1011-248-1205 1028-043-1205 Pull Off Strength FT FT 90 90 FP FP Connector FP [N] FT [N] DT04-2P / DT06-2S DT04-3P / DT06-3S DT04-4P / DT06-4S DT04-6P / DT06-6S DT04-08P* / DT06-08S* DT04-12P* / DT06-12S* 50 / 50 50 / 50 50 / 50 50 / 50 50 / 50 50 / 50 50 / 10 50 / 50 50 / 25 50 / 30 50 / 35 50 / 40 53 DT Family Mounting Clips Mounting clips are used to mount DT Series connectors. To meet design needs, the clips are available for several configurations and in plastic, stainless steel, or steel with zinc plating. Mounting Clip 54 Part Number Used On (Receptacles) Mounting Direction Color/Material Hole O.D. inches (mm) 1027-003-1200 DT 2, 3, 4, 6, 12 DTM, DTP (all) Straight Stainless steel .433 (11.0) 1027-005-1200 DT 2, 3, 4, 6, 12 DTM, DTP (all) Straight Stainless steel .512 (13.0) 1027-004-1200 DT 2, 3, 4, 6, 12 DTM, DTP (all) Straight Steel w/ zinc plating .512 (13.0) 1027-008-1200 DT 2, 3, 4, 6, 12 DTM, DTP (all) Side Steel w/ zinc plating .433 (11.0) 1027-013-1200 DT 2, 3, 4, 6, 12 DTM, DTP (all) Side Steel w/ zinc plating .323 (8.2) 1027-001-0800 DT 8 cavity only Straight Stainless steel .433 (11.0) 1027-006-0800 DT 8 cavity only Straight Stainless steel .512 (13.0) 1027-002-0800 DT 8 cavity only Straight Steel w/ zinc plating .512 (13.0) 1027-014-0800 DT 8 cavity only Straight Steel w/ zinc plating .323 (8.2) 1011-026-0205 DT 2, 3, 4, 6, 12 DTM, DTP (all) Straight Gray plastic .200 (5.08) 1011-030-0205 DT 2, 3, 4, 6, 12 DTM, DTP (all) Straight Black plastic --- *Connector removeable with 50N of force 1011-310-0205* DT 2, 3, 4, 6, 12 DTM, DTP (all) Straight Black plastic --- 1011-027-0805 DT 8 cavity only Straight Gray plastic .200 (5.08) DT Family DT Family Printed Circuit Board Connectors The DT Family offers printed circuit board (PCB) connectors that are heavy duty environmentally sealed connectors designed for wire-to-circuit board connections. Available in a variety of styles for the DT, DTM, and DTP connector series, DEUTSCH PCB connectors cover a range of pin counts from 2 to 48 and wire gauges from 10 to 22. Many of the connectors are available in straight or 90 pin options. PCB Part Numbering System DT* 13 - 6 P * - XXXX Special Modifications Series Blank = DT Series F = DTF Series M = DTM Series MF = DTMF Series P = DTP Series Key A, B, C, or D (if applicable) Contacts P = Pin S = Socket Style 13 = 90 pins 15 = Straight pins Configuration DT Family PCB Configurations Pin/Flange Style Connector Description 2 way receptacle, DT Series 3 way receptacle, DT Series 4 way receptacle, DT Series 4 way receptacle, DTP Series 6 way receptacle, DT Series 8 way receptacle, DT Series 12 way receptacle, DT Series 12 way receptacle, DTM Series 48 way receptacle, DTM Series 90 Flange Straight Flange 90 Flangeless DT13-2P DT13-4P DTP13-4P DT13-6P DT13-08P* DT13-12P* DTM13-12P* - DT15-2P DT15-4P DTP15-4P DT15-6P DT15-08P* DT15-12P* DTM15-12P* - DTF13-2P DTF13-3P DTF13-4P DTF13-6P DTF13-12P* - Straight Flangeless DTF15-12P* DTMF15-48P * = Keying (A, B, C, or D) Notice For additional information, please see the PCB section. 55 DT Family DTV Series Overview The DEUTSCH DTV Series connectors offer the same time tested reliability and performance as the DT Series, with the added flexibility of an 18 cavity flanged design. DTV Series Part Numbering System DTV 06 - 18 S * Key Series A, B, C, or D Style Contacts 02 = Receptacle 06 = Plug P = Pin S = Socket Configuration DTV Series Dimensions E B C Cavity 18 F A DTV Plug Overall Length Overall Height A B 1.405 (35.69) 1.059 (26.90) D DTV Receptacle Overall Width Overall Length Overall Height Overall Width C D E F 1.450 (36.83) 2.495 (63.37) 1.786 (45.36) 3.194 (81.12) Dimensions are for reference only. Secondary Wedgelocks DTV Series Wedgelocks Receptacle WV-18P 56 Plug Wedgelock for 18 way receptacle WV-18S Wedgelock for 18 way plug DT Family DTMH Series & High Temperature Modification Overview The DTMH Series and DTM Series EE04 modification connectors are environmentally sealed, high temperature connectors capable of operating in temperatures -55 to +150C. They accept size 20 contacts and carry 7.5 amps each. The DTMH connectors are available in 2-4 cavity arrangements and feature an integrated TPA for easy assembly. The EE04 connectors are available in 6, 8, and 12 cavity arrangements and require a secondary wedgelock. DTMH Series Part Numbering System DTMH 04 - 2 P * Key Series A, B, C, or D Style Contacts 04 = Receptacle 06 = Plug P = Pin S = Socket Configuration DTMH Series Configurations DTMH0*-2** DTMH0*-3** DTMH0*-4** 2 size 20 3 size 20 4 size 20 DTMH Series Dimensions B C DTMH Plug Cavity Overall Length Overall Height A B 2 1.085 (27.56) .508 (12.90) 3 1.085 (27.56) .558 (14.17) 4 1.185 (30.10) .652 (16.56) Dimensions are for reference only. E A D F Overall Width C .555 (14.10) .640 (16.26) .680 (17.27) DTMH Receptacle Overall Length Overall Height D E 1.620 (41.15) .638 (16.21) 1.620 (41.16) .638 (16.21) 1.720 (43.69) .772 (19.61) Overall Width F .729 (18.52) .894 (22.71) .834 (21.18) 57 DT Family DTM Series (EE04 Mod) Part Numbering System DTM 06 - 6 S * - EE04 High Temperature, Black Modification Series Style 04 = Receptacle 06 = Plug Key (if applicable) Contacts Configuration P = Pin S = Socket 6, 8, or 12 DTM Series Configurations DTM0*-6*-EE04 6 size 20 DTM0*-08**-EE04 8 size 20 A, B, C, D DTM0*-12**-EE04 12 size 20 A, B, C, D DTM Series Dimensions E B C A DTM Plug Cavity Overall Length Overall Height A B 6 1.185 (30.10) .817 (20.75) 8 1.185 (30.10) .600 (15.24) 12 1.185 (30.10) .600 (15.24) Dimensions are for reference only. Notice DTM EE04 modification connectors require a secondary wedgelock that is sold separately. 58 F Overall Width C .600 (15.24) 1.245 (31.62) 1.575 (40.01) D DTM Receptacle Overall Length Overall Height Overall Width D E F 1.720 (43.69) .937 (23.80) .756 (19.20) 1.720 (43.69) .792 (20.12) 1.245 (31.62) 1.720 (43.69) .796 (20.22) 1.575 (40.01) DT Family DTMN Series Overview The DTMN is a non-environmentally sealed connector. The DTMN is available in a 2 or 3 cavity connector and accepts size 20 contacts. The DTMN connector is designed to offer high quality and reliability when a sealed connector is not required. DTMN Series Part Numbering System DTMN 04 - 2 P Contacts Series P = Pin S = Socket Style 04 = Receptacle 06 = Plug Configuration DTMN Series Configurations DTMN0*-2** DTMN0*-3** 2 size 20 3 size 20 DTMN Series Dimensions C F B E A DTMN Plug Cavity Overall Length Overall Height A B 2 .950 (24.13) .346 (8.78) 3 .945 (24.00) .406 (10.31) Overall Width C .370 (9.40) .785 (19.93) D DTMN Receptacle Overall Length Overall Height Overall Width D E F 1.198 (30.43) .334 (8.48) .444 (11.28) 1.188 (30.18) .400 (10.16) .810 (20.56) Dimensions are for reference only. 59 DT Family How To Instructions Contact Insertion Step 1: Grasp crimped contact approximately one inch behind the contact barrel. Step 2: Hold connector with rear grommet facing you. Step 3: Push contact straight into connector grommet until a click is felt. A slight tug will confirm that it is properly locked in place. Step 2: To remove the contacts, gently pull wire backwards, while at the same time releasing the locking finger by moving it away from the contact with a screwdriver. Step 3: Hold the rear seal in place, as removing the contact will displace the seal. Contact Removal Step 1: Remove green wedge using needlenose pliers to pull wedge straight out. Notice The receptacle is shown, use the same procedure for the plug. 60 Step 4: Once all contacts are in place, insert green wedge. The green wedge will snap into place. HD10 Series Contents HD10 Series Overview 62 Part Numbering System 62 Dimensions 62 Connector Styles 63 Configurations 63 Special Modifications 63-64 Accessories 64-67 61 HD10 Series HD10 Series Overview The HD10 Series is an environmentally sealed, thermoplastic cylindrical connector series and offers arrangements from 3 to 9 cavities. All HD10 connectors are available either in-line or flanged and accept size 12 or 16 contacts, or a combination of size 16 and size 4 contacts. The HD10 Series is heavily used for diagnostic connectors, helps reduce assembly issues and maintenance time, and is designed for long service life. Part Numbering System HD 10 - 9 - 96 P * XXXX Special Modifications Series Wire Seals Style Blank = Normal E = Extra Thin 10 = Square Flange Receptacle 14 = In-line Receptacle 16 = Plug Contacts S = Socket P = Pin Configuration Threaded Rear 4 = 4 Configuration 12 = No Coupling Ring on Plug, 6 Configuration 96 = 3, 6, or 9 Configurations Non-Threaded Rear 16 = 3, 5, or 9 Configurations Dimensions A OB C OD HD10 Plug HD10 Receptacle Cavity Overall Length Overall Height Overall Length Overall Height A OB C OD 3 1.609 (40.87) 1.069 (27.15) 1.639 (41.63) .851 (21.62) 4 1.639 (41.63) 1.595 (40.51) 1.639 (41.63) 1.281 (32.54) 5 1.609 (40.87) 1.218 (30.94) 1.639 (41.63) 1.001 (25.43) 6 1.619 (41.12) 1.453 (36.91) 1.639 (41.63) 1.141 (28.98) 9 1.609 (40.87) 1.593 (40.47) 1.639 (41.63) 1.281 (32.54) Dimensions are for reference only. 62 HD10 Series Connector Styles Plug HD16 Square Flange Receptacle HD10 In-line Receptacle HD14 Configurations Insert Arrangement Configuration Number and Size of Cavities XX-XX X size XX 3-16/3-96* 3 size 16 4-4 1 size 4 3 size 16 5-16 5 size 16 6-12 6 size 12 6-96 6 size 16 9-16 9 size 16 9-96* 9 size 16 *Also available in an "E" seal Special Modifications The HD10 Series connectors offer several modifications to enhance the design flexibility and meet application specific needs. Options include the addition of a coupling ring and connector body color, just to mention a few. By combining the HD10 Series connectors with the available modifications and accessories, the design possibilities are increased. B010 Modification E004 Modification The B010 modification provides the addition of a coupling ring used for mating. The B010 modification is only available on the HD16-6-12S-B010 connector. The E004 modification changes the HD10 Series connector from the standard gray to a black connector body. 63 HD10 Series N005 Modification J1939 Modifications (BP03, P080) The N005 modification is an HD10 Series receptacle with molded-in, straight PCB pins. The P080 modification changes the HD10 Series connector body color from the standard gray to green and meets the J1939 Type II requirements. The BP03 modification is similar to the P080 modification, but features a panel mount. Notice Please see Contacts section for extended PCB pins. Accessories Several accessory items are available to complement the HD10 Series connectors including boots, backshells, gaskets, and protective caps. Accessory items cover a wide array of design requirements such as assisting with mounting, providing additional protection, and offering enhanced aesthetics. tio LAD D l u si v e t n xc o E Backshells The DEUTSCH HD10 Series backshells are designed to screw onto all threaded HD10 connectors. Rated for temperatures from -40C to +134C, the rigid, durable backshells offer a high level of protection, provide strain relief, and improve aesthetics. D i s tr i b u Backshell and Compression Nut Assembly Cable Connector Part Number Diameter DEUTSCH HD10 Series 3 Way HD1*-3-96* .187-.300 .300-.430 DEUTSCH HD10 Series 6 Way HD1*-6-96* .187-.300 HD1*-6-12* .300-.430 .430-.570 .570-.710 DEUTSCH HD10 Series 9 Way HD1*-9-96* .187-.300 HD1*-9-1939** .300-.430 .430-.570 .570-.710 Backshell Technical Specifications: Material - PC/PET Polyester Blend, UV-Stabilized, Flame Retardant, Black Flammability - UL94-VO, Weatherability - UL746C 64 Backshell Part Number Compression Nut Part Number M902-2131 M902-2132 M902-2041 M902-2042 M902-2161 M902-2162 M902-2163 M902-2164 M902-2041 M902-2042 M902-2053 M902-2054 M902-2191 M902-2192 M902-2193 M902-2194 M902-2041 M902-2042 M902-2053 M902-2054 HD10 Series Strain Relief DEUTSCH HD10 Series strain reliefs are designed to screw onto threaded 3, 4, 6, and 9 cavity HD10 connectors. The rigid, durable strain reliefs offer a high level of protection, provide tie wrap holders to reduce the strain from the wires, and improve aesthetics. Part Number HD18-003 HD18-006 HD18-009 Description 3 cavity strain relief 6 cavity strain relief 4 or 9 cavity strain relief h el p fu l hi nt Attaching the connector to a structure eliminates straining the electrical system in service. Protective Dust Caps The HD10 Series protective dust caps provide an environmental seal and are used to protect the connector interface when the connector is not mated. HDC14 Protective Cap for Plug Part Number Description HDC14-3 3 cavity plug protective cap HDC14-6 6 cavity plug protective cap HDC14-9 9 cavity plug protective cap HDC16 Protective Cap for Receptacle Part Number Description HDC16-3 3 cavity receptacle protective cap 5 cavity receptacle protective cap HDC16-5 HDC16-6 6 cavity receptacle protective cap HDC16-6-E004 6 cavity receptacle protective cap, black HDC16-9 9 cavity receptacle protective cap HDC16-9-E004 9 cavity receptacle protective cap, black 65 HD10 Series tio LAD D l u si v e t n xc o E Boots D i s tr i b u Boots provide a professional looking finishing touch for DEUTSCH HD10 Series connectors. Made of durable plastisol, these slip-on boots are not only aesthetically appealing, but also provide increased protection from dirt, paint overspray, and pressure washing. The plastisol boots are rated from -20 F to +212 F and offer a slip-on design making installation quick and easy. Part Number HD10-3BT HD10-5BT HD10-5BT-BK HD10-6BT HD10-6BT-BK HD10-9BT HD10-9BT-BK Description 3 cavity boot, gray 5 cavity boot, gray 5 cavity boot, black 6 cavity boot, gray 6 cavity boot, black 9 cavity boot, gray 9 cavity boot, black *Distorting the boots can lessen their longevity tio LAD D l u si v e t n xc o E Gaskets D i s tr i b u Moisture, dirt, salt, sand, and road debris can work their way into electrical panels through unsealed mounting flanges. Rated to operate in environments from -70F to +225F, these rugged high quality neoprene gaskets form a tight seal between the panel face and connector flange to help keep out destructive elements. The gaskets have a thickness of .125" and meet the UL-94-HBF, Mil-R6130C, and FMVSS-302 flammability specifications. Gasket P/N HD10-3-GKT HD10-5-GKT HD10-6-GKT HD10-9-GKT 66 Connector P/N HD10-3-**** HD10-5-**** HD10-6-**** HD10-9-**** HD10 Series tio LAD D Lanyards are available in nitrile or nylon coated steel and designed for use with protective dust caps. l u si v e t n xc o E Lanyards D i s tr i b u HDC9-JDL082397 (DEUTSCH HDC16-9-E004 dust cap assembled with JDL082397) HDC16-9-L47N (DEUTSCH HDC16-9 dust cap assembled with L47N-600-1) Lanyard Material Material Diameter Length Minimum Breaking Strength .07 inches 5.31 inches --- JDL082397 Nitrile o-ring, 3M heat shrink with thermoplastic adhesive 7 x 7 galvanized steel cable coated with clear nylon .047 inches 6 inches 270 lbs. Lanyard Material Nitrile Nitrile Steel Nitrile Nitrile Steel Steel Nitrile Steel Nitrile Nitrile Steel Steel Dust Cap Color Gray Gray Gray Gray Gray Gray Gray Gray Gray Gray Black Gray Black L47N-600-1 Dimensions are for reference only. Dust Cap/Lanyard Assemblies Part Number* Used On HDC14-3-JDL Plug HDC14-6-JDL Plug HDC14-6-LA Plug HDC14-9-JDL Plug HDC16-3-JDL Receptacle HDC16-3-LA Receptacle HDC16-5-LA Receptacle HDC16-6-JDL Receptacle HDC16-6-LA Receptacle HDC16-9-JDL Receptacle HDC9-JDL082397 Receptacle HDC16-9-L47N Receptacle HDC16-9-E004-L47N Receptacle Connector Cavities 3 6 6 9 3 3 5 6 6 9 9 9 9 *Other dust cap/lanyard assemblies may be available 67 HD30 & HDP20 Series Contents HD30 & HDP20 Series Overview 70 Mounting 78-79 Dimensions 70 How To Instructions 79-80 Part Numbering System 71 Configurations 72-73 Wire Insulation 73 Special Modifications 73-74 Accessories 75-78 69 HD30 & HDP20 Series HD30 & HDP20 Series Overview Designed specifically for the truck, bus, and off-highway industry, the HD30 & HDP20 Series are heavy duty, environmentally sealed, multi-pin circular connectors. Available in metal or thermoplastic housings, these connectors offer multiple pin configurations that accept contact sizes 4 through 20. The HD30 is a metal shell while the HDP20 Series shells are thermoplastic. Both feature quick connect-disconnect bayonet coupling, single hole bulkhead mounting, silicone seals, and a rear insertion/rear removal contact system. HD30 Series Overview The DEUTSCH HD30 Series connectors are constructed from a metal shell developed to meet the needs of the heavy duty equipment and transportation industries. The HD30 features include quick connect-disconnect bayonet coupling, single hole bulkhead mounting, silicone seals, and a rear insertion/rear removal contact system. HDP20 Series Overview The HDP20 Series is a heavy duty rated, environmentally sealed, composite shell, multi-pin connector. The composite thermoplastic shell is ideal in applications where chemicals can damage a connector housing. HDP20 features quick connect-disconnect bayonet coupling, single hole bulkhead mounting, silicone seals, and a rear insertion/rear removal contact system. HD30 & HDP20 Series Dimensions OB Shell Size 18 24 HD/HDP Plug Overall Length Overall Height A OB 1.521 (38.63) 1.700 (43.17) 1.521 (38.63) 1.950 (49.53) Dimensions are for reference only. 70 A OD C HD/HDP Receptacle Overall Length Overall Height C OD 1.648 (41.86) 1.750 (44.45) 1.648 (41.86) 2.000 (50.80) HD30 & HDP20 Series HD30 Series Part Numbering System HD X 36 - 24 - 21 S N - XXX Special Modifications Series 072 = Threaded adapter 059 = Cable clamp/adapter B = Breakaway plug option N = Non-environmental option Wire Seals N = Normal position wire seals (green ring) T = Thin wall wire seals (gray ring) E = Extra thin wall wire seals (blue ring Style 4 = Receptacle 6 = Plug Shell Size 18 or 24 Contacts Configuration P = Pin S = Socket Notice Reverse arrangements are available as a keying option for the HD30 & HDP20 Series. HDP20 Series Part Numbering System HDP 26 - 24 - 21 S N - XXXX Special Modifications Series L015 = Threaded adapter L017 = Ring adapter L024 = Wide threaded adapter Style 4 = Receptacle 6 = Plug Wire Seals N = Normal position and wire seals (green ring) T = Thin wall wire seals (gray ring) E = Extra thin wall wire seals (blue ring) Shell Size 18 or 24 Configuration Contacts P = Pin S = Socket h el p fu l hi nt Correct Making the socket contact side the "hot side" can reduce the danger of electric shock. Incorrect 71 HD30 & HDP20 Series HD30 & HDP20 Series Configurations Insert Arrangement Wire Seal Options N = Normal wire seals (green ring) T = Thin wall wire seals (gray ring) E = Extra thin wall wire seals (blue ring) Shell Size - Configuration Number and Size of Cavities XX-XX X size XX X, X, X 18 Shell Size Configurations 18-6 2 size 4 & 4 size 16 N, E 18-8 8 size 12 N, E 18-14 14 size 16 N, T, E 18-20 2 size 16 & 18 size 20 N, E 18-21 21 size 20 N 24 Shell Size Configurations 1 24-7(-C038 only) 3 size 4 & 4 size 16 N 24-9 1 size 4, 2 size 8 & 6 size 12 N, E 24-14 1 size 4, 1 size 12 & 12 size 16 N, E 24-16 16 size 12 N, E 24-18 1 size 8, 3 size 12 & 14 size 16 N, E 24-23 23 size 16 N, T, E 24-29 4 size 12, 19 size 16 & 6 size 20 E* 24-31 31 size 16 T*, E* 3 24-19 6 size 12 & 13 size 16 N, E 72 24-21 4 size 12 & 17 size 16 N, E Requires size 4 contact part numbers, 5960-203-04**(pin) and 5962-203-04**(socket) *Modified seal, see drawing. HD30 & HDP20 Series 24-33 33 size 20 N 24-35 3 size 16 & 32 size 20 N, E 24-47 5 size16 & 42 size 20 E* *Modified seal, see drawing Without P064 modification, plug cavities 4 and 5 are internally connected 24-91-P064 2 size 8, 2 size 12 & 5 size 16 N, E Wire Insulation Contact Size 20 16 12 8 4 Recommended Wire Insulation O.D. N Seal T Seal E Seal Green Ring Gray Ring Blue Ring .040-.095 (1.02-2.41) .040-.095 (1.02-2.41) .040-.095 (1.02-2.41) .100-.134 (2.54-3.40) .088-.134 (2.23-3.40) .053-.120 (1.35-3.05) .134-.170 (3.40-4.32) .113-.170 (2.87-4.32) .097-.158 (2.46-4.01) .190-.240 (4.83-6.10) .170-.240 (4.32-6.10) .135-.220 (3.43-5.59) .280-.292 (7.11-7.42) .261-.292 (6.63-7.42) .261-.292 (6.63-7.42) Notice Undersized wire insulation is a major cause for leakage. Color code is visible from the rear of the receptacle or plug. Green: Normal Seal Gray: Thin Wall Seal Blue: Extra Thin Seal Color Coded Ring Special Modifications The HD30 & HDP20 Series connectors offer several modifications to enhance design flexibility and meet application specific needs. Options include breakaway plugs, adapters, and high amperage options just to mention a few. By combining the HD30 & HDP20 Series connectors with the available modifications and accessories, the design possibilities are greatly expanded. HDB - Breakaway Plug (HD30 Series Only) The HDB is designed to provide an emergency disconnect between farm tractors and implements that require power connections. The HDB breakaway plug is designed to break the connection before damaging the wiring system. These plugs can be specified with pin or socket contacts and connect only with the HD30 Series receptacles. As an added design convenience, the HDB is also available with an optional cable clamp (059 mod). Breakaway function occurs at an axial load 73 of 50-100 lbs. HD30 & HDP20 Series L015/L017/L024 Modifications The L015/L024 threaded adapters and L017 ring adapter modifications are available for the DEUTSCH HDP20 Series. These adapter modifications provide simple, low cost assembly solutions for applications that require a backshell or conduit. The modifications must be ordered with the initial connector, as it is factory assembled. The adapters are designed to be used with the backshell of your choice. * * * L015 Threaded Adapter The L015 threaded adapter is available on size 24 shells in the HDP20 Series. The L017 ring adapter is available on size 24 or size 18 shells in the HDP20 Series. The L024 wide threaded adapter is available on size 24 or size 18 shells in the HDP20 Series. L017 Ring Adapter L024 Wide Threaded Adapter C030 Modification Originally designed for multiplexing and battery cable applications, the DEUTSCH C030 modification is an environmentally sealed, heavy duty two cavity connector that accepts size 4 solid contacts rated up to 100 amps for each cavity. The C030 modification is available in size 18 shell in both metal (HD30 Series) and thermoplastic (HDP20 Series) to meet your heavy wire gauge application needs. Cable Clamp/Backshell Modifications DEUTSCH cable clamps provide positive support to the wire bundle while reducing strain on the connector. The backshell is available with or without drain holes. Part Number Suffix -072 -059 -L006 74 Description Adapter only Adapter and cable clamp assembly with drain holes Adapter and cable clamp assembly without drain holes HD30 & HDP20 Series Accessories Several accessory items can be used to complement the connectors. The HD30 & HDP20 family accessories include items such as boots, backshells, gaskets, and protective caps. Accessories are designed to complete the application and meet a wide array of design requirements such as solutions for mounting, providing additional protection, and offering increased aesthetics. tio LAD D l u si v e t n xc o E Boots D i s tr i b u Boots provide a professional looking finishing touch for the DEUTSCH HD30 & HDP20 family of connectors. Made of durable plastisol, these slip-on boots are not only aesthetically appealing, but also provide increased protection from dirt, paint overspray, and pressure washing. The plastisol boots are rated from -20 F to +212 F and offer a slip-on design making installation quick and easy. Part Number HD30-18BT HD30-18BT-BK HD30-18BT-90-BK LC-90BT-HT HD30-24BT HD30-24BT-BK HD30-24BT-90-BK MT-90BT-HT-24 Description 18 shell size boot, gray 18 shell size boot, black 18 shell size boot, 90 bend, black 18 shell size boot, 90 bend, high temperature material, yellow 24 shell size boot, gray 24 shell size boot, black 24 shell size boot, 90 bend, black 24 shell size boot, 90 bend, high temperature material, yellow *Distorting the boots can lessen their longevity Protective Dust Caps Protective caps are available for both plug and receptacle halves of the connectors. The metal caps, for use with the HD30 Series, come with a mounting chain and are used to protect the connector while not mated. The thermoplastic caps, for use with the HDP20 Series, are available with or without a lanyard. HDP20 Series Dust Caps Shell Part Number Size 18 HDC26-18 24 HDC26-24 HD30 Series Dust Caps Shell Part Number* Size 18 HDC36-18 24 HDC36-24 18 HDC34-18 24 HDC34-24 Description Plug cap for receptacle protection, environmentally sealed Description Plug cap for receptacle protection Receptacle cap for plug protection *To order HD30(HD3*-**) protective caps without the mounting chain, add -1E to the end of the part number 75 HD30 & HDP20 Series Strain Relief The DEUTSCH HD30 & HDP20 Series offers several backshell options to meet your design needs. Backshell options include straight or 90 and plastic or metal. The metal backshells work best with the HD30 Series. It is attached to the rear of the connector using an adjustable screw and is secured to the wire bundle with the use of a tie wrap. The plastic backshells work best with the HDP20 Series and attach to the rear of the connector with either a clamshell snap closure or by screwing them on to a threaded adapter. The rigid, durable backshells offer a high level of protection, provide strain relief, and improve aesthetics. HD30 Series Backshell Shell Orientation Size 18 Straight 24 18 90 24 HDP20 Series L017 Backshell Shell Size Orientation Straight 18 90 Straight 24 90 Straight 24 90 Part Number WHDS-18-1 WHDS-24-1 WHDS-18-2 WHDS-24-2 Part Number Conduit Size 2428-016-1805 13, 17, 19 (mm) NW 2428-015-1805 13, 17, 19 (mm) NW 2428-008-2405 1" 2428-004-2405 1" 2428-010-2405 17, 19, 23, 26 (mm) NW 2428-011-2405 17, 19, 23, 26 (mm) NW NW = Nominal Width of the conduit's inside diameter. See drawings for full specifications. Seal Ring Cap Nut HDP20 Series L015 Conduit Adapter Shell L015 Conduit Adapter Size Part Numbers Seal Ring: Cap Nut: 24 SRN21 CN21 Conduit Size 22 (mm) NW tio LAD D l u si v e t n xc o E Backshells for L015 Modification The DEUTSCH HDP20 Series backshells are designed to screw onto connectors with the L015 modification, which adds a threaded adapter. Rated for temperatures from -40C to +134C, the rigid, durable backshells offer a high level of protection, provide strain relief, and improve aesthetics. D i s tr i b u Backshell 76 Compression Nut HDP20 Series L015 Backshell Shell Cable Diameter Backshell Size .430-.570 M902-2243 24 .570-.710 M902-2244 Compression Nut M902-2053 M902-2054 Backshell Technical Specifications: Material - PC/PET Polyester Blend, UV-Stabilized, Flame Retardant, Black Flammability - UL94-VO, Weatherability - UL746C HD30 & HDP20 Series Backshells for L024 Modification The DEUTSCH HDP20 Series backshells are designed to screw onto connectors with the L024 modification, which adds a wide threaded adapter. The rigid, durable backshells offer a high level of protection, provide strain relief, and improve aesthetics. HDP20 Series L024 Backshell Shell Size Orientation Part Number 18 24 Straight Straight 2428-025-1805 2428-024-2405 tio LAD D l u si v e t n xc o E Gaskets D i s tr i b u Moisture, dirt, salt, sand, and road debris can all work their way into electrical panels through unsealed mounting flanges. Rated to operate in environments from -70F to +225F, these rugged high quality neoprene gaskets form a tight seal between the panel face and connector flange to help keep out destructive elements. The gaskets have a thickness of .125" and meet the UL-94-HBF, Mil-R-6130C, and FMVSS-302 flammability specifications. 16-04978 (18 Shell Size Receptacle) 16-04477 (24 Shell Size Receptacle) Mounting Hardware DEUTSCH lockwashers and panel nuts are available to aid in mounting the HD30 and HDP20 Series connectors. The lockwashers are used to add tension between the threads and the nut to provide a secure mount. The lockwasher and the panel nut should be used together. B OA Panel Lockwasher Shell Series Part Number Size HDP20 2414-002-1886 18 HD30 114021 HDP20 2414-001-2486 24 HD30 112264 OA B 1.892 (48.06) 1.699 (43.15) .062 (1.57) 2.080 (52.83) 1.887 (47.93) .062 (1.57) Dimensions are for reference only. 77 HD30 & HDP20 Series A Panel Nut Shell Series Size HDP20 18 HD30 HDP20 24 HD30 Panel Nut Mounting Torque 260-280 IN. LB. HD30 18 Shell Size (29.4-31.6 N.M.) 45-55 IN. LB. HDP20 18 Shell Size (5.1-6.1 N.M.) 350-375 IN. LB. HD30 24 Shell Size (39.5-42.6 N.M.) 65-75 IN. LB. HDP20 24 Shell Size (7.4-8.4 N.M.) B Part Number Material A B 2411-002-1805 114020-90 2411-001-2405 112263-90 Plastic Metal Plastic Metal 1.685 (42.80) .250 (6.35) .178 (4.52) .250 (6.35) .178 (4.52) 1.875 (47.63) Dimensions are for reference only. Mounting Receptacle Mounting AO + .005 (0.13) B Flat +.010 (0.25) -.000 (0.00) Panel Nut Lockwasher .1875 (4.76) .0625 (1.59) Recommended Size of Mounting Hole Shell Size AO B 18 1.507 (38.28) 1.442 (36.63) 24 1.696 (43.08) 1.632 (41.45) h el p fu l hi nt 78 Mounting connectors horizontally allows proper water drainage. Connector Receptacle HD30 & HDP20 Series The D hole punch is a hand tool used to cut a D shaped hole. The D shaped hole allows the connector to be securely mounted and prevents the connector from spinning. tio LAD D l u si v e t n xc o E D Hole Punch Punchable Material: Up to .078" mild steel or aluminum. Up to .1875" plastic, wood, paneling, or other soft material. D i s tr i b u Tool Material: A2 material heat treated to a Rockwell hardness of 60 to 62. Tool Size: (rough dimensions) 5.5"L x 2"H x 2" D Counter nut Sharpening: The tool can be sharpened as needed. Die Die Usability: A .625" minimum pilot hole is required to accommodate the draw stud. Air tools can be used. * Counter nut Exploded view Draw Stud *The rods included with the "D" hole punch are used to remove the cutout and are not used in the cutting process. Shell Size 18 24 Part Number 18-D-PUNCH 24-D-PUNCH How To Instructions Mating Instructions To mate the plug and the receptacle, line up the index groove on the plug with the flat surface on the receptacle, turn 1/4 turn clockwise. You will feel and hear the pieces snap into the locked position. To unmate the plug and receptacle, release the coupling ring by turning it counter-clockwise. Visually Inspectable Bayonet for Proper Mating Polarizing Indicator HDP20 Series & HD30 Series Mate Unmate Connector Receptacle Mating Slot Positions Notice When mating or unmating connectors, disassemble by hand. Do not use pliers or any other tool. 79 HD30 & HDP20 Series Contact Insertion Step 1: Grasp contact approximately one inch behind the contact crimp barrel. Step 2: Hold connector with rear grommet facing you. Step 3: Push contact straight into connector grommet until a positive stop is felt. A slight tug will confirm that it is properly locked in place. Contact Removal Step 1: With rear insert toward you, snap appropriate size removal tool over the wire of contact to be removed. Notice Do not twist or insert tool at an angle. 80 Step 2: Slide tool along the wire into the insert cavity until it engages contact and resistance is felt. Step 3: Pull contact wire assembly out of connector. STRIKE Series Contents STRIKE Series Connector Overview 82 Part Numbering System 82 Dimensions 82 Configurations 83 Accessories 83 How To Instructions 84 81 STRIKE Series STRIKE Series Connector Overview The STRIKE connector series features a lever lock system and is designed for heavy duty equipment applications. The environmentally sealed series offers two different size rugged housings that accept contacts from size 20 to 16 with arrangements of 32 and 64 cavities. The lever lock combined with varying cavity arrangements allows the STRIKE Series connectors to offer flexible options for electrical designs. Part Numbering System SRK 06 - FLA - 32A - 001 Series Cable Attachment 001 = Standard attachment Style Configuration 02 = Receptacle 06 = Plug 13 = PCB Receptacle, 90 Pins 15 = PCB Receptacle, Straight Pins Key A-J (MD and FL size) Shell Size MD = Medium FL = Full Dimensions E B C Shell Size MD FL F D STRIKE Plug STRIKE Receptacle Overall Length Overall Height Overall Width Overall Length Overall Height Overall Width A B C D E F 3.189 (81.00) 1.909 (84.50) 1.531 (38.90) 3.228 (82.00) 2.205 (56.00) 1.575 (40.00) 3.358 (85.28) 1.913 (48.60) 2.780 (70.60) 3.228 (82.00) 2.205 (56.00) 2.953 (75.00) Dimensions are for reference only. 82 A STRIKE Series Configuration Insert Arrangement Connector Styles I = In-line F = Flange Mount Receptacle P = PCB Receptacle MD*-32A 4 Size 16 28 Size 20 I, F, P Shell Size/Key- Configuration Number and Size of Cavities XX*-XX X size XX X, X, X FL*-64A 8 Size 16 56 Size 20 I, F Accessories Backshells can be used to complement the DEUTSCH STRIKE Series connectors. The backshells are designed to snap onto the connectors and accept convoluted tubing. The backshells assist with wire routing to ease engagement and disengagement of the lever lock. Backshells Backshell Part Number Size Direction Convoluted Tubing SRK-BS-MD-90-001 SRK-BS-MD-90-002 Medium SRK-BS-FL-90-001 SRK-BS-FL-90-002 Full NW22 & 26(-001) NW26(-002) SRK-BS-MD-ST-001 SRK-BS-MD-ST-002 Medium NW17(-001) NW22(-002) SRK-BS-FL-ST-001 SRK-BS-FL-ST-002 Full 90 Straight NW17 & 22(-001) NW22(-002) NW22(-001) NW26(-002) Description 90 plastic backshell for medium or full size plugs and receptacles Straight plastic backshell for medium or full size plugs and receptacles 83 STRIKE Series How To Instructions Contact Insertion Step 1: Ensure TPA locking is open. Step 2: Hold connector with rear seal retainer facing you. Step 3: Push contact straight into the grommet until a positive stop is felt. A slight tug will confirm that it is properly locked in place. Step 4: Push to close the TPA. TPA will not close unless all contacts are fully seated in connector. Step 2: Repeat step 1 on the other side of the TPA. Step 3: Remove the TPA. Step 4: Unlock the contacts and pull on the wire. Contact Removal Step 1: Use DT-RT1 to open the TPA with light turn against the locking clip. 84 Bussing Options Contents DT Bussed Feedback Overview 86 HDFB Series Overview 88 DT Family Part Numbering System 86 HDFB Part Numbering System 88 DT Series Dimensions 86 HDFB Series Dimensions 89 HDFB Series Arrangements 89 HDFB Series Accessories 89 DT Bussed Arrangements 87-88 85 Bussing Options Bussed Overview DEUTSCH industrial bussed feedback receptacles are environmentally sealed connectors designed for use in heavy duty applications where multiple circuits require a common electrical pathway. Available in the DT and HDFB Series, DEUTSCH bussed connectors feature integrated bussbars with standard DEUTSCH contacts. A bussbar, or buss, is a thin conductive strip connecting two or more contacts within the body of a connector. Bussbars allow power or data to be fed into a connector through one or more terminals and drawn out as needed through the other contacts on the same buss. Connectors can carry one or more bussbars, creating multiple independent electrical circuits within the same connector body and distributing power or data to many components. A single bussed connector can replace several standard connectors or splices, saving space, wiring, and weight. DT Series Bussed Feedback Receptacles DT bussed feedback receptacles are a compact economical bussing option housed in rugged, fieldproven DT receptacle bodies. The bussed DTs mate with standard DT plugs and meet all the performance specifications for the DT Series. The connectors are available in multiple buss configurations using standard size 16 contacts, with plating options in nickel or gold. DT Family Part Numbering System DT 04 - 4 P * - XXXX Special Modifications Series Key (if applicable) Style 04 = Receptacle Contacts Configuration P = Pin DT Series Dimensions DT Receptacle Cavity Overall Length Overall Height A B 2 1.818 (46.18) .670 (17.15) 4 1.868 (47.45) .797 (20.24) B A C 6 8 12 1.858 (47.19) 1.848 (46.94) 2.043 (51.89) Dimensions are for reference only. 86 .972 (24.69) 1.000 (25.40) .876 (22.25) Overall Width C .675 (17.15) .820 (20.83) .820 (20.83) 1.435 (36.45) 1.597 (40.56) Bussing Options 6.5 amps 10 amps 6.5 amps 3 amps 13 amps 13 amps In the examples, there are three size 16 pins each rated for 13 amps mounted to the buss. A total of 13 amps can be pulled into one pin and going out the 13 amps are split between the remaining two pins. No more than 13 amps can go through any single pin. DT Series Bussed 2, 4, 6, & 8 Way Arrangements Bussing Arrangements Notice The maximum current rating is the total amount of current for the entire buss. Current can be distributed in many combinations, but cannot exceed 13 amps per contact. Maximum Current Rating* Buss Plating Connector Color Receptacle Part Number Mating Plug Part Number (1) 2 Pin Buss=13 amps Nickel Black DT04-2P-P060 DT06-2S-**** (1) 4 Pin Buss=26 amps Nickel Nickel Black Gray DT04-4P-EP13 DT04-4P-P021 DT06-4S-**** DT06-4S-**** (1) 6 Pin Buss=39 amps Nickel Nickel Black Gray DT04-6P-EP13 DT04-6P-P021 DT06-6S-**** DT06-6S-**** (2) 3 Pin Busses=13 amps each Nickel Black DT04-6P-EP14 DT06-6S-**** (1) 8 Pin Buss=52 amps Nickel Nickel Gray Black DT04-08PA-P021 DT04-08PB-P021 DT06-08SA-**** DT06-08SB-**** (1) 3 Pin Buss=13 amps (1) 5 Pin Buss=26 amps Nickel Nickel Gray Black DT04-08PA-P028 DT04-08PB-P028 DT06-08SA-**** DT06-08SB-**** (2) 4 Pin Busses=26 amps each Nickel Nickel Gray Black DT04-08PA-P026 DT04-08PB-P026 DT06-08SA-**** DT06-08SB-**** (1) 2 (1) 4 (1) 6 (2) 3's (1) 8 (1) 3, (1) 5 (2) 4's *Maximum current rating is the total amperage for the buss 87 Bussing Options DT Series Bussed 12 Way Arrangements Bussing Arrangements Maximum Current Rating* Buss Plating Connector Color Receptacle Part Number Mating Plug Part Number (1) 12 Pin Buss=78 amps Gold Gold Nickel Nickel Gray Black Gray Black DT04-12PA-P016 DT04-12PB-P016 DT04-12PA-P021 DT04-12PB-P021 DT06-12SA-**** DT06-12SB-**** DT06-12SA-**** DT06-12SB-**** (2) 6 Pin Busses=39 amps each Nickel Nickel Gold Gray Black Black DT04-12PA-P026 DT04-12PB-P026 DT04-12PB-P027 DT06-12SA-**** DT06-12SB-**** DT06-12SB-**** (3) 4 Pin Busses=26 amps each Nickel Gray DT04-12PA-P075 DT06-12SA-**** (4) 3 Pin Busses=13 amps each Nickel Nickel Gold Gold Gray Black Gray Black DT04-12PA-P030 DT04-12PB-P030 DT04-12PA-P031 DT04-12PB-P031 DT06-12SA-**** DT06-12SB-**** DT06-12SA-**** DT06-12SB-**** (1) 12 (2) 6's (3) 4's (4) 3's *Maximum current rating is the total amperage for the buss HDFB Series Overview DEUTSCH HDFB connectors are self-contained, environmentally sealed, bussed feedback modules designed for use in heavy duty applications. Available in five bussing arrangements with two contact sizes, each HDFB holds one or more integrated busses formed from standard DEUTSCH pin contacts and a thin conductive strip. HDFBs mount in place with lightweight aluminum brackets, and the pins inside mate with standard DEUTSCH sockets. HDFB Series Part Numbering System HDFB - 12 - **S Series Contact Size 12 or 16 88 Arrangement 01 = (1) 10 pin bus 02 = (1) 6 pin bus & (1) 4 pin bus 03 = (2) 4 pin busses & (1) 2 pin bus 04 = (3) 2 pin busses & (1) 4 pin bus 06 = (1) 9 pin bus & (4) 3 pin busses Bussing Options HDFB Series Dimensions HDFB Receptacle Bussing Arrangement Overall Length Overall Height Overall Width A B C 01-04 1.197 (30.40) 1.589 (40.36) 2.310 (58.67) 06 1.197 (30.40) 1.619 (41.12) 2.326 (59.08) B A C Dimensions are for reference only. HDFB Series Arrangements Size 12 Contacts HDFB-12-01S 01 Arrangement HDFB-12-02S 02 Arrangement HDFB-12-03S 03 Arrangement HDFB-12-04S 04 Arrangement Size 16 Contacts HDFB-16-06S 06 Arrangement Accessories Mounting brackets are available for use with the HDFB Series. The brackets are aluminum and accommodate two or three HDFB modules. Please request a drawing for mounting specifications. Mounting Brackets Part Number 0427-202-0290 0427-201-0390 Description 2 module capacity mounting bracket, outside dimensions 3.575 x 3.019 (90.81 x 76.68) 3 module capacity mounting bracket, outside dimensions 3.575 x 4.016 (90.81 x 102.01) 89 Controller Area Networks Contents CAN Overview 92 J1939/13 9-pin Diagnostic 93 J1939/11 Connector Options 94 J1939/15 Connector Options 95 ISO Box 95 91 Controller Area Networks CAN Overview Controller Area Networks, or CAN, are multiplex data systems. Multiplexing allows multiple data signals to travel on the same wires, integrating separate electronic systems and applications to a single point control and monitoring system. Using signals sent over a serial network, CAN systems provide instantaneous monitoring of diagnostic and control systems allowing early detection of potential problems. Early detection of problems leads to lower repair costs and reduced downtime. CAN systems allow an operator to use a single command station to control diagnostic systems and receive such varied information as brake and transmission temperature, tire pressure, fuel efficiency, and emissions levels. Anything that can be measured and controlled electronically can be monitored and directed by a CAN system. Whether you're building a Controller Area Network for anything from on/off-highway, construction, material handling, agriculture machines, or your OEM fleet of fire engines, there is a DEUTSCH solution for your CAN needs. Options include several configurations: 2-wire, 3-wire, and 4-wire, with in-line and flange mount, along with splitters, heavy duty breakaway connectors, and an off-board 9-pin diagnostic connector. SAE J1939 is a specific type of CAN that defines the communications pathways for vehicle networks. Improved electrical systems as defined under SAE J1939 allow electrical devices to communicate with each other. Communication occurs using a Controlled Area Network between intelligent sensors over a serial network. Through a series of microprocessors a CAN interconnects every device establishing a common link between each. There are four main electrical interconnect subsets of J1939 including /11, /12, /13, and /15: * J1939/11 is a 3-wire system that uses the DEUTSCH DT Series connectors primarily for truck and bus. The DT Series accepts size 16 contacts and 14-20 AWG. Connector options include in-line, bulkhead, "Y" splitter, and terminating resistors. * J1939/12 is a system that requires the DEUTSCH DT Series, HD30 Series, and ISO Box (HDBox). This group of electrical interfaces terminates a CAN between the tractor and its implement. Its main feature is a breakaway function that prevents damage to the tractor or implement in case of an accidental driveaway disconnect. * J1939/13 is a system that uses the DEUTSCH HD10 Series connectors for on-board diagnostics. The HD10 Series accepts size 16 contacts and 14-20 AWG. * J1939/15 is a 2-wire system that uses the DEUTSCH DTM Series connectors. The DTM Series accepts size 20 contacts and 16-22 AWG. Connector options include in-line, "Y" splitter, and terminating resistors. The continued sophistication in design of equipment is demanding increased response of electrical systems. The application of J1939 has allowed designers to improve both the quantity and the quality of the options offered along with the increased electrical system reliability. 92 Controller Area Networks J1939/13 Universal 9-pin Diagnostic Part Number Description HD10-9-1939P Receptacle HD10-9-1939P-B022 Receptacle, Panel Nut Mount HD10-9-1939PE-B022 Receptacle, Panel Nut Mount, Reduced Wire Seal HD10-9-1939PE Receptacle, Reduced Wire Seal HD16-9-1939S Plug, Coupling Ring HD16-9-1939SE Plug, Coupling Ring, Reduced Wire Seal HD17-9-1939S Plug, No Coupling Ring (Slip-on) HD17-9-1939SE Plug, No Coupling Ring (Slip-on), Reduced Wire Seal 0460-202-1631 Pin, Solid, Size 16, Gold 0460-247-1631 Pin, Solid, Size 16, Gold, Extended 0462-201-1631 Socket, Solid, Size 16, Gold 0462-221-1631 Socket, Solid, Size 16, Gold, Extended DEUTSCH J1939/13, HD10 9 pin connector is a standard diagnostic tool interface for on- and offhighway OEMs. The HD10-9-1939P is a data port connector designed to allow an on-board CAN system to mate with a diagnostic computer. The connectors are for use with the 250 kbps network. The DEUTSCH HD10 J1939/13 connectors offer several mounting options for the receptacle, and a mating plug that is available with or without a coupling ring. J1939/13 Type II Universal 9-pin Diagnostic Part Number Description HD10-9-1939P-P080 Receptacle, Flange Mount, Type II HD10-9-1939PE-P080 Receptacle, Flange Mount, Type II, Reduced Wire Seal HD10-9-1939P-BP03 Receptacle, Panel Nut Mount, Type II HD10-9-1939PE-BP03 Receptacle, Panel Nut Mount, Type II, Reduced Wire Seal HD14-9-1939P-P080 Receptacle, Type II HD14-9-1939PE-P080 Receptacle, Type II, Reduced Wire Seal HD16-9-1939S-P080 Plug, Coupling Ring, Type II HD16-9-1939SE-P080 Plug, Coupling Ring, Type II, Reduced Wire Seal HD17-9-1939S-P080 Plug, No Coupling Ring (Slip-on), Type II HD17-9-1939SE-P080 Plug, No Coupling Ring (Slip-on), Type II, Reduced Wire Seal 0460-202-1631 Pin, Solid, Size 16, Gold 0460-247-1631 Pin, Solid, Size 16, Gold, Extended 0462-201-1631 Socket, Solid, Size 16, Gold 0462-221-1631 Socket, Solid, Size 16, Gold, Extended DEUTSCH J1939/13, HD10 9 pin connector is a standard diagnostic tool interface for on- and offhighway OEMs. The HD10-9-1939P*-P080 is a data port connector designed to allow an on-board CAN system to mate with a diagnostic computer. The green, Type II connectors, HD10-9-1939P-P080, are for use with the 500 kbps network. The DEUTSCH HD10 J1939/13 connectors offer several mounting options for the receptacle, and a mating plug that is available with or without a coupling ring. 93 Controller Area Networks SAE J1939/11 DEUTSCH Connector Options Part Number DT04-3P-P007 DT04-3P-E008 DT04-3P-P006 DT04-3P-EE01 DT04-3P-EP10 DT06-3S-E008 DT06-3S-P006 DT06-3S-EP11 DT06-3S-PP01 DT06-3S-PE01 DT06-3S-P032 W3P-1939 W3S W3S-P012 W3S-1939 W3S-1939-P012 0460-202-1631 1060-16-0144 0460-247-1631 0462-201-1631 1062-16-0144 0462-221-1631 94 Description Receptacle, "Y" Connector Receptacle, Gray, Shrink Boot Adapter Receptacle, Gray, 120 Ohm Resistor Receptacle, Black, Shrink Boot Adapter Receptacle, Black, 120 Ohm Resistor Plug, Gray, Shrink Boot Adapter Plug, Gray, 120 Ohm Resistor Plug, Black, Shrink Boot Adapter Plug, Black, 120 Ohm Resistor Plug, Black, 120 Ohm Resistor, Latch Guard Plug, Black, Single Piece Shrink Boot Adapter Wedgelock, Blue Wedgelock, Orange Wedgelock, Green Wedgelock, Blue Wedgelock, Blue Pin, Solid, Size 16, Gold Pin, Stamped & Formed, Size 16, Gold Pin, Solid, Size 16, Gold, Extended Socket, Solid, Size 16, Gold Socket, Stamped & Formed, Size 16, Gold Socket, Solid, Size 16, Gold, Extended DEUTSCH J1939/11 connectors are rugged field proven DT 3 pin connectors designed to meet the SAE requirements for 3-wire CAN applications linking ECUs for serial data communications. The DT 3 way connectors accommodate the CAN_HI, CAN_LO and shield wires with a variety of options including "Y" receptacles, connectors with mounting flanges, keyed wedgelocks to prevent mis-mating, and network terminating connectors with molded-in 120 resistors. Controller Area Networks SAE J1939/15 DEUTSCH Connector Options Part Number DTM04-2P-P007 DTM04-2P-E007 DTM04-2P-P006 DTM04-2P-EE03 DTM06-2S-E007 DTM06-2S-P006 DTM06-2S-EE03 DTM06-2S-EP10 WM-2P WM-2PA WM-2PB WM-2S WM-2SA WM-2SB 0460-202-2031 1060-20-0144 0462-201-2031 1062-20-0144 Description Receptacle, "Y" Connector Receptacle, Gray, Shrink Boot Adapter Receptacle, Gray, 120 Ohm Resistor Receptacle, Black, Shrink Boot Adapter Plug, Gray, Shrink Boot Adapter Plug, Gray, 120 Ohm Resistor Plug, Black, Shrink Boot Adapter Plug, Black, 120 Ohm Resistor Wedgelock, Orange Wedgelock, Gray Wedgelock, Black Wedgelock, Orange Wedgelock, Gray Wedgelock, Black Pin, Solid, Size 20, Gold Pin, Stamped & Formed, Size 20, Gold Socket, Solid, Size 20, Gold Socket, Stamped & Formed, Size 20, Gold SAE J1939/15 defines the requirements for reduced physical layer 2-wire CAN systems consisting of an unshielded twisted pair of wires. DEUTSCH DTM 2 way connectors are offered in several modifications to meet the requirements of this standard. DTM connectors for serial data communications include "Y" receptacles, connectors with end caps and shrink boot adapters, and receptacles with molded-in 120 resistors for network terminations. ISO/CD 11783-2 & J1939/12 ISO Box and Associated Connectors Part Number HDBOX-24-91PN HDBOX-24-91PE HD36-24-91SN-059 HD36-24-91SE-059 Description ISO Box Assembly ISO Box Assembly, Reduced Wire Seal Plug, Cable Clamp Assembly Plug, Cable Clamp Assembly, Reduced Wire Seal HDB36-24-91SN-059 Plug, Breakaway Coupling, Cable Clamp Assembly HDB36-24-91SE-059 Plug, Breakaway Coupling, Cable Clamp Assembly, Reduced Wire Seal DT06-4S-EP06* Plug, Black, End Cap DT06-2S-EP06* Plug, Black, End Cap W4S-P012 Wedgelock, Green W2S-P012 Wedgelock, Green 0460-204-08141 Pin, Solid, Size 8 0460-204-12141 Pin, Solid, Size 12 0460-202-1631 Pin, Solid, Size 16, Gold 0462-203-08141 Socket, Solid, Size 8 0462-203-12141 Socket, Solid, Size 12 0462-201-1631 Socket, Solid, Size 16, Gold Originally designed for agricultural applications, the DEUTSCH J1939/12 ISO Box creates a communication pathway between an on-board CAN system and the electronic components on an attached implement. The HDBox, which holds two DT13 connectors and an HD30 Series receptacle, mounts on the vehicle and mates with an HD30 plug connector that features a breakaway coupling ring. DEUTSCH breakaway couplings are designed to help prevent damage to the vehicle or the attached implement by fragmenting and separating from the vehicle in the event of a drive-away disconnect. *DT Series receptacles are molded in the HDBox 95 Diodes & Resistors Contents Diodes & Resistors Overview 98 Part Numbering System 98 Configurations 98 Diode & Resistor Characteristics 99 97 Diodes & Resistors Diodes & Resistors Overview DEUTSCH DT connectors with diodes and resistors are useful anywhere you need to regulate power or protect a device against a potential power surge. A diode allows current to flow in one direction only. By preventing current from traveling a circuit in the wrong direction, a diode can protect an electronic device from damage. Devices with batteries will often use diodes to prevent power from flowing in reverse if the battery is not installed correctly. A resistor limits or blocks current flow in both directions. Resistors protect sensitive electronics by limiting the amount of electricity that can flow to the device through the resistor, and therefore preventing power spikes. For example, resistors are used to prevent power surges from burning out an LED by restricting current flow to the light. DEUTSCH diode and resistor connectors are easily added to an application after the fact if unwanted power surges are discovered. Part Numbering System DT* 04 - 2 P - RT XX Special Modifications Series Blank = DT Series M = DTM Series Electronic Package Designator Style Contacts 04 = Receptacle 06 = Plug P = Pin S = Socket Configuration Diode & Resistor Configurations Notice Insert Arrangement Please see DT Family for connector dimensions. DT04-4P-**** 4 size 16 DTM Series Configurations 98 DTM0*-2*-**** 2 size 20 Part Number Number and Size of Cavities DT Series Configurations DT0*-2*-**** 2 size 16 DT0*-3*-**** 3 size 16 DT0*-4*-**** 4 size 16 Diodes & Resistors DEUTSCH Diode Characteristics DT Series Part Number Plug or Receptacle DT04-2P-RT01 Receptacle DT04-2P-RT02 Receptacle DT04-4P-RT01 Receptacle DT04-4P-RT03 Receptacle Diode Part Number Motorola Diode: MUR460 Toshiba Diode: 3GZXX Motorola Diode: MUR460 (3) Motorola Diode: MUR460 (2) Peak Reverse Peak Forward Avg. Forward Color Volts Volts Current 600 V max. 1.28 V max. 4.0 A max. Black 400 V max. 1.0 V max. 3.0 A max. Black 600 V max. 1.28 V max. 4.0 A max. Black 600 V max. 1.28 V max. 4.0 A max. Gray DEUTSCH Resistor Characteristics DTM Series DT Series Part Number Plug or Receptacle Resistor Ohms Resistor Watts Resistor Tolerance Color DTM04-2P-EP10 Receptacle 120 0.4 5% Black (B keyed wedgelock included) DTM04-2P-P006 Receptacle 120 0.4 5% Gray (A keyed wedgelock included) DTM06-2S-EP10 Plug 120 0.4 5% Black (B keyed wedgelock included) DTM06-2S-P006 Plug 120 0.4 5% Gray (A keyed wedgelock included) Part Number Plug or Receptacle Resistor Ohms Resistor Watts Resistor Tolerance Color DT04-2P-RT25 Receptacle 27k 0.5 1% Black DT04-3P-EP10 Receptacle 120 0.4 min. 10% Black (J1939 keyed wedgelock included) DT04-3P-P006 Receptacle 120 0.4 min. 10% Gray (J1939 keyed wedgelock included) DT06-3S-EP10 Plug 120 0.4 min. 10% Black (J1939 keyed wedgelock included) DT06-3S-P006 Plug 120 0.4 min. 10% Gray (J1939 keyed wedgelock included) 99 Printed Circuit Board Contents Printed Circuit Board Overview 102 PCB Connector Options 102 AMPSEAL Connectors 103 DRC Series 103-105 DT Family 105-107 HD10 Series 107 STRIKE Series 108 PCB Enclosures and Headers 108-110 101 Printed Circuit Board Connectors Printed Circuit Board Overview Printed circuit board or PCB connectors are heavy duty environmentally sealed connectors designed for wire-tocircuit board connections. TE Connectivity's Industrial & Commercial Transportation connectors are built to maintain the integrity and continuity of data and power signals in harsh environments. Developed and designed for heavy duty electronically equipped vehicles, TE Connectivity's printed circuit board connector bodies will withstand dust, dirt, moisture, and vibration. Available in a variety of styles from several different connector families, TE Connectivity's printed circuit board connectors cover a range of pin counts from 2 to 76 and wire gauges from 10 to 22. Many of the connectors are available in straight, 90, or solder pot options. Printed Circuit Board Connector Options AMPSEAL Connectors * * 8, 14, 23, and 35 cavity arrangements Mating connectors accept 16-20 AWG HD10 Series * * 6 and 9 cavity arrangements Mating connectors accept 14-20 AWG DRC Series STRIKE Series * * * * 24, 40, 50, 60, 64, 70, and 76 cavity arrangements Mating connectors accept 14-22 AWG 32 cavity arrangement Mating connectors accept 14-22 AWG EEC Enclosure and Flange Receptacle DT Family * * * * * * * * * DT Series 2, 3, 4, 6, 8, and 12 cavity arrangements DT Series mating connectors accept 14-20 AWG DT Series flangeless options available DTM Series 8, 12, and 48 cavity arrangements DTM Series mating connectors accept 16-22 AWG DTM Series flangeless 48 way option DTP Series 4 cavity arrangement DTP Series mating connectors accept 10-14 AWG Some arrangements of the DT and DTM Series are available with A, B, C, and D keying options Notice See individual series sections for part numbering system. 102 * * * * * DT Series header 12, 24, 36, and 48 cavity arrangements DT Series mating connectors accept 14-20 AWG DTM Series header 12 and 24 cavity arrangements DTM Series mating connectors accept 16-22 AWG Some arrangements of the DT and DTM Series are available with A, B, C, and D keying options Printed Circuit Board Connectors AMPSEAL Connectors Materials Cover: Glass filled PBT Wire Seal: Silicone rubber Contacts: Tin or gold plated brass 8 Positions 8 size 1.3 mm h el p fu l hi nt 14 Positions 14 size 1.3 mm Mating Plugs 8 Position: 776286-* 14 Position: 776273-* 23 Position: 770680-* 35 Position: 776164-* 23 Positions 23 size 1.3 mm 35 Positions 35 size 1.3 mm By fixing the connectors to the board prior to soldering, pressure can be greatly reduced at the solder joint. DRC10 Series Straight Materials Housing: Thermoplastic Grommet: Silicone elastomer Receptacle Threaded Insert: Steel Contacts: Molded-in copper alloy, tin plated solder pot standard (gold optional - see modifications) DRC10-24P* 24 size 16 Mating Plugs 24 Pin: DRC16-24S* 40 Pin: DRC16-40S Modifications A004: Tin plated PCB pins AG02: Some terminals are gold plated DRC10-40P* 40 size 16 103 Printed Circuit Board Connectors DRC13 Series 90 Materials Housing: Thermoplastic Receptacle Threaded Insert: Steel/ Brass Contacts: Molded-in copper alloy, tin plated PCB pins standard (gold optional - see modifications) Mounting Seal: Silicone DRC13-24P* 24 size 16 Mating Plugs 24 Pin: DRC16-24S* 40 Pin: DRC18-40S* 70 Pin: DRC16-70S* Modifications C023: 5mm2 threaded insert mounting holes G002: Only outside terminal rows are gold plated N012: One piece connector design DRC13-40P* 40 size 16 DRC13-70P* 70 size 16 DRC20/22 Series Straight Materials Housing: Thermoplastic Grommet: Silicone elastomer Receptacle Threaded Insert: Steel Contacts: Molded-in copper alloy, gold plated mating side, tin plated PCB side (size 12 contacts are tin plated on mating and PCB sides) Mounting Seal: Silicone rubber DRC2*-50P* 50 size 20 104 Mating Plugs 50 Pin: DRC26-50S** 60 Pin: DRC26-60S** 76 Pin: (2)DRC26-38S** DRC20-60P* 60 size 20 DRC22 DRC20 DRC20-76P**** 68 size 20, 8 size 12 Printed Circuit Board Connectors DRC23 Series 90 Materials Housing: Thermoplastic Grommet: Silicone elastomer Receptacle Threaded Insert: Steel Contacts: Molded-in copper alloy, gold plated PCB pins standard (tin optional) Mounting Seal: Silicone rubber DRC23-24** 24 size 20 Mating Plugs 24 Pin: DRC26-24S* 40 Pin: DRC26-40S* 64 Pin: DRC26-24S*, DRC2640S* Modifications N010: Custom mount N012: One piece connector design DRC23-64** 64 size 20 DRC23-40** 40 size 20 Notice Camcar thread forming screws are recommended. See drawing. DT13/15 Series 90 or Straight Materials Housing: Thermoplastic Contacts: Molded-in copper alloy, nickel plated mating side, tin plated PCB side (gold optional - contact your representative) Mounting Seal: Silicone rubber Mating Plugs 2 Pin: DT06-2S 4 Pin: DT06-4S 6 Pin: DT06-6S 8 Pin: DT06-8S* 12 Pin: DT06-12S* Modifications B016: Extended shell and additional keys G003: Gold plated pins DT13 DT1*-2P 2 size 16 DT1*-4P 4 size 16 DT1*-6P 6 size 16 DT1*-08P* 8 size 16 A, B, C, D DT1*-12P* 12 size 16 A, B, C, D DT15 105 Printed Circuit Board Connectors DTF13 Series Flangeless 90 Materials Housing: Thermoplastic Contacts: Molded-in copper alloy, tin plated (gold optional - contact your representative) DTF13-2P 2 size 16 DTF13-3P 3 size 16 DTF13-4P 4 size 16 Mating Plugs 2 Pin: DT06-2S 3 Pin: DT06-3S 4 Pin: DT06-4S 6 Pin: DT06-6S 12 Pin: DT06-12S* DTF13-6P 6 size 16 Modifications G003: Gold plated pins DTF13-12P* 12 size 16 A, B, C, D DTF15 Series Flangeless Straight Materials Housing: Thermoplastic Contacts: Molded-in copper alloy, tin plated (gold optional - contact your representative) Mating Plugs 12 Pin: DT06-12S* Modifications G003: Gold plated pins DTF15-12P* 12 size 16 A, B, C, D DTM13/15 Series 90 or Straight Materials Housing: Thermoplastic Contacts: Molded-in copper alloy, tin plated (gold optional - contact your representative) Mounting Seal: Silicone rubber Mating Plugs 12 Pin: DTM06-12S* DTM13 DTM1*-12P* 12 size 20 A, B, C, D 106 DTM15 Printed Circuit Board Connectors DTMF15 Series Miniature Straight Materials Housing: Thermoplastic Contacts: Molded-in copper alloy, tin plated (gold optional - contact your representative) Mating Plugs 12 Pin: (4) DTM06-12S* Modifications B026: Alternate keying position DTMF15-48P (4)12 size 20 DTP10/13/15 Series 90 or Straight Materials Housing: Thermoplastic Contacts: Molded-in copper alloy, tin plated Mounting Seal: Silicone rubber Mating Plugs 4 Pin: DTP06-4S DTP13 DTP1*-4P 4 size 12 DTP10 HD10 Series Straight Materials Housing: Thermoplastic Contacts: Molded-in copper alloy, nickel plated Mounting Seal: Standard O-rings may be used HD10-6-96P-N005 6 size 16 Mating Plugs 6 Pin: HD16-6-96S 9 Pin: HD16-9-96S Modifications N005: Straight reduced diameter pins supplied as standard HD10-9-96P-N005 9 size 16 107 Printed Circuit Board Connectors STRIKE13/15 Series 90 or Straight Materials Housing: Thermoplastic Contacts: Molded-in copper alloy, tin plated (gold optional - contact your representative) Mounting Seal: Silicone rubber Mating Plugs 32 Pin: SRK06-MD*-32A-*** SRK1*-MD*-32A-001-**** 4 - Size 16 28 - Size 20 Printed Circuit Board Enclosures and Headers Compact circuit board enclosures that accept snap-in headers are available. The enclosure features a through hole mounting flange on each side, as well as optional venting. Designed with space to accommodate one or more DT or DTM Series interfaces, the headers feature 90 pins. A radial flange seal provides environmental sealing to the enclosure. The headers mate with the DT and DTM standard plugs. DT Series Enclosure and Header Dimensions DT Series Enclosure with Header Overall Length Overall Height Overall Width A B C 7.93 (201.30) 2.15 (54.63) 6.30 (160.00) A B C Dimensions are for reference only. DT Header Connector Materials Contacts: Molded-in tin (gold optional - contact your representative) Mating Plugs 12 Pin: DT06-12S* 24 Pin: (2) DT06-12S* 36 Pin: (3) DT06-12S* 48 Pin: (4) DT06-12S* Modifications GR02: DT Series snap-in header with gold plated pins R015: DT Series snap-in header Notice Keying position of receptacle must match keying position of mating plug(s). 108 DT13-12PA-**** 12 size 16 A DT13-24PAB-**** (2) 12 size 16 A, B DT13-36PABC-**** (3) 12 size 16 A, B, C DT13-48PABCD-**** (4) 12 size 16 A, B, C, D Printed Circuit Board Connectors DT PCB Enclosure Material Housing: Thermoplastic Venting* A: With vent hole B: Without vent hole Board Size 5" X 6.50" EEC-5X650* DTM Series Enclosure and Header Dimensions DTM Series Enclosure with Header Overall Length Overall Height Overall Width A B C 5.24 (133.03) 1.42 (36.00) 4.68 (118.80) A B Dimensions are for reference only. C DTM Header Connector Materials Contacts: Molded-in nickel mating side, tin plated PCB side DTM13-12P*-**** 12 size 20 A, B, C, D Mating Plugs 12 Pin: DTM06-12S* 24 Pin: (2) DTM06-12S* DTM13-12PA-12PB-**** (2) 12 size 20 A, B Modifications GR01: DTM Series snap-in header with gold plated pins R008: DTM Series snap-in header DTM13-12PC-12PD-**** (2) 12 size 20 C, D 109 Printed Circuit Board Connectors DTM PCB Enclosure Material Housing: Thermoplastic Venting* A: With vent hole B: Without vent hole Board Size 3.25" X 4" EEC-325X4* 110 EEC-325X4*-E016 Modifications E016: Molded in clear Ultem(R) material Single Terminal Contents DTHD Series Overview 112 DTHD Part Numbering System 112 DTHD Dimensions 112 DTHD Special Modifications 113 DTHD Accessories 113 Jiffy Splice Overview 114 Jiffy Splice Dimensions 114 Jiffy Splice How To Instructions 114 111 Single Terminal Solutions Single Terminal Overview Two different solutions are available for applications that require heavy duty single terminal connections. The DEUTSCH DTHD Series and Jiffy Splices provide environmentally sealed field-serviceable connections for the full range of wire gauges covered by the DEUTSCH contacts. The DTHD connectors are heavy duty power terminations for in-line and mounted applications. Jiffy Splices are lightweight in-line splices for quick connections. Both options provide easy installation and service with standard tools and contacts. DTHD Series Overview DTHD connectors are single terminal connectors for heavy duty applications. Easy to install, environmentally sealed and compact in size, they are a simple, field serviceable alternative to a splice. DTHD connectors are available in three sizes, carry 25 to 100 amps, and can be mounted or used in-line. DTHD Series Part Numbering System DTHD 06 - 1 - 4 S - XXXX Special Modifications Series Contacts Style 04 = Receptacle 06 = Plug P = Pin S = Socket Single Terminal Contact Size 4, 8, or 12 DTHD Series Dimensions F B C A DTHD Plug Contact Overall Length Overall Height Size A B 12 1.498 (38.05) .771 (19.58) 8 1.498 (38.05) .861 (21.87) 4 1.498 (38.05) 1.076 (27.33) Dimensions are for reference only. 112 E D DTHD Receptacle Overall Width Overall Length Overall Height C D E .570 (14.48) 2.068 (52.53) .850 (21.59) .660 (16.76) 2.068 (52.53) .940 (23.88) .875 (22.23) 2.068 (52.53) 1.170 (29.72) Overall Width F .710 (18.08) .800 (20.32) 1.045 (26.54) Single Terminal Solutions Special Modifications The DTHD Series connectors offer modifications to enhance the design flexibility and meet application specific needs. Options include end caps and flanges. E003 Modification L013 and L009 Modification The E003 is an end cap modification. The end cap is a protective cap that is sonically welded to the rear of the connector. The L013 and L009 are sealed flange modifications. The L013 offers outside mounting and the L009 offers inside mounting. L009 L013 Accessories There is a full line of mounting clips available for use with the DTHD Series. The mounting clips offer straight or side mounting and several material options. The mounting clips are designed to be used on all DTHD receptacles. Mounting Clip Part Number Mounting Direction Color/Material Hole O.D. inches (mm) 1027-003-1200 Straight Stainless steel .433 (11.0) 1027-005-1200 Straight Stainless steel .512 (13.0) 1027-004-1200 Straight Steel w/ zinc plating .512 (13.0) 1027-008-1200 Side Steel w/ zinc plating .433 (11.0) 1027-013-1200 Side Steel w/ zinc plating .323 (8.2) 1011-026-0205 Straight Gray plastic .200 (5.08) 1011-030-0205 Straight Black plastic --- Straight Black plastic --- 1011-310-0205* *Connector removeable with 50N of force 113 Single Terminal Solutions tio LAD D l u si v e t n xc o E Jiffy Splice Overview D i s tr i b u DEUTSCH Jiffy Splices are a unique, field-serviceable alternative to permanent splices. Made from the same high quality silicone elastomer as DEUTSCH connector seals and grommets, the Jiffy Splice body houses a contact retention system that secures a mated pair of contacts in a compact environmentally sealed unit. Jiffy Splices are easy to install and service. A B Dia. Part Number Notice Jiffy Splices accept one pin and one socket. Size JS-04-00 4 JS-12-00 12 JS-16-00 16 A B (min.) 3.437 (87.30) 2.500 (63.50) 2.465 (62.61) .765 (19.43) .500 (12.70) .385 (9.78) Wire AWG 6 12-14 14-20 Insulation O.D. .280-.292 (7.11-7.42) .134-.170 (3.40-4.32) .100-.134 (2.54-3.40) Dimensions are for reference only. How To Instructions Contact Insertion Step 1: Grasp contact approximately one inch behind the contact crimp barrel. Step 2: Hold Jiffy Splice between thumb and forefinger approximately one half inch behind cavity. Step 3: Push contact straight into Jiffy Splice until a positive stop is felt. An audible "snap" will occur when correctly mated. A light tug will confirm it is properly seated. Step 2: Hold Jiffy Splice between thumb and forefinger approximately one half inch behind cavity. Slide tool into cavity until resistance is felt and retaining fingers are engaged. Do not twist or insert tool at an angle. Step 3: Grip Jiffy Splice between thumb and forefinger and slowly pull contact wire assembly with removal tool out of cavity. Contact Removal Step 1: Snap appropriate size removal tool over the wire. 114 Contacts Contents Contacts Overview Performance Specifications 116 117-118 Wire Sealing Ranges 119 Solid Contacts 120 Stamped & Formed Contacts Crimp Inspection Accessories How To Instructions 120-122 PCB Pins 123 Crimping 124 115 125 126-127 128 Contacts Contacts Overview Several contacts are used interchangeably across most connector product lines. This commonality improves performance, reliability, and maintainability by reducing changes in the assembly of the wire harness. The use of the same contact systems helps eliminates many of the failures reported in harnesses where hundreds of different terminations are used. Contact Styles Two styles of contacts are available: solid and stamped & formed. Both contact types use a crimp style termination, eliminating the need for solder. The variations in the contact system are those dictated by wire gauge and contact style. Solid The solid contacts are designed for use with larger wire size and heavy duty applications. Solid contacts are manufactured using a cold heading process with solid copper alloy wire and are available with either a nickel or gold plating finish. Solid contacts terminate wire from 4 AWG to 20 AWG (25 - 0.5mm2) and are available in 5 sizes each of the pin and socket. The applicable contact is determined by the size of the conductor only. Stamped & Formed Stamped & formed contacts are designed for use where wire termination costs are of primary concern without sacrificing reliability of electrical circuits. The stamped & formed contacts are made on a precision stamping machine using flat strip stock, then a durable and corrosion proof nickel, tin, or optional gold plating is applied. The stamped & formed style contacts terminate wire from 10 AWG to 22 AWG (6.0 - 0.35mm2) and are available in multiple sizes to accommodate a wide range of wire insulation. The specific contact is determined by the outside diameter of wire insulation and conductor size. Design Materials and Selection Engineers combined superior material selection with mechanical CAD/CAM designs to create stamped & formed contacts that exceed the demands of today's industrial electrical systems. To provide exceptional durability, performance, corrosion, and oxidation resistance, contacts are made from copper alloys, finished with nickel, tin, or gold plating. To provide resistance to crimp relaxation and displacement of metal, the contacts are designed with the conductor wings formed in the direction of the crimp to achieve gas tight crimps that eliminate the need for solder. 116 In keeping with the commitment to total quality, all stamped & formed contacts are manufactured using statistical process controls and are subjected to extensive rigorous testing programs, in the lab and in actual field performance. Contacts 1.3 mm Contact (AMPSEAL) Performance Specifications Durability TE Spec 109-27. Mate and unmate specimens for 10 cycles at maximum rate of 600 cycles per hour. See note. Contact Retention TE Spec 109-30. Apply an axial load of 115 N to contacts in the axial direction with wedge lock in locked position. Contacts shall not dislodge. Current Rating Up to 17 amps gold, up to 8 amps tin, consult TE product document 108-1329. Crimp Tensile Strength Contact Size Tensile Strength Size 20 80 lbs 90 lbs Size 18 Size 16 150 lbs Note: Shall meet visual requirements, show no physical damage and shall meet requirements of additional tests as specified in Test Sequence in Figure 3 of TE product document 108-1329. HDSF 1.58 mm Contact (AMPSEAL 16) Performance Specifications Durability SAE J2030 6.11. 50 cycles. See note. Current Rating Up to 13 amps, consult TE product document 1082184. Contact Retention IEC 512-8, Test 51a. Apply axial load of 111 N to contacts at a maximum rate of 10 N per second (or 50mm per minute) and hold for 10 seconds. Contacts shall not dislodge. Crimp Tensile Strength USCAR 21 @ 50mm/min Wire Gauge Tensile Strength 90 N Min 18 AWG 16 AWG 120 N Min 14 AWG 180 N Min Voltage Drop Contact Size Test Current Amps Voltage Drop (millivolts max) 18 16 14 8 10 13 100 100 100 Note: Shall meet visual requirements, show no physical damage, and meet requirements of additional tests as specified in the Product Qualification and Requalification Test Sequence in Figure 3 of TE product document 108-2184. USCAR is a trademark. 117 Contacts DEUTSCH Contact Performance Specifications Durability No electrical or mechanical defects after 100 cycles of engagement and disengagement. Current Rating (Contact current rating @ 125 C continuous) Contact Size Max. Current Size 20 7.5 amps 13 amps Size 16 Size 12 25 amps 60 amps Size 8 Size 4 100 amps Contact Retention (Solid and Stamped & Formed) Contacts withstand a minimum load of: 20 lbs (89 N) for size 20 25 lbs (111 N) for size 16 30 lbs (133 N) for size 12 35 lbs (156 N) for size 8 35 lbs (156 N) for size 4 Crimp Tensile Strength (Solid) Contact Size Tensile Strength Size 20 20 lbs Size 16 25 lbs 70 lbs Size 12 Size 8 90 lbs Size 4 300 lbs Crimp Tensile Strength (Stamped & Formed) Contact Size Tensile Strength Size 20 20 lbs Size 16 25 lbs Size 12 70 lbs h el p fu l hi nt A crimp tensile test easily and rapidly identifies a proper crimp. Contact Millivolt Drop Contact Size Test Current Amps Millivolt Drop* Solids Millivolt Drop* S&F 20 16 12 8 4 7.5 13 25 60 100 60 60 60 60 60 100 100 100 N/A N/A *Less drop through wire Typical Wire Insulation Ranges (measured in diameter inches) Wire Gauge 20 18 16 14 12 10 8 6 Dimensions are for reference only. 118 TXL .065-.072 .073-.084 .082-.091 .098-.105 .120-.128 .146-.157 .178-.185 N/A GXL .080-.087 .089-.098 .097-.107 .114-.122 .137-.146 .170-.185 .209-.221 N/A SXL .092-.099 .103-.110 .116-.123 .138-.145 .159-.168 .190-.196 .222-.236 .287-.294 Contacts Wire Sealing Ranges Dimensions are for reference only. AMPSEAL Rear Grommet Sealing Ranges Contact Size Standard Seal 1.3 mm .067-.106 16-20 AWG (1.5-0.5mm2) (1.7-2.7) AMPSEAL 16 Rear Grommet Sealing Ranges Contact Size Standard Seal 16 14-20 AWG (2.0-0.5mm2) .086-.144 (2.18-3.67) AEC, DRB, DRC, HD30, HDP20 Series Rear Grommet Sealing Ranges Standard/ Thin Seal T-Seal Contact Size Normal Seal T-Seal Modified* N-Seal 20 .040-.095 .040-.095 N/A 16-22 AWG (1.0-0.35mm2) (1.02-2.41) (1.02-2.41) 16 .100-.134 .088-.134 .088-.106 14-20 AWG (2.0-0.5mm2) (2.54-3.40) (2.23-3.40) (2.24-2.69) 12 .134-.170 .113-.170 N/A 10-14 AWG (5.0-2.0mm2) (3.40-4.32) (2.87-4.32) 8 .190-.240 .170-.240 N/A 2 8-10 AWG (8.0-5.0mm ) (4.83-6.10) (4.32-6.10) 4 .280-.292 .261-.292 N/A 6 AWG (13.0mm2) (7.11-7.42) (6.63-7.42) 4 .311-.420 N/A N/A 4 AWG (25.0-21.0mm2) (7.90-10.67) Reduced Diameter Seal .051-.100 (1.30-2.54) Extra Thin Seal E-Seal E-Seal Modified* .040-.095 (1.02-2.41) .053-.120 (1.35-3.05) .097-.158 (2.46-4.01) .135-.220 (3.43-5.59) .261-.292 (6.63-7.42) .040-.083 (1.01-2.10) .053-.103 (1.35-2.62) .097-.158 (2.46-4.01) N/A N/A N/A N/A *DEUTSCH cavity arrangements 24-29, 24-47, and 24-31 are only available with the modified seals. Arrangement 24-31 Modified E Seal = .053-.106. Please see drawings 0425-016-0000 and 0425-021-0000 for full specifications. DT, DTM, DTP Series Rear Grommet Sealing Ranges Extra Thin Contact Size Standard Seal Seal E-Seal 20 .053-.120 N/A 16-22 AWG (1.0-0.35mm2) (1.35-3.05) 16 .088-.145 .053-.120 14-20 AWG (2.0-0.5mm2) (2.23-3.68) (1.35-3.05) 12 .134-.170 .097-.158 2 10-14 AWG (5.0-2.0mm ) (3.40-4.32) (2.46-4.01) HD10 Series Rear Grommet Sealing Ranges Extra Thin Contact Size Standard Seal Seal E-Seal 16 .100-.150 .053-.120 2 14-20 AWG (2.0-0.5mm ) (2.54-3.81) (1.35-3.05) 12 .134-.170 N/A 10-14 AWG (5.0-2.0mm2) (3.40-4.32) 4 .280-.292 N/A 6 AWG (13.0mm2) (7.11-7.42) STRIKE Series Rear Grommet Sealing Ranges Standard Contact Size Seal 20 .061-.095 16-22 AWG (1.0-0.35mm2) (1.55-2.41) 16 .061-.120 2 14-20 AWG (2.0-0.5mm ) (1.55-3.05) h el p fu l hi nt Proper wire outside diameters help provide water tight seals. O 119 Contacts Solid Contacts Solid Contacts - DEUTSCH Solid Contact Part Numbers Size Pin Socket 20 0460-202-20** 0462-201-20** 20 0460-010-20** 0462-005-20** 16 0460-202-16** 0462-201-16** 16 0460-215-16** 0462-209-16** 12 0460-204-12** 0462-203-12** 8 0460-204-08** 0462-203-08** 4 0460-204-04** 0462-203-04** RecomWire Size mended Strip AWG Length (mm2) Inches (mm) Min. Contact Retention Ref Crimp Tensile Lbs. (N) Max Rated Amps at 125 Continuous 20 .156-.218 (0.50) (3.96-5.54) 16-18 .156-.218 (1.0-0.75) (3.96-5.54) 16-20 .250-.312 (1.5-0.50) (6.35-7.92) 14 .250-.312 (2.0) (6.35-7.92) 12-14 .222-.284 (3.0-2.0) (5.64-7.21) 8-10 .430-.492 (10.0-5.0) (10.92-12.50) 6 .430-.492 (16.0-13.0) (10.92-12.50) 20 (89) 20 (89) 25 (111) 25 (111) 30 (134) 35 (156) 35 (156) 20 (89) 20 (89) 35-20 (156-89) 70 (311) 75-70 (334-311) 125-90 (556-400) 300 (1334) RecomWire Size mended Strip AWG Length (mm2) Inches (mm) Min. Contact Retention Ref Crimp Tensile Lbs. (N) Max Rated Amps at 125 Continuous 4 .430-.492 (25.0-21.0) (10.92-12.50) 35 (156) 300 (1334) 100 7.5 7.5 13 13 25 60 100 ** = Plating Codes. Contact your representative for custom finish needs. Solid Contacts - C038 Modification Solid Contact Part Numbers Size Pin 4 Notice Socket 5960-203-04141 5962-203-04141 See information drawing 0425-015-0000. Contact your representative for alternate finishes. Solid Contact Plating Codes Part Number Material Suffix (**) 31 Gold 90 Nickel (Size 4 pin only) 141 Nickel Stamped & Formed Contacts Stamped & Formed Receptacles - 1.3 mm AMPSEAL Receptacles Part Numbers Size Package Loose Package Strip Form Quantity Piece Quantity 770520-1 5000 770854-1 1000 1.3 mm 770520-3 5000 770854-3 1000 120 Wire Size AWG (mm2) Insulation Diameter (mm) Finish 16-20 (1.5-0.5) .067-.106 (1.7-2.7) Pre-tin plated Selective gold plated Contacts Stamped & Formed Pins - HDSF 1.58 mm AMPSEAL 16 Part Numbers Wire Size Size AWG Strip Package Loose Package (mm2) Form Qty Piece Qty 1924463-1 4000 1924579-1 1000 18-20 (0.8-0.5) 1924463-3 4000 1924579-3 1000 776349-1 4000 18-20 (0.8-0.5) 776349-3 4000 638078-1 4000 776300-1 1000 14-18 (2.0-0.8) 4000 776300-2 1000 HDSF 16 638078-3 1.58 mm 638112-1 4000 776298-1 1000 14-18 (2.0-0.8) 638112-3 4000 776298-2 1000 2098250-1 4000 18 (1.5-0.8) 2098250-3 4000 2098252-1 4000 14 (2.0-1.5) 2098252-3 4000 - Insulation Diameter (mm) Wire Insulation Support .107-.05 (2.72-1.27) yes .131-.089 (3.33-2.26) yes .131-.089 (3.33-2.26) yes .155-0.077 (3.94-1.96) no .118-.065 (3.00-1.65) yes .128-.083 (3.25-2.10) yes Insulation Diameter (mm) Wire Insulation Support .107-.05 (2.72-1.27) yes .131-.089 (3.33-2.26) yes .131-.089 (3.33-2.26) yes .155-.077 (3.94-1.96) no 18 (1.5-0.8) .118-.065 (3.00-1.65) yes 14 (2.0-1.5) .128-.083 (3.25-2.10) yes Stamped & Formed Receptacles - HDSF 1.58 mm AMPSEAL 16 Part Numbers Wire Size Size AWG Strip Package Loose Package 2 ) (mm Form Qty Piece Qty 1924464-1 4000 1924580-1 1000 18-20 (0.8-0.5) 1924464-2 4000 1924580-2 1000 776493-1 4000 18-20 (0.8-0.5) 776493-2 4000 776492-1 4000 776299-1 1000 14-18 (2.0-0.8) 4000 776299-2 1000 HDSF 16 776492-2 1.58 mm 776491-1 4000 776297-1 1000 14-18 (2.0-0.8) 776491-2 4000 776297-2 1000 2098251-1 2098251-2 2098253-1 2098253-2 4000 4000 4000 4000 - - Finish Gold Nickel Gold Nickel Gold Nickel Gold Nickel Gold Nickel Gold Nickel Finish Gold Nickel Gold Nickel Gold Nickel Gold Nickel Gold Nickel Gold Nickel 121 Contacts Stamped & Formed Contacts- DEUTSCH Carrier Stamped & Formed Wire Size Strip Contact Part Numbers AWG Size Identifica(mm2) Pin Socket tion 16-22 20 1060-20-01** 1062-20-01** 20-01 (1.5-0.35) 16-22 20 1060-20-02** 1062-20-02** 20-02 (1.5-0.35) 1062-20-03** 16-22 20 N/A 20-03 sleeveless (1.5-0.35) 14-16 20 1060-20-06** 1062-20-06** 20-06 (2.5-1.0) 14-18 16 1060-14-01** 1062-14-01** 14-16 (2.0-.75) 14-18 16 1060-14-10** 1062-14-10** 14-16 (2.0-.75) 14-18 16 1060-16-01** 1062-16-01** 16-18 (2.0-.75) 16-20 16 1060-16-06** 1062-16-06** 0.5-1.0 (1.0-.50) 14-18 16 1060-16-09** 1062-16-09** 16-18 (2.0-.75) 12-16 16 1060-16-12** 1062-16-12** 1.0-2.5 (2.5-1.0) 12-16 1062-16-14** 14-16 16 N/A (2.5-1.0) sleeveless 12-14 12 1060-12-01** 1062-12-01** 12-14 (4.0-2.0) 10 12 1060-12-02** 1062-12-02** 10-12 (6.0-4.0) RecomWire mended Strip Insulation Length O.D. Range Inches (mm) .075-.125 (1.91-3.18) .051-.085 (1.30-2.16) .075-.125 (1.91-3.18) .075-.125 (1.91-3.18) .095-.150 (2.41-3.81) .095-.150 (2.41-3.81) .075-.140 (1.90-3.55) .055-.100 (1.40-2.54) .075-.140 (1.90-3.55) .075-.140 (1.90-3.55) .075-.140 (1.90-3.55) .113-.176 (2.87-4.47) .140-.204 (3.56-5.18) ** = Plating Codes. Contact your representative for custom finish needs. = TXL wire insulation is preferred Notice See information drawing 0425-015-0000. Contact your representative for alternate finishes. 122 S&F Contact Plating Codes Part Number Material Suffix (**) 22 Nickel 44 Gold 66 Tin/Nickel 77 Tin 88 Selective Gold .150-.200 (3.81-5.08) .150-.200 (3.81-5.08) .150-.200 (3.81-5.08) .150-.200 (3.81-5.08) .150-.200 (3.81-5.08) .150-.200 (3.81-5.08) .150-.200 (3.81-5.08) .150-.200 (3.81-5.08) .150-.200 (3.81-5.08) .175-.225 (4.45-5.72) .175-.225 (4.45-5.72) .225-.275 (5.72-6.99) .225-.275 (5.72-6.99) Min. Contact Retention 20 (89) 20 (89) 20 (89) 20 (89) 25 (111) 25 (111) 25 (111) 25 (111) 25 (111) 25 (111) 25 (111) 30 (134) 30 (134) Max Rated Amps at 125 Continuous 7.5 7.5 7.5 7.5 13 13 13 13 13 13 13 25 25 Contacts PCB Pins Straight reduced diameter extended pins are available for installation in the DEUTSCH family of connectors. The use of removable contacts provides design flexibility and a low cost alternative to meet application needs. These solid copper alloy pins may be specified in various platings and assembled in HD30, HDP20, HD10, DRC, or DT receptacles. Material Copper alloy Plating Codes 31: Gold 90: Tin 141: Nickel PCB Mounting Consult factory for PCB mounting details and pin positions. End of Connector D A Contact Size 20 16 12 B Part Number A B C 0460-208-2031 0460-208-2090 0460-208-16141 0460-208-1631 0460-229-16141 0460-241-16141 0460-244-16141 0460-244-1631 0460-208-12141 0460-245-1231 0460-245-1290 1.305 (33.15) 1.305 (33.15) 1.300 (33.02) 1.300 (33.02) .545 (13.84) 1.305 (33.15) .976 (24.79) .976 (24.79) 1.305 (33.15) 1.024 (26.01) 1.024 (26.01) .248 (6.30) .248 (6.30) .248 (6.30) .248 (6.30) .248 (6.30) .160 (4.06) .400 (10.16) .400 (10.16) .248 (6.30) .500 (12.70) .500 (12.70) .025 (.64) .025 (.64) .025 (.64) .025 (.64) .025 (.64) .040 (1.02) .041 (1.04) .041 (1.04) .025 (.64) .041 (1.04) .041 (1.04) Notice C See information drawing 0425-202-0000 for full specifications. Series HD30/HDP20 HD10 DT DT04-2P DT04-3P DRC D* .939 (23.85) .925 (23.50) .777 (19.74) .677 (17.20) .677 (17.20) 1.063 (27.00) *D is equal to the distance from the contact shoulder to the end of the connector. Dimensions are for reference only. HD10 Series HDP20 Series HD30 Series 123 Contacts Crimping Crimping is defined as the act of joining a conductor to a pin or socket contact using a mechanical tool to compress and displace metal. In a good crimp joint, there is a mutual flow of metal, causing a symmetrical distortion of wire strands and contact material. A proper crimp will establish mechanical strength and excellent electrical conductivity. Crimping Configurations Stamped & Formed Style Stamped & formed contacts use a folded type of crimp (Fig. 1) while solid contacts use a 1, 2, or 4 indent crimp (Fig. 2). In both styles of crimps, the wire strands and the contact material are formed together in a solid mass creating a reduction of the wire strands area. The reduced wire strand area creates a minimum of voids allowing for excellent conductivity. Crimping may be accomplished with hand tools or power tools. Cross-Section Across Axis Figure 1 Solid Style Indenter Crimp Cross-Section Across Axis Figure 2 Benefits of Crimped Contacts Mechanically crimping contacts is the dominant wire termination method, for some very good reasons: 1. With smaller wire, the crimp is as strong as the wire itself. 2. The joint can be visually inspected. Viewing the wire through an inspection hole in the contact makes inspection quick and easy, both by the operator and by the inspector. 3. Plating thickness is not restricted, as in solder joints, so better corrosion resistance and contact reliability are achieved. 4. Crimping can be done anywhere, without special preparation. Terminations are replaced or modified in the field exactly the same as in the shop, using the same tools and the same techniques, and with the same ease of operation and certainty of results. 5. Total installed and maintenance costs are lower. Notice The use of dielectric grease is not recommended. 124 h el p fu l hi nt Solder should not be added to DEUTSCH terminals. Contacts Crimp Inspection Crimping tools provide lower total installation and maintenance costs. However, controls are required to help ensure that the proper crimp tools designed for the type and size contact are used, the pin or socket is properly inserted into the tool, the wire insulation is stripped properly, and the wire fully inserts into the contact. When a crimp is completed, correct termination can be visually inspected. The inspector should check for: * The removed insulation should expose a conductor length that will pass beyond the inspection hole in the contact and still reveal the appropriate length of conductor between the contact and the insulation on the wire. * Wire strands intact. * All wire strands enter the contact barrel. * Wire inserted to the proper depth in the contact. When the correct crimp tool and process are used, a good termination results. Notice For more detailed crimp dimensions please request a drawing. Solid Contact Crimp Crimp centered between the inspection hole and crimp barrel end Conductor strands are visible through inspection hole Correct insulation gap (.100" max) Acceptable Crimp Conductor strands not visible Birdcage Flayed wire Unacceptable Crimps Stamped & Formed Contact Crimp All strands captured Bare wire strands extended from conductor crimp Conductor strands not visible on both sides of conductor crimp Conductor strand not captured Conductor strands bent and not completely captured Insulation spaced from conductor crimp area Acceptable Crimp Unacceptable Crimps 125 Contacts Accessories Additional accessories are available to aid in the design flexibility and sealing requirements of applications. Accessory items such as keying pins and sealing plugs assist in maintaining an environmental seal and preventing mismating. Keying Pins Keying pins are solid plastic rods used to help prevent mis-mating of like connectors in close proximity. Applicable DEUTSCH product lines include HD10, HD30, HDP20, DT, and DTM Series. Keying pins are inserted into the retention fingers of an empty socket cavity. Once installed, the keying pin blocks a mating contact pin from being inserted. The contact pin will be blocked before the coupling device mates the connectors, preventing the mis-mating of like connectors. Proper usage requires that the corresponding mating pin be omitted and a sealing plug is inserted in the rear cavity of the mating connector. Individual applications will vary, and testing should be done to determine the best pattern arrangement to prevent improper connector mating. Part Number 0413-216-2005 0413-215-1605 0413-214-1205 Contact Size 20 16 12 Color Red White Yellow Notice Multiple keying pins may be required to prevent unintentional forced mating. Contact Crimp Sleeve Reducer A crimp sleeve reducer is available to allow DEUTSCH size 4 solid contacts to accept 8-10 AWG wire. When populating a connector using a contact with a reducer sleeve, be sure the insert seal penetrates the rear grommet. The use of the crimp sleeve reducer requires no extra crimp tools and provides an easy transition and increased flexibility. Notice TXL wire insulation with 10 AWG wire is not recommended because it may not provide an environmental seal against the insert seal. 126 Insert Seal 0410-241-0406 Crimp Sleeve 0421-203-04141 Contacts Sealing Plugs Open cavities provide pathways for contaminates to enter the connectors. To maintain seal integrity, any unused cavity must be filled with the appropriate size sealing plug. Sealing Plug Part Number Contact Size Wire Gauge Range Description 114019 Size 4 4-6 AWG silicone rubber, used with DEUTSCH contacts 114018 Size 8 8-10 AWG thermoplastic, used with DEUTSCH contacts 114017 Size 12, 16 12-20 AWG thermoplastic, used with DEUTSCH contacts 0413-217-1605 (locking sealing plug) Size 16 14-20 AWG thermoplastic, used with DEUTSCH contacts, retained by locking fingers 0413-003-1605 Size 16 14-20 AWG thermoplastic, used with STRIKE Series 770678-1 1.3 mm 16-20 AWG nylon, used with AMPSEAL 776363-1 1.58 mm 16-20 AWG PBT, used with AMPSEAL 16 (standard diameter cavities) 776364-1 Size 20 16-20 AWG PBT, used with AMPSEAL 16 (reduced diameter cavities) 0413-204-2005 Size 20 20 AWG thermoplastic, used with DEUTSCH contacts h el p fu l hi nt Sealing plugs are used to seal the connector when all the cavities are not used by wires. Plug 127 Contacts How To Instructions Sealing Plug Installation Step 1: Holding the sealing plug with large diameter end away from the connector, gently apply downward pressure to force the sealing plug into the cavity. Step 2: With perpendicular motion, apply downward pressure to the large diameter end of the sealing plug. Step 3: Apply pressure until sealing plug is forced to stop by contact with rear grommet. Visually inspect the sealing plug to confirm it is flush with cavity opening. Locking Sealing Plug Installation Step 1: Holding the sealing plug with large diameter end towards the connector, gently apply downward pressure to force the sealing plug into the cavity. Step 2: With perpendicular motion, apply downward pressure to the small diameter end of the sealing plug. Step 3: Apply pressure until sealing plug locks into place. A slight tug on the sealing plug will confirm it is locked into place. Contact Crimp Sleeve Reducer Assembly Step 1: Place crimp sleeve reducer into contact barrel. 128 Step 2: Slide insert seal onto 8-10 AWG wire stopping just at the edge of the stripped insulation. Step 3: Insert wire into barrel of contact and crimp using designated tooling. Step 4: Ensure seal is not distorted. Tooling Contents Tooling Overview 130 Benefits of Crimping 130 Crimp Inspection 130 Automated Tooling 131-133 Hand Tools 134-135 Removal Tools 135-136 How To Instructions 137--139 129 Tooling Tooling Overview There are two types of contacts manufactured, solid and stamped & formed. Both styles of contacts are designed for crimp style terminations - no solder is required or recommended. A crimp style termination displaces the wire strands creating a superior bond between the wire and the contact. Several types of tools are available to assist with hand and production wire crimping, wire insertion and removal and wedgelock/terminal position assurance removal. The tools are specific to the solid contacts or the stamped & formed contacts. To create a proper crimp and achieve the highest performance specifications, contacts must be crimped with the recommended tooling. Benefits of Crimping Mechanically crimping contacts is the dominant wire termination method, for some very good reasons: 1. Since no wet process is involved, corrosion is not a problem. No adhesive, flux, or additives are used. 2. Strength, accuracy and overall reliability of a crimped contact are controlled by the crimp tool, not the operator. The field tools (except size 4 solid style) release the contact only after the full crimping cycle is completed. 4. Crimping can be done anywhere, without special preparation. Terminations are replaced or modified in the field exactly the same as in the shop, using the same tools and the same techniques, and with the same ease of operation and certainty of results. 5. Total installed and maintenance costs are lower. 3. The crimp tool is universal, accepts both pins and sockets of many sizes. Solid Contact Crimp Inspection Crimp centered between the inspection hole and crimp barrel end Conductor strands are visible through inspection hole Correct insulation gap (.100" max) Acceptable Crimp Conductor strands not visible Birdcage Flayed wire Unacceptable Crimps Stamped & Formed Contact Crimp Inspection All strands captured Bare wire strands extended from conductor crimp Conductor strands not visible on both sides of conductor crimp Conductor strand not captured Insulation spaced from conductor crimp area 130 Acceptable Crimp Unacceptable Crimps Conductor strands bent and not completely captured Tooling Automated Tooling Overview For higher production volumes, a pneumatic power crimp tool is available for the solid contacts, and applicator dies for stamped & formed contacts. The HDP-400, the pneumatic solid crimp tool, is a fast, bench-top tool that crimps most DEUTSCH contacts. The HDP-400 has a foot control, and easy-to-change dies and locators for each contact size. TE Connectivity's stamped & formed OCEAN applicator dies are heavy duty mini-dies that work in many industry standard presses. The OCEAN applicator dies offer simple adjustments and the flexibility to accept different sized contacts and wire gauge. Automated Tooling for Solid Contacts Tool P/N Contact Size 4 8 12 HDP-400 16 20 HDP-400 Dies and Locators Crimp Tool Part Number HDP-400 Contact Part Number 0460-204-0490 0462-203-04141 0460-204-08141 0462-203-08141 0460-204-12** 0462-203-12** 0460-202-16** 0462-201-16** 0460-215-16** 0462-209-16** 0460-202-20** 0462-201-20** Drawing Number Reference 0425-205-0000 HDP-400 Tooling Accessories Go-No-Go Gauges Part Number GA20N 450GA-16N 450GA-12N GA8-SPEC 450GA-4-SPEC Go-No-Go Gauges HDP-400 Size 20 HDP-400 Size 16 HDP-400 Size 12 HDP-400 Size 8 HDP-400 Size 4 131 Tooling Automated Tooling for Stamped & Formed Contacts 1.3 mm Applicator Tooling - 1.3 mm Contacts (AMPSEAL) Insulation Range Socket P/N Applicator P/N O.D. (mm) 770520-1 770520-3 .067-.106 (1.70-2.70) 2151376-1 The -1 suffix on the applicator p/n represents a mechanical feed, for other feed options or additional information contact your representative. HDSF 1.58 mm Applicator Tooling - HDSF 1.58 mm Contacts (AMPSEAL 16) Insulation Range Pin P/N Receptacle P/N Applicator P/N O.D. (mm) 2098250-1 2098250-3 2098251-1 .065-.118 (1.65-3.0) 2151617-1 - 2098251-2 .065-.118 (1.65-3.0) 2151617-2 638112-1 638112-3 - .077-.155 (1.96-3.94) 2151239-1 - 776491-1 776491-2 .077-.155 (1.96-3.94) 2151239-2 The -1 suffix on the applicator p/n represents a mechanical feed and the -2 suffix represents a pneumatic feed, for other feed options or additional information contact your representative. Size 12 - Group 2 Size 12 - Group 1 Applicator Tooling - DEUTSCH Contacts Insulation Range Pin P/N Socket P/N O.D. (mm) 1060-12-0144 1060-12-0166 1060-12-0222 1060-12-0244 1062-12-0144 1062-12-0166 1062-12-0222 1062-12-0244 Applicator P/N Conversion Kit P/N .151-.176 (3.83-4.47) 2266124-1 7-2266124-8 .130-.154 (3.30-3.91) 2266125-1 7-2266125-8 .113-.135 (2.87-3.43) 2266126-1 7-2266126-8 .185-.204 (4.70-5.18) 2266127-1 7-2266127-8 .155-.190 (3.94-4.83) 2266128-1 7-2266128-8 .140-.160 (3.56-4.06) 2266129-1 7-226129-8 The -1 suffix on the applicator p/n represents a mechanical feed, for other feed options contact your representative. The conversion kit is to convert applicators within the same group. For more information, please reference TE catalog 1-1773730-8 or contact your representative. 132 Tooling Size 20 - Group 1 Size 16 - Group 3 Size 16 - Group 2 Size 16 - Group 1 Applicator Tooling - DEUTSCH Contacts (continued) Insulation Range Pin P/N Socket P/N O.D. (mm) Applicator P/N Conversion Kit P/N 1060-14-0122 1060-14-0144 1060-14-0177 1062-14-0122 1062-14-0144 1062-14-0177 .120-.150 (3.05-3.81) 2266100-1 7-2266100-8 1060-14-1077 1060-14-1088 1062-14-1077 1062-14-1088 .105-.125 (2.67-3.18) 2266101-1 7-2266101-8 1060-16-0122 1060-16-0144 1060-16-0177 1062-16-0122 1062-16-0144 1062-16-0177 .105-.125 (2.67-3.18) 2266101-1 7-2266101-8 1060-16-0722 1060-16-0744 1060-16-0777 1062-16-0722 1062-16-0744 1062-16-0777 .085-.111 (2.16-2.82) 2266102-1 7-2266102-8 .075-.105 (1.91-2.67) 2266103-1 7-2266103-8 1060-16-0977 1060-16-0988 1062-16-0977 1062-16-0988 .063-.094 (1.60-2.39) 2266104-1 7-2266104-8 1060-16-0622 1060-16-0644 1060-16-0677 1060-16-0688 1062-16-0622 1062-16-0644 1062-16-0677 1062-16-0688 .063-.094 (1.60-2.39) 2266110-1 7-2266110-8 .050-.075 (1.27-1.91) 2266111-1 7-2266111-8 1060-16-1222 1060-16-1244 1060-16-1277 1062-16-1222 1062-16-1244 1062-16-1277 .120-.140 (3.05-3.56) 2266112-1 7-2266112-8 .105-.125 (2.67-3.18) 2266113-1 7-2266113-8 - 1062-16-1422 1062-16-1444 1062-16-1477 .090-.110 (2.29-2.79) 2266114-1 7-2266114-8 .075-.095 (1.91-2.41) 2266115-1 7-2266115-8 1060-20-0122 1060-20-0144 1060-20-0177 1062-20-0122 1062-20-0144 1062-20-0177 .105-.125 (2.67-3.18) 2266116-1 7-2266116-8 - 1062-20-0322 1062-20-0344 1062-20-0377 .085-.111 (2.16-2.82) 2266117-1 7-2266117-8 .075-.105 (1.91-2.67) 2266118-1 7-2266118-8 1060-20-0222 1060-20-0244 1060-20-0277 1062-20-0222 1062-20-0244 1062-20-0277 .063-.085 (1.62-2.16) 2266119-1 7-2266119-8 .050-.075 (1.27-1.91) 2266120-1 7-2266120-8 The -1 suffix on the applicator p/n represents a mechanical feed, for other feed options contact your representative. The conversion kit is to convert applicators within the same group. For more information, please reference TE catalog 1-1773730-8 or contact your representative. 133 Tooling Hand Tool Overview For field service, prototype, and low-volume production, there are several easy-to-use hand crimp tools for both solid barrel and stamped & formed contacts. All hand crimp tools provide a tight, complete crimp with minimal effort. The HDT-48-00, the most commonly used tool for solid contacts, crimps a wide range of contact sizes. It provides a symmetrical four indent crimp, is compact and easy-to-use for field service, yet sturdy and reliable enough for low volume production. Hand crimp tools for DEUTSCH stamped & formed contacts are wire gauge specific and simultaneously crimp the insulation and conductor, saving time and effort during field service. The PRO-CRIMPER III hand tool features interchangeable dies and locators for different AMPSEAL and AMPSEAL 16 stamped & formed contacts. HDT-04-08 HDT-48-00 Contact Size Contact Part Number 0460-204-0490 4 0462-203-04141 0460-204-08141 8 0462-203-08141 12 0460-204-12** 0462-203-12** 16 0460-202-16** 0462-201-16** 0460-215-16** 0462-209-16** 20 HDT-50-00 Crimp Type HDT-04-08 Two Indent Crimp HDT-04-08 Two Indent Crimp HDT-48-00 HDT-1561 HDT-50-00 Four Indent Crimp Two Indent Crimp One Indent Crimp HDT-48-00 Four Indent Crimp HDT-1561 Two Indent Crimp HDT-50-00 One Indent Crimp HDT-48-00 HDT-1561 HDT-50-00 Four Indent Crimp Two Indent Crimp One Indent Crimp HDT-48-00 Hand Tool Accessories h el p fu l hi nt HDT-48-00 Adjustment Screw and Locking Nut Part Number Crimp Tool Replacement Part 0426-209-0000 Adjustment Screw and Locking Nut M2700-395-10 Locking Nut Go-No-Go Gauge Part Number G454 134 Description HDT-48-00 Go-No-Go Gauge D i s tr i b u HDT-1561 Tool Part Number 0460-202-20** 0462-201-20** tio LAD D l u si v e t n xc o E Hand Tools for Solid Contacts Go-no-go gauges are used to inspect crimp tooling. The G454 gauge is used with the HDT-48-00 hand tool. Tooling Hand Tools for DEUTSCH Stamped & Formed Contacts DTT-12-00 DTT-12-01 Contact Size Contact Part Number 1060-12-01** 1062-12-01** 12 1060-12-02** 1062-12-02** DTT-16-00 DTT-16-01 DTT-20-00 DTT-20-02 16 1060-16-01** 1062-16-01** 1060-16-06** 1062-16-06** 20 1060-20-01** 1062-20-01** 1060-20-02** 1062-20-02** Tool Part Number DTT-12-00 DTT-12-01 DTT-16-00 (14-16 AWG) DTT-16-01 (18 AWG) DTT-20-00 DTT-20-02 Hand Tools for AMPSEAL and AMPSEAL 16 Stamped & Formed Contacts Part Number Wire Size AWG Description 58529-1 16-20 PRO-CRIMPER III hand tool for AMPSEAL contacts 91337-1 14-18 PRO-CRIMPER III hand tool for AMPSEAL 16 contacts 2119118-1 18-20 PRO-CRIMPER III hand tool for AMPSEAL 16 contacts Removal Tools Tool Part Number Description 776441-1 Tool for PLR (Primary Latch Reinforcement) and contact removal for use with AMPSEAL 16 connectors DT-RT1 Multi-use tool with a small hook on one end for wedgelock removal, and a small screwdriver on the other end to push back the locking fingers and release the contact. For use with the DT, DTM, DTP, DTV, DRB, and STRIKE Series. 135 Tooling Removal Tools DEUTSCH removal tools are designed to simplify contact removal and field service repair in connectors that utilize a round shoulder contact retention system. Removal tools are compact, easy-to-use, and manufactured of heavy duty plastic to remove contacts without damage to the wire, insulation, connector seals, or connector body. The removal tools are required for wire removal in the DTHD, Jiffy Splices, HD10, HDP20, HD30, DRC, AEC, and WT Series. Removal Tool h el p fu l hi nt 136 Part Number Contact Size Wire Gauge Range Color 0411-027-0405 Size 4 4 AWG Black 114009 Size 4 6 AWG White 114008 Size 8 8-10 AWG Green 0411-353-0805 Size 8 for HD Box 8-10 AWG Green Extended 114010 Size 12 12 AWG Yellow 0411-337-1205 Size 12 12-14 AWG Extra Thin Wall (E-Seal) Orange 0411-291-1405 Size 16 14-16 AWG Green 0411-310-1605 Size 16 16-20 AWG Light Blue 0411-336-1605 Size 16 16-18 AWG Extra Thin Wall (E-Seal) Dark Blue 0411-240-2005 Size 20 20-22 AWG Red A contact removal tool taped or tie wrapped to the harness will make it easily available, should repairs be needed. Tooling How To Instructions Wire Stripping Step 1: 1. Choose the correct AWG for the contact being used. Step 2: 1. After stripping, a small piece of the insulation should come off. 2. Measure from the end of the wire the recommended strip length according to the contact size. 2. Check for any broken strands or for a dent in the wire. If either exist, the wire is damaged and should be cut and stripped again. 3. Place the wire into a stripping tool at the recommended strip length. Strip the wire according to stripping tool instructions. Step 3: Measure the exposed strands to be sure the crimp length is correct. h el p fu l hi nt Leaving the stripped portion of the insulation on the wire until prior to crimping will avoid flayed wire strands. Incorrect Correct Crimping with the HDT-48-00 Hand Tool Step 1: 1. Strip insulation from wire. 2. Raise selector knob and rotate until arrow is aligned with wire size to be crimped. 3. Loosen locknut, turn adjusting screw in until it stops. Step 2: Insert contact with barrel up. Turn adjusting screw counterclockwise until contact is flush with indentor cover. Tighten locknut. Step 3: 1. Insert wire into contact. Contact must be centered between indentors. Close handles until crimp cycle is completed. 2. Release handles and remove crimped contact. Notice Tool must be adjusted for each type/ size of contact. 137 Tooling Crimping with DTT Style Hand Tools (size 16 & 20) Step 1: Cycle the hand tool to the open position. Place the contact into the correct die nest. Step 2: Partially close the tool until the contact is held in place. Step 3: Insert the prestripped wire into the crimp area of the contact. Step 4: Close the tool until the ratchet releases. The ratchet is released when a loud click is heard and crimp is complete. Crimping with DTT-12-01 Hand Tool Proper contact position, front view Insulation diameters Proper contact position, side view Insulation selector Step 1: Cycle handles to release ratchet and fully open crimp jaws. Pull out insulation selector and push into proper diameter using the chart below. 138 Step 2: 1. Insert contact into locator. Adjust alignment and width of crimp wings if necessary to help ensure capture by crimp jaws. 2. Insert stripped wire into the contact. Close crimp tool until full-cycle ratchet control releases. Wire Type Insulation Selector 10 TXL .150-.170 10 GXL .160-.180 10 SXL .170-.205 2 .160-.180 5.0 mm 2 .170-.205 6.0 mm Tooling Crimping with DTT-12-00 Hand Tool Step 1: Cycle the tool to release ratchet and open tool. Lift the locator gate, and place the contact into the correct die nest. Adjust alignment of crimp wings to help ensure capture by crimp jaws. Step 3: Insert the prestripped wire into the crimp area of the contact. Step 2: Partially close the tool until the contact is held in place. Step 4: Close the tool until the ratchet releases. The ratchet is released when a loud click is heard and crimp is complete. 139 Additional Resources Contents Modification List Requirements & Standards 142-148 149 Glossary 150-156 Index 157-159 141 Additional Resources Modification List Mod # A Series Description A004 DRC Receptacle with molded-in PCB pins, 24 and 40 way A006 DRC Receptacle with molded-in PCB pins, 40 way, #40 pin removed B009 HD10 Receptacle with raised key removed from front of flange, no rear threads B010 HD10 Plug with coupling ring added B016 DT, DT13/15 B019 HD30 Custom snap ring mount B022 HD10 Receptacle with D-hole panel mount, rear threads, J1939, black B025 HD10 Receptacle with D-hole panel mount, no rear threads, black B026 DTMF PCB receptacle with alternate keying, requires plugs with WM-12S-B026 wedgelocks B028 DT15 5 P.S.I rating B Receptacle has extended shell and enhanced keys, plug has enhanced seal retention (P012), 12 way BE BE02 DT Receptacle with extended shell and enhanced keys (B016), end cap BE03 DT Receptacle with extended shell and enhanced keys (B016), end cap, black BE04 DT Receptacle with extended shell and enhanced keys (B016), end cap, reduced diameter seals (E seal), black BE05 DT Receptacle with extended shell and enhanced keys (B016), end cap, sealed flange, reduced diameter seals (E seal), threaded stainless steel flange inserts BL04 DT Receptacle with extended shell and enhanced keys (B016), welded flange BL08 DT Receptacle with extended shell and enhanced keys (B016), welded flange, black BL10 DT Receptacle with extended shell and enhanced keys (B016), sealed flange, reduced diameter seals (E seal), shrink boot adapter, threaded stainless steel flange inserts BL11 DT Receptacle with extended shell and enhanced keys (B016), sealed flange, reduced diameter seals (E seal), end cap, threaded stainless steel flange inserts BL 142 Additional Resources Mod # BP Series Description BP03 HD10 Receptacle with D-hole panel mount, J1939 Type II, green C003 HDN Standard cavity marking identification C008 DT C012 HD30 C015 DT, DTP C016 HD10 C C017 Cavity blocked (C) Cavities blocked (J, P) Reduced diameter seals (E seal) Cavities blocked (H, J) - HD10 Series 9 way DT, DTM, DTP Solid rear grommet C018 HD30 Cavities blocked (11, 18, 19), N/E seal options C019 HD30 Cavities blocked (1, 2, 8, 9), N/E seal options C020 HD30 Cavities blocked (A, D), N/E seal options C021 HD30 Cavities blocked (A, B, C, D) C022 HD30 Cavities blocked (A, D, J, M), with reduced diameter seals (E seal) C024 HD10 Cavities blocked (B, C, D) C026 DRC Cavities blocked, 50 way C030 HD30, HDP20 Four size 16 cavities blocked (1, 2, 5, 6) C038 HD30, HDP20 Three size 4, four size 16, requires special size 4 AWG contacts C041 HDP20 Receptacle with diagnostic keying CE CE01 DT CE02 DT, DTP CE03 DT Reduced diameter seals (E seal), end cap, black CE04 DT Reduced diameter seals (E seal), shrink boot adapter CE05 DT Plug with reduced diameter seals (E seal), enhanced seal retention (P012), end cap CE06 DT Plug with reduced diameter seals (E seal), enhanced seal retention (P012) CE07 DT Receptacle with extended shell and enhanced keys (B016), reduced diameter seals (E seal), end cap CE08 DT Receptacle with extended shell and enhanced keys (B016), reduced diameter seals (E seal) CE09 DT Reduced diameter seals (E seal), shrink boot adapter, black CE10 DT Plug with reduced diameter seals (E seal), enhanced seal retention (P012), black CE11 DT Plug with reduced diameter seals (E seal), enhanced seal retention (P012), end cap, black CE12 DT Plug with reduced diameter seals (E seal), enhanced seal retention (P012), shrink boot adapter, black CE13 DT Plug with reduced diameter seals (E seal), enhanced seal retention (P012), shrink boot adapter CE14 DT Plug with reduced diameter seals (E seal), enhanced seal retention (P012), latch guard end cap, black Reduced diameter seals (E seal), end cap Reduced diameter seals (E seal), black 143 Additional Resources Mod # CL Series Description CL01 HD30 CL03 DT Reduced diameter seals (E seal), welded flange CL07 DT Reduced diameter seals (E seal), sealed flange, shrink boot adapter CL08 DT Reduced diameter seals (E seal), welded flange, end cap, disabled latch CL09 DT Reduced diameter seals (E seal), sealed flange, end cap, black CL15 DT Reduced diameter seals (E seal), welded flange, black CL20 HDP20 Cavities blocked (J, Q, R, S, X), adapter for cable clamp (072) Plug with diagnostic keying CG CG01 DRC 5mm threaded insert with silver plating, molded-in contacts, outside rows gold CP CP01 DT All cavities plugged, enhanced seal retention (P012), end cap E E003 DT, DTHD, DTM, DTP End cap E004 DT, DTM, DTP, Black HD10 E005 DT, DTM, DTP Black, end cap E007 DTM Shrink boot adapter E008 DT Shrink boot adapter E009 DRC 24 way and 40 way receptacle, B keys, housing is gray, flange is black E016 EEC Standard EEC box, molded-in transparent Ultem material E019 AEC Backshell adapter EE EE01 DT Shrink boot adapter, black EE03 DTM Shrink boot adapter, black EE04 DTM High temp, black EE05 DT High temp, enhanced seal retention (P012) on plug, end cap, black EF01 DT Fluorosilicone front seals, end cap EF02 DT Fluorosilicone front seals, latch guard end cap DT Plug, 18 cavity DT with 18 size 16 contacts, enhanced seal retention (P012), end cap, "A" key is gray, "B" key is black, "C" key is green, "D" key is brown EF EK EK02 144 Additional Resources Mod # EP Series Description EP04 DT End cap (same as E003 mod) EP05 DT Latch guard end cap EP06 DT Plug with enhanced seal retention (P012), end cap EP07 DT Plug with enhanced seal retention (P012), black EP08 DT Plug with enhanced seal retention (P012), end cap, black EP09 DT Plug with enhanced seal retention (P012), latch guard end cap, black EP10 DT, DTM EP11 DT Plug with enhanced seal retention (P012), shrink boot adapter, black EP12 DT Bussed receptacle, 4 and 6 way only, 1 buss, black, gold plated pins EP13 DT Bussed receptacle, 4 and 6 way only, 1 buss, black, nickel plated pins EP14 DT Bussed receptacle, 6 way, 2 busses, black, nickel plated pins EP20 DT Plug with enhanced seal retention (P012), shrink boot adapter 120 ohm terminating resistor (J1939), black F F001 HDN Inserts within connector made of Ultem G001 DRC Gold plated pins G002 DRC Outside rows of pins are gold plated and rest are tin plated G003 DT13/15 G004 DRC Interface side pins are nickel plated, PCB side pins are tin plated G005 DRCP Tin plated signal pins, tin plated power pins GC03 DRCP Gold plated signal pins, depopulated power pins GC05 DRCP Tin plated signal pins, depopulated power pins G Gold plated pins GC GR GR01 DTM13 (EEC Snap-in DTM PCB mounted header for DTM EEC enclosure, 12 and 24 pins, gold plated headers) pins H H001 HD30 Plated with yellow chromate conversion HL01 HD30 Dust cap plated with yellow chromate conversion, sash chain with eyelet for #10 screw HL02 HD30 Adapter for cable clamp (-072) plated with yellow chromate conversion HD30 Reverse cavity marking identification on grommet HL J J001 145 Additional Resources Mod # J059 Series HD30 Description Reverse cavity marking identification on grommet, cable clamp (-059) K K001 AEC Molded-in shell marking, remove blue stripe, end cap K003 DT16 Plug, 15 cavity DT with two size 12 contacts and 13 size 16 contacts, enhanced seal retention (P012), end cap, black K004 DT16 Plug, 18 cavity DT with 18 size 16 contacts, enhanced seal retention (P012), end cap, black DT16 Plug, six cavity DT with six size 16 contacts, enhanced seal retention (P012), end cap, green L001 HD30 Same as -059 (cable clamp) L003 HD30 Cable clamp adapter (-072) L005 HD30 Cable clamp adapter (-072) without drain holes L006 HD30 -059 modification using adapter without drain holes L009 DTHD Sealed flange, inside mount L011 DRC KP KP01 L L012 Wire router DT, DTP, DTM Welded flange L013 DTHD Sealed flange, outside mount L015 HDP20 Threaded adapter for backshell strain relief L017 HDP20 Ring adapter for backshell strain relief L018 DRB L020 Wire router HD30, HD50 Removes #10 eyelet from the dust cap chain L024 HDP20 Wide threaded adapter for backshell strain relief L072 HD30 Adapter ring LE 146 LE01 DT Sealed flange, inside mount, gasket, end cap LE03 DT Sealed flange, outside mount, o-ring sold separately, end cap, NOTE: DT04-08PA-LE03 comes with shrink boot adapter and o-ring on flange LE05 DT Sealed flange, inside mount, gasket, end cap LE06 DT Sealed flange, inside mount, reduced diameter seals (E seal), end cap LE07 DT, DTP LE08 DT Welded flange, shrink boot adapter, gray LE09 DT Sealed flange, o-ring, end cap, black LE10 DT Sealed flange, inside mount, gasket, end cap, black LE11 DT Welded flange, end cap, black LE12 DT Welded flange, shrink boot adapter, black Welded flange, end cap Additional Resources Mod # LE13 Series DT Description Special adapter, round housing, end cap LE14 DT Welded flange, black LE17 DT Receptacle with extended shell and enhanced keys (B016), sealed flange, gasket sold separately, end cap, black LE21 DT Receptacle with extended shell and enhanced keys (B016), sealed flange, reduced diameter seals (E seal), end cap, one piece connector design, threaded stainless steel flange inserts N N005 HD10 N006 DT Receptacle with 90 molded-in contacts N012 DRC Receptacle, one piece connector design P005 AEC Special oversized seal on AEC Series plugs and dust caps P006 DT, DTM 120 ohm terminating resistor (J1939) P007 DT, DTM Receptacle "Y" connector (J1939) P012 DT P013 DRC P016 DT P017 DRC Stainless steel retention clip for jackscrew P018 DTP Receptacle with 12 AWG wires attached P019 DRC Zinc chromate retention clip for jackscrew P021 DT Bussed receptacle, 6, 8, and 12 way, one buss, nickel plated pins P026 DT Bussed receptacle, 8 and 12 way, two busses, nickel plated pins P027 DT Bussed receptacle, 12 way, two busses, gold plated pins P028 DT Bussed receptacle, 8 way, two busses, nickel plated pins P030 DT Bussed receptacle, 12 way, four busses, nickel plated pins P031 DT Bussed receptacle, 12 way, four busses, gold plated pins P032 DT Integrated shrink boot adapter (J1939), black P060 DT Bussed receptacle, 2 way, one buss, nickel plated pins Receptacle with molded-in PCB pins, modified shell P P064 Plug with enhanced seal retention, 2-6 way are black, 8 and 12 way "A" key is gray, "B" key is black, "C" key is green, "D" key is brown Plug with bonded front seal, silicone adhesive Bussed receptacle, 12 way, gold plated contacts HD30, HDP20 24-91 arrangement without internal jumper P075 DT P080 HD10 Bussed receptacle, 12 way, three busses, nickel plated pins J1939 Type II, green PE PE01 DT Latch guard, 120 ohm terminating resistor (J1939) DT Plug with enhanced seal retention (P012), 120 ohm terminating resistor (J1939), end cap, black PP PP01 147 Additional Resources Mod # R Series R004 DTM13 Custom enclosure header, 90 pins R005 DTM13 Custom flange, 90 pins R008 R015 Description DTM13 (EEC Snap-in DTM PCB mounted header for DTM EEC enclosure, 12 and 24 pins headers) DT13 (EEC headers) Snap-in DT PCB mounted header for DT EEC enclosure, 12, 24, 36, and 48 pins RT RT01 DT Receptacle with MUR 460 diode RT02 DT Receptacle with Toshiba diode 3GZ41 RT03 DT Receptacle with MUR 460 diode, 4 way available RT06 DT Receptacle with Phillips T.V.S diode 1.5KE130CA, green RT25 DT Receptacle with 27k ohm resistor, black #'s 148 059 HD30 Addition of threaded adapter and cable clamp assembly 072 HD30 Addition of threaded adapter 1E HD30 Removes rivet and chain from protective dust cap Additional Resources Requirements & Standards IMDS The International Material Data System (IMDS) is a collective, computer-based material data system developed as a collaborative effort by large automotive OEMs to manage environmentally relevant aspects of parts used in vehicles. It has been adopted as the global standard for reporting material content in the automotive industry. TE Connectivity recognizes IMDS and will work with customers that use the system. IP Rating The IP Rating system is a way of classifying the degree of protection provided against the intrusion of solid objects, dust, and water in electrical enclosures. The 6 in IP 67 means that the connectors have to be completely sealed from fine dust. The 7 in IP 67 means that the connector needs to be protected from the effects of a one meter submersion. AMPSEAL and AMPSEAL 16 connectors are IP 67 rated. DEUTSCH connectors are rated for three feet submersion, which is just short of the IP Rating system's one meter requirement. IP 6K9K IP 6K9K is similar to the standard IP Ratings, but is commonly referred to as a pressure washing specification. The letter K is used after the numbers to denote special testing. The 6K means the connectors need to be completely sealed from fine dust. The 9K means the connector needs to be protected from the penetrating effects of water used for high pressure/ steam jet cleaning purposes. Several DEUTSCH connectors in the DT, DTM, DRC, and DRB Series have been through independent lab testing and pass IP 6K9K, as well as AMPSEAL connectors. J2030 J2030 is an SAE standard for connectors between two cables or between a cable and an electrical component. The standard primarily focuses on the connectors used to mate to the electrical component. J2030 also provides environmental test and acceptance criteria for connectors used in DC electrical systems of 50 V or less in heavy duty applications typically used in off-highway equipment. Severe applications may require more rigid test levels, or field-testing on the intended application. AMPSEAL 16 connectors meet the SAE J2030 standard. RoHS RoHS is a European directive on the Restriction of Hazardous Substances in electrical and electronic equipment. The directive restricts the use of lead, mercury, cadmium, hexavalent chromium, polybrominated biphenyls, and polybrominated diphenyl ether in new electrical and electronic components. All AMPSEAL, AMPSEAL 16, and DEUTSCH products are RoHS compliant, as well as LADD Distribution's boots, backshells, and gaskets. UL Recognized A UL Recognized component is one that is expected to be installed within a larger assembly by a manufacturer, and this larger assembly is then expected to be tested by UL to become UL Listed. AMPSEAL, AMPSEAL 16, and many DEUTSCH connectors are UL Recognized. DEUTSCH connectors that are UL Recognized include the AEC, DRC, DT, DTM, DTP, HD10, and HDP20 Series. Not every variation and/or modification within a DEUTSCH series may be UL Recognized. AMPSEAL connectors are UL 94 V-0 rated and AMPSEAL 16 connectors are UL 94 HB rated. For additional information, visit www.ul.com. J1939/11, J1939/13, and J1939/15 See CAN section. 149 Glossary Glossary AWG (American Wire Gauge): Standardized system of wire diameter measurement. Commonly referred to as wire gauge. (Reference: National Bureau of Standards, Copper Wire Table [Handbook 100] AVS.) Adapter: Device attached to a connector to allow connection to a second device that it would not otherwise be able to attach. Ambient Temperature: The temperature of a medium (gas or liquid) surrounding an object. Ampere (amp): The unit of current. One ampere is the current flowing through one ohm of resistance at one volt potential. ARC Resistance: Time required for an electrical current to render the surface of a material conductive due to carbonization by the arc flame. Or, the time required for an arc to establish a conductive path in a material. Applicator: Tooling used in automatic machines to crimp stamped & formed contacts. Backshell: A secondary attachment for the rear of a connector to provide strain relief, environmental protection, and/or improved aesthetics. Barrel: (1) Conductor Barrel: the section of the terminal, splice, or contact that accommodates the stripped wire. (2) Insulation Barrel: the section of the terminal, splice, or contact that accommodates the unstripped wire. Barrel Chamfer: Beveled entry at mating end of the 150 socket contact. Reduces contact mating force for easier connector mating. Blocked Cavities: Unused holes or contact positions in a connector which have been filled with sealing plugs or made inaccessible by modification to the rear grommet. Breakaway: Connector with a slotted coupling ring. Coupling ring is intended to fragment and allow connectors to separate without damage to the implement in the event of an unintended pull-away. Boot: Attachment for the back of a connector. Boots are typically flexible, made from plastic or plastisol, and may provide wire strain relief, environmental protection, and/or improved aesthetics. Bulkhead: Dividing wall or partition. Bulkhead connectors are designed to be mounted to a dividing wall through a cutout. Buss (also bussbar, bus or busbar): A thin conductive strip connecting multiple contacts within the body of a connector. Used to distribute electrical current to the branches of a circuit. Cable Clamp: An attachment to provide support and strain relief to the wire bundle where it exits the connector. Cavity: Hole in the connector grommet and housing, into which the contact must fit. Cold Heading: Process by which contacts are formed from individual pieces of metal using dies and punches. Glossary Compression Nut: Secondary backshell assembly. Threads onto rear of backshell to compact the wire bundle and provide additional support. Conductivity: The capability of a material to carry an electrical current. Conductor: Any material capable of carrying an electrical charge easily. The most common materials for wire and cable applications are aluminum and copper (bare or coated). Connector Position Assurance (CPA): A locking mechanism on the connector that prevents the mated connectors from accidental unmating. Contact: Conductive device crimped or soldered onto the end of conductor wire to allow the transfer of electricity or data to a second conductor. Contacts are most frequently used in multiples in connectors. Also commonly referred to as terminals, pins and/or sockets. cylinder eyelet or hook to accept a conductor and retain the applied solder. Contact Area: The area where two conductors, a wire termination and a conductor, or two wire terminations touch, permitting the flow of electricity. Contact Arrangement: The number, spacing, and organization of cavities in a connector. Contact Rating: The maximum recommended amperage to be passed through a wire terminal. Contact Resistance: The measurement of opposition to electrical flow through a pair of mated wire terminations. Resistance may be measured in ohms or in millivolt drop at a specified current over the mated terminals. Contact Retention: The axial load in either direction that a terminal can withstand without being dislodged from its correct position in the connector. Contact, Crimp: Wire termination engineered to be permanently applied to conductor wire end with pressure. Does not use solder or heat. Contact Shoulder: A small flange or collar on a terminal that limits the contact's travel into or removal from the connector. Contact, Insertable/Removable: Wire termination that can be mechanically joined to or removed from the connector body. Contact Size: Overall size of barrel determined by size of wire it will accept. Contact, Pin: Wire termination with solid mating end. Provides connection by insertion into a female or socket contact. Also referred to as male contact. Contact, Receptacle: Wire termination with hollow mating end into which the pin or male terminal is inserted. Also referred to as a female contact. Contact, Socket: Wire termination with hollow mating end into which the pin or male terminal is inserted. Also referred to as a female contact. Contact, Solder: Wire termination joined to the wire conductor with a metal joining compound. Contacts intended for solder will typically have a cup, hollow- Corrosion Resistance: The ability of a substance to withstand corrosion. Coupling Ring: Attached cylindrical ring used to lock mated connectors together. Crimping: To mechanically secure a terminal or splice to a conductor by use of pressure. Crimping Die: The part of a crimping tool that physically compresses the contact barrel and shapes the crimp. Crimp Tool: Implement that permanently attaches a contact to a wire using pressure. 151 Glossary Current (I): The rate of transfer of electricity usually expressed in amperes. Current Rating: The maximum continuous electrical flow of a current recommended for a given wire situation. Expressed in amperes. Dielectric Strength: The voltage which an insulating material can withstand before breakdown occurs, usually expressed as a voltage gradient (such as volts/ mil). Dielectric Test: A test in which a voltage higher than the rated voltage is applied for a specific time to determine the adequacy of the insulation under normal conditions. Dielectric Withstanding Voltage: The amount of leakage current that flows through the insulation. Diode: Electronic component that allows electrical flow in one direction only. Direct Current: An electrical current that flows in one direction only. Dust Cover: Cap used to protect and conceal the interface of an unmated connector. "E" Seal: Reduced diameter insert cavity in the rear grommet. Creates a proper seal with smaller than standard wire or insulation. Also referred to as extra thin or European seal. "E" seals are smaller than "N" and "T" seals. End Cap: A protective cover integral to, or sonically welded onto the rear of a connector. Engaging and Separating Force: Measured pull required to mate or unmate contacts or connectors. Enhanced Key: Additional indexing or polarization to help prevent mis-mating. Enhanced Seal Retention: Modification to the plug, front seal, and wedgelock to help prevent the seal from separating from the connector during unmating. Environmentally Sealed: Maintains functionality when exposed to environmental elements. Extraction Tool: An implement for removing contacts from a connector. Flange: A flat, perpendicular extension of the connector body. Flanges are used for mounting and are typically found on receptacles. Flange Seal: Elastomeric silicone seal used between flange and mounting surface to prevent leakage around the mounting cutout. Front Seal: Elastomeric silicone seal or o-ring on the mating face of a connector. The front seal is also referred to as an interfacial seal and is usually found on the plug. Grommet: Rubber or elastomeric seal. On connectors the grommet is on the rear or cable end of the connector and has the cavities through which the contact is inserted into the connector body. Ground: A conducting connection between an electrical circuit and the earth or other large conducting body to serve as an earth thus making a complete electrical circuit. Header: Flanged connector designed for wire to printed circuit board applications. Heat Seal: In cabling, a method of sealing a tape wrap jacket by means of thermal fusion. Heat Shrink: Type of tubing that shrinks to form a tight bond when heated. Indenter: The part of a crimp tool or die that compresses the contact barrel onto the conductor. 152 Glossary In-line: Connectors that are not intended for use in mounted or PCB applications. Jacket: An outer nonmetallic protective covering applied over an insulated wire or cable. Insertion Tool: A device used to guide contacts into proper position within a connector. Key: Unique pattern of corresponding notches and projections on a set of mating connectors. The projections are intended to match the notches and prevent mis-mating. Inspection Hole: An opening in a barrel contact to allow visual inspection of the conductor to verify that it has been inserted to the right depth. Insulation Resistance: The measure of resistance offered by insulation material to the flow of current. Insulation: A material having high resistance to the flow of electric current. Keying Pin: Solid plastic rod designed to be inserted into an empty socket cavity to help prevent mismating. Locator: A device in a crimp tool to help provide proper contact position during crimping. Lockwasher: Thin metal ring used between the panel nut and mounting surface to create spring force to ensure a tight fitting mount. Insulation Crimp: (1) The physical deformation of the insulation sleeve covering a terminal or splice and the adjacent conductor insulation to hold the sleeve in place; (2) Shape combination of insulation sleeve to terminal or splice and conductor insulation after crimping. Millimeters Squared or mm2: Unit of measure for European Wire Size Standards (ref. DIN 72551-6 and ISO 6722-3). Insulation Resistance: That property of an insulating material which resists electrical current flow through the insulating material when a potential difference is applied. Moisture Resistance: Amount of water (in any form) that a properly wired and mated connection will withstand without loss of electronic qualities or leakage. Insulation Support: The portion of the contact barrel enclosing but not crimped to the conductor insulation. Mounting Bracket: A rectangular metal device used to attach or mount connectors in an application. Interface: The surfaces of a mating pair of connectors that face each other when connected. Interfacial Seal: A seal at the mating edge of the connector to prevent ingress of moisture or contaminants when a connector is properly mated. Internal Seal: Waterproof form, typically made of silicone elastomer, that is inside the body of the connector. Provides moisture and fluid resistance when connectors are properly mated. Mounting Clip: A plastic or metal piece that attaches to a non-flanged connector to allow surface mounting. "N" Seal: Normal wire seal diameter. Neoprene: Thermosetting material, chemically known as polychloroprene, with excellent flame retarding and abrasion resisting qualities. Nest: The part of a crimping die that supports the barrel during crimping. 153 Glossary Newton (N): A unit of force which is based on the metric system. It is the force that produces an acceleration of 1 meter per second per second when exerted on a mass of 1 kilogram. O-ring: Circular seal found around the inside diameter of a receptacle: typically made from elastomeric or silicone material. Provides an environmental seal. Oxidation: The process of uniting a compound with oxygen, usually resulting in an unwanted surface degradation of the material or compound. Ratchet Control: A crimping device that helps provide a full crimping cycle by allowing motion in only one direction until contact is fully crimped. Receptacle: One half of a mated pair of connectors. Receptacles mate with a plug and usually house pins. Panel Nut: A hexagonal threaded plastic or metal ring. Along with a lockwasher, a panel nut is used for mounting. Receptacle Housing (Plug): One half of a mated pair of connectors. AMPSEAL and AMPSEAL 16 plugs typically have the locking mechanism for the mated pair, house the receptacle contacts, and mate with a pin housing (cap) or header. Partial Strip: A quantity less than a standard full reel of stamped & formed contacts. Reduced Diameter Seal: Smaller than standard holes in the connector grommet. PCB (Printed Circuit Board) Mount: Connectors designed for wire to printed circuit board applications. Removal Tool: Device to disengage contacts from connector body. Peak Voltage: The maximum instantaneous voltage. Retaining Bolt: Screw used to draw and hold mating connectors together. Pin Housing (Cap): One half of a mated pair of connectors. AMPSEAL 16 pin housings mate with a receptacle contact housing (plug) and house pin contacts. Retaining Sleeve: Lining sheath that fits into receptacle body to maintain internal seal and provide keying. Plating: Thin overlay coating of metal on contacts or components. Can be used to improve conductivity, provide for easy soldering, and prevent corrosion. Reverse Arrangement: Non-standard cavity/contact assignment (eg. Plug connectors that require pin contacts, and receptacles that require socket contacts). Plug: One half of a mated pair of connectors. Plugs typically have the locking mechanism for the mated pair, usually house the sockets, and mate with a receptacle. Ring Adapter (HDP20): Cylindrical rim or collar attached to the rear of a connector to allow the attachment of backshells or strain relief. Pre-Tinned: Solder applied to the contact and/or conductor prior to soldering. Sealed Flange: A flange that is molded or tooled as an integral part of the connector body to help prevent leakage at the mounting site. Primary Latch Reinforcement (PLR): Locking mechanism that snaps into place on the mating face of a connector after the connector is populated. A PLR holds contacts in correct alignment for mating and prevents them from being removed. 154 Pull-Out Force: Measured energy required to separate a conductor from a contact, or a contact from a termination assembly. Sealing Plug: A non-conductive dummy pin inserted to fill an open cavity in a connector. Sealing plugs are required to maintain the integrity of the environmental seal. Glossary Seamless Terminal or Splice: Terminal or splice conductor barrel made from a single piece of metal, finished without lines or grooves that would typically appear where metal is joined to metal. Splice: A connection of two or more conductors or cables to provide good mechanical strength as well as good conductivity. Secondary Lock: Device inserted into or onto the connector interface to position and hold contacts in correct alignment. Secondary locks are called wedgelocks or terminal position assurance. Socket Contact Sleeve: A cylindrical, protective encasement for the contact fingers or a contact spring. The socket contact sleeve holds the inner mechanism of the contact in place and provides a smooth exterior surface. Self-Extinguishing: The characteristic of a material whose flame is extinguished after the igniting flame is removed. Solderless Connection: Joint between two metals created by pressure without the use of metallic alloy compounds or heat. Selective Plating: Application of a thin coating of a finish metal to specific parts of a contact, but not to others. If selective plating is used, plating is typically applied to the mating surface to provide better conductivity and reduce wear and corrosion. Solid Contact: Closed barrel terminal manufactured using a cold heading process. Shells: Outside case into which the insert and contacts are assembled. Shells of mating connectors usually also provide proper alignment and protection of projecting contacts. Also known as housing or body. Strain Relief: Hard plastic or metal device that attaches to the rear of a connector to provide wire support. Shield: A metallic layer, commonly aluminum or copper, of tape, braid or spiral wrapped wire construction. Its primary purpose is to prevent electrostatic or electromagnetic interference between adjacent wires and external sources. Shielded Cable: A cable in which the insulated conductor or conductors is/are enclosed in a conducting envelope or envelopes. Constructed so that essentially every point on the surface of the insulation is at ground potential or at some predetermined potential with respect to ground. Shrink Boot Adapter: Thermoplastic rear adapter designed to provide a lip for heat shrink to form around to attach it securely to a connector. Signal: An electric current used to convey information either digital, analog, audio or video. Sleeving: A braided, knitted or woven tube. Stamped & Formed Contact: Open barrel terminal manufactured using a precision stamping process. Strand: A single filament of uninsulated wire. Strip: To remove insulation from a conductor. Swedge: A cold-forging process to press-fit or force two metal forms into one. "T" Seal: Reduced diameter insert cavity in the rear grommet. Also referred to as thin seal, a "T" seal allows for the use of smaller wire or thinner insulation diameter. A "T" seal is larger than an "E" seal and smaller than an "N" seal. Temperature Coefficient of Resistivity: The change in resistance per degree of change in temperature. Terminal: A device designed to attach to the end of a conductor wire to allow it to connect to another conductor wire and allow electrical current to pass between them. Also commonly referred to as a contact. 155 Glossary Terminating Resistor: A connector that includes a device to create electrical resistance. Commonly used on J1939 applications to end the main trunk line or bus network. Wire Range: The limits of conductor size accommodated by a contact barrel. Also applies to the insulated conductor diameter accommodated by a sealing grommet. Thermal Cycling: Temperature modulation process developed to improve the performance, strength, and longevity of a variety of materials. Wire Router: Protective device attached to the rear of connector to provide wire bundle strain relief. Threaded Adapter: A cylindrical device with screw threads attached to rear of connector to allow the attachment of a threaded backshell or strain relief. Threaded Rear: Screw threads at the non-mating end of a connector to allow the attachment of a threaded backshell or strain relief. Terminal Position Assurance (TPA): A secondary locking mechanism. Snapped into place on the mating face of a connector after the connector is populated, a TPA holds contacts in correct alignment for mating and prevents them from being removed. Vibration: A periodic motion of the particles of sound or other waves. Volt: A volt is the unit of electromotive force or electric pressure, a kin to water pressure in pounds per square inch. Voltage: The term most often used to designate electric pressure that exists between two points and is capable of producing a flow of current when a closed circuit is connected between the two points. Wedgelock: A device inserted into or onto the mating face of a connector to position and hold contacts in correct alignment. Wicking: The longitudinal flow of a liquid in a wire or cable construction. Wiping Action: Movement of two electrical contacts sliding against each other. 156 Index Index A Adapters 072 adapter 74 L015 conduit adapter 76 L015 threaded adapter 74 L017 ring adapter 74 L024 wide threaded adapter 74 Shrink boot adapter 49 AEC Series 13-15 AMPSEAL Connectors 17-21 AMPSEAL 16 Connectors 23-27 B Backshells AMPSEAL 20 AMPSEAL 16 26 DRC Series 41 DT Series 52 HD10 Series 64 HD30/HDP20 Series 76-77 STRIKE Series 83 Boots AEC Series 15 DRB Series 33 DRC Series 41 DT/DTM/DTP Series 51 HD30/HDP20 Series 75 Breakaway connector HD30 Series 73, 95 Bussing Options 85-89 C Cable clamps HD30 Series 74 CAN (Controller Area Network) 91-95 Compression nuts HD10 Series 64 HD30/HDP20 Series 76 Contacts 115-128 Contact specifications 117-118 Contact styles Solid 116, 120 Stamped & formed 116, 120-121 Coupling rings HD10 Series 63 Crimp General 124 Inspection 125 Tools 131-135 Crimp sleeve reducer 126 Crimp tools. See also Tooling Automated 131-133 Hand 134-135 D D hole punch 79 Dimensions AEC Series 14 AMPSEAL 18 AMPSEAL 16 24 Bussed feedback receptacles 86 DRB Series 30 DRC Series 39 DT/DTM/DTP Series 45 DTHD Series 112 DTMH Series 57 DTMN Series 59 DTV Series 56 EEC enclosures 109-110 HD10 Series 62 HD30/HDP20 Series 70 HDFB Series 89 Jiffy Splices 114 STRIKE Series 82 Diodes 97-99 DRB Series 29-36 DRC Series 37-42 DT/DTM/DTP Series 43-54 DTHD Series 112-113 157 Index DTMH Series 57 DTMN Series 59 DTT Style Hand Tools 135 DTV Series 56 Dust caps AEC Series 15 DT/DTM Series 50 HD10 Series 65 HD30/HDP20 Series 75 E EEC enclosures 108-110 End caps DTHD Series 113 DT Series 49 "E" seal DT Series 49 HD30/HDP20 Series 72-73 F Flange modifications DTHD Series 113 DT Series 49 Flanges DRB Series 32 G Gaskets DRC Series 42 DT/DTM/DTP Series 50 HD10 Series 66 HD30/HDP20 Series 77 Grommet sealing ranges 119 H HD10 Series 61-67 HD30/HDP20 Series 69-80 HDFB Series 88-89 I Instructions (How To) AMPSEAL 20-21 AMPSEAL 16 27 Crimp sleeve reducer 128 DRB Series 34-35 DT Family , 27 DTT style hand tools 138-139 HD30/HDP20 Series 79-80 HDT-48-00 hand tool 137 Jiffy Splice 20, 114 Sealing plugs 128 STRIKE Series 84 158 Wire stripping 137 ISO box 95 J J1939 J1939/11 94 J1939/12 95 J1939/13 93 J1939/15 95 Jiffy Splices 114 K Keying pins 126 L Lanyards HD10 Series 67 Lockwashers HD30/HDP20 Series 77 M Material specifications 7 Modifications Descriptions 142-148 059 74 072 74 A004 103 AG02 103 B010 63 B016 48, 105 B026 107 BL04 49 BL08 49 BL10 49 BP03 64 C015 49 C023 104 C030 74 CL03 49 CL07 49 CL09 49 E003 19, 24, 49, 113 E004 49, 63 E005 49 E007 49 E008 49 E016 110 EE04 58 Flange 49 G002 104 G003 105, 106 GR01 109 Index GR02 108 L006 74 L009 113 L012 49 L013 113 L015 74 L017 74 L018 30 L024 74 LE01 49 LE05-LE12 49 LE14 49 LE17 49 LE21 49 N005 64, 107 N012 104, 105 P012 48 P064 73 P080 64 R008 109 R015 108 Mounting brackets 89 Mounting clips AMPSEAL 16 26 DT/DTM/DTP Series 54 DTHD Series 113 N "N" seal HD30/HDP20 Series 72-73 P Panel nut HD30/HDP20 Series 78 PCB pins 123 PCB (Printed Circuit Board) 101-110 Performance specifications Connectors 5-6 Contacts 117-118 Primary latch reinforcement (PLR) 25, 27 Performance Connectors 5, 6 Contacts 117-118 Standards 149 Strain relief AMPSEAL 20 AMPSEAL 16 26 DT Series 52-53 HD10 Series 65 HD30/HDP20 Series 76-77 STRIKE Series 81-84 T Tooling Crimp tools Automated 131-132 Hand 134-135 D hole punch 79 Insert/removal tools 135-136 Tooling accessories 131-133 TPA (Terminal Position Assurance) 7, 57 "T" seal HD30/HDP20 Series 72-73 W Wedgelocks DRB Series 32, 33 DT/DTM/DTP Series 47-48 DTV Series 56 Wire router DRB Series 30 DRC Series 41 Wire sealing ranges 119-120 R Removal tools 135-136 Resistors 97-99 S Sealing plugs 127 Shrink boot adapter DT/DTM Series 49 Specifications Material 7 159 While LADD Distribution has made every reasonable effort to ensure the accuracy of the information in this catalog, LADD does not guarantee that it is error-free, nor does LADD make any other representation, warranty or guarantee that the information is accurate, correct, reliable or current. LADD reserves the right to make any adjustments to the information contained herein at any time without notice. LADD expressly disclaims all implied warranties regarding the information contained herein, including, but not limited to, any implied warranties of merchantability or fitness for a particular purpose. The dimensions in this catalog are for reference purposes only and are subject to change without notice. Specifications are subject to change without notice. Consult LADD for the latest dimensions and design specifications. LADD, TE Connectivity, TE and TE connectivity (logo), AMPSEAL, AMPSEAL 16, DEUTSCH, STRIKE are trademarks. (c) 2014 LADD Distribution LLC, a TE Connectivity company LADD Distribution | 800-223-1236 | laddinc.com Edition 1004