ZF Marine ClearCommand 9000 Series Installation, Operation And Troubleshooting Manual page 153

D e u t s c h C o n n e c t o r A s s e m b l y
Step 1: Contact Removal
1. Remove wedgelock using
needlenose pliers or a hook
shaped wire. Pull wedge
straight out.
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.
3. Hold the rear seal in
place, as removing the
contact may displace the
seal.
Step 3: Contact Crimping
Use Crimp Tool #HDT48-00
1. Strip insulation from wire.
(See Step 2).
2. Raise selector knob and
rotate until arrow is aligned with
wire size to be crimped.
3. Loosen locknut, turn adjust-
ing screw in until it stops.
4. Insert contact with barrel up.
Turn adjusting screw counter–
clockwise until contact is flush
with indentor cover. Tighten
locknut.
5. Insert wire into contact.
Contact must be centered
between indicators. Close
handles until crimp cycle is
completed.
6. Release handles and remove
crimped contact.
7. Inspect terminal to ensure
that all strands are in crimp
barrel.NOTE: Tool must be
readjusted for each type/size
of contact. Use HDT04-08 for
size 8 and 4 contacts.
DT Type
Step 2: Wire Stripping
Contact Part
Number
0460-202-20141
0462-201-20141
0460-202-16141
0462-201-16141
0460-215-16141
0462-209-16141
0460-204-12141
0462-203-12141
0460-204-08141
0462-203-08141
0460-204-0490
0462-203-04141
Step 4: Contact Insertion
P a g e A - 2 3
Solid Contacts
Wire Gauge
Strip Length
(inches)
Range
20 AWG .156-.218
20 AWG .156-.218
16, 18 & 20 AWG .250-.312
16, 18 & 20 AWG .250-.312
14 AWG .250-.312
14 AWG .250-.312
12 & 14 AWG .222-.284
12 & 14 AWG .222-.284
8 & 10 AWG .430-.492
8 & 10 AWG .430-.492
6 AWG .430-.492
6 AWG .430-.492
1. Grasp crimped contact
approximately (25.2 mm) one
inch behind the contact barrel.
2. Hold connector with rear
grommet facing you.
3. Push contact straight into
connector grommet until a click
is felt. A slight tug will confirm
that contact is properly locked
in place.
4. Once all contacts are in place,
insert wedgelock with arrow pointing
toward exterior locking mechanism.
The wedgelock will snap into place.
Rectangular wedges are not oriented.
They may go in either way.
NOTE: The receptacle is shown –use the
same procedure for plug.
(800) 223-1236