SECTION 3 GROUP 6

COMMON TOOLS OTHERS

790-222-4000 Repair kit (A) 790-222-4100 Repair kit (B)

1. GENERAL DESCRIPTION OF KIT

Two types of repair kits are provided: the repair kit (A) for all connectors in DT Series (Part No.: 790-222-
4000) and the repair kit (B) for 2-, 3-, 4-, and 6-ways connectors frequently used (Part No.: 790-222-4100).
As for HD30 connector bodies, more than 100 types are provided and not used very frequently.
For this reason, no repair kit is available for the HD30 connector bodies. You must place an order separately
when you need it. Also, components of this kit are also selectively available.

2. Outline of the kits

2-1 Repair kit (A)
For repair of connectors at repair shop. All parts of
DT connector and required tools are included in a
kit. Separately get a HD30 connector body only and
the kit is applicable to every connector.

3-6 Regarding the components list, refer to 6-1. This kit
does not include a case. Obtain one if necessary.
2-2 Repair kit (B)
For repair of connectors in the field. Mainly the
parts of frequently used 2-, 3-, 4-, and 6-ways DT
connectors are available as a compact kit. Like the
repair kit (A), the repair kit (B) also includes a
terminal crimp tool and terminal pull-out tool. 3-6

Therefore, it is well serviceable in the field. Re-
garding the components list, refer to 6-2. This kit
does not include a case (P/N: 799-601-7910 and
7920), either. Obtain one if necessary.

Case (Option)
Large size: Part No. 799-601-7910
Size: 410 x 240 x 325mm
Weight: 6.0Kg
Medium size: Part No. 799-601-7920
Size: 550 x 325 x 365mm
Weight: 2.9Kg

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3 FEATURES OF NEW CONNECTORS

1) All connectors are waterproofed.
2) A common terminal is used on both DT and
HD30 connectors.
3) One type of terminal crimp tool is provided,
which is common to both.
4) On-site terminal replacement is easy.

There is no need to caulk a shielding rubber
together with the terminal.

The terminal has no protrusion, not damag-
ing
the shielding rubber when attaching and
5) detaching.
Durability of the terminal was improved. DT connector

The terminal is nickel-plated, improving the
durability when connecting and disconnecting
the connectors.

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

4 BASIC PERFORMANCE
Particularly, the waterproof capability was improved,
increasing reliability.
Working temperature: –55 to 125°C
(X connector: –50 to 120°C)
Waterproof capability:
No water enters even if it is put one meter below
water surface for four hours. No water enters even
if water of 8 to 10 megapascal is sprayed on the

3-6 connector from a position 100mm away. 3-6

(X connector: Spray test level)

HD30 connector.

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COMMON TOOLS OTHERS

5 GENERAL DESCRIPTION OF CONNECTOR

5-1 DT connector
As DT connectors, DT2-, 3-, 4-, 6-, 8-, and 12-ways types and DTHD 1-ways and DTM 2-ways types are
provided. Regarding the DTHD connector, three types are available depending on the size of electric wire to
be connected, each of which is given a different Part No.

<Configuration of DT connector>

5-2 HD30 connector

Two sizes of connectors (shell size: 18 and 24) and also connectors with different nine pin configurations are
provided. This type connector is mountable on a housing of either the pin or socket terminal type. (The
housing Part No. is different according to whether it is a pin-terminal-mounted connector or socket-terminal-
mounted connector.)

3-6 Other than, various kinds of combinations are available. Be careful to place an order by specifying a correct 3-6

Part No.

<Configuration of HD30 connector>

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 SECTION 3 GROUP 6
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6 LIST OF REPAIR KIT COMPONENTS

6-1 Repair kit (A) component list (Part No.: 790-222-4000)
No. Part No. Part name Q'ty Remarks
1 08191-05310 Pin (Nickel-plated) 100 (#20)
2 08191-05320 Pin (Nickel-plated) 50 (#16: AWG16-0)
3 08191-05330 Pin (Nickel-plated) 50 (#16: AWG14-6)
4 08191-05340 Pin (Nickel-plated) 20 (#12)
5 08191-05350 Pin (Nickel-plated) 10 (#8)
6 08191-05360 Pin (Nickel-plated) 10 (#4)
7 08191-07310 Pin (Gold-plated) 10 (#20)
8 08191-07320 Pin (Gold-plated) 5 (#16: AWG16-0)
9 08191-07330 Pin (Gold-plated) 5 (#16: AWG14-6)
10 08191-05410 Socket (Nickel-plated) 100 (#20)
11 08191-05420 Socket (Nickel-plated) 50 (#16: AWG16-0)
12 08191-05430 Socket (Nickel-plated) 50 (#16: AWG14-6)
13 08191-05440 Socket (Nickel-plated) 20 (#12)
14 08191-05450 Socket (Nickel-plated) 10 (#8)
15 08191-05460 Socket (Nickel-plated) 10 (#4)
16 08191-07410 Socket (Gold-plated) 10 (#20)
17 08191-07420 Socket (Gold-plated) 5 (#16: AWG16-0)
18 08191-07430 Socket (Gold-plated) 5 (#16: AWG14-6)
19 08192-02100 Connector (Receptacle) 3 (DTM)
20 08192-12100 Connector (Receptacle) 3 (DT2)
21 08192-13100 Connector (Receptacle) 3 (DT3)
22 08192-14100 Connector (Receptacle) 3 (DT4)
23 08192-16100 Connector (Receptacle) 3 (DT6)
24 08192-18101 Connector (Receptacle) 1 (DT8) Grey
25 08192-18102 Connector (Receptacle) 3 (DT8) Black, standard

3-6 26
27
08192-18103
08192-18104
Connector (Receptacle)
Connector (Receptacle)
1 (DT8) Green
1 (DT8) Brown 3-6

28 08192-19101 Connector (Receptacle) 1 (DT12) Grey
29 08192-19102 Connector (Receptacle) 3 (DT12) Black, standard
30 08192-19103 Connector (Receptacle) 1 (DT12) Green
31 08192-19104 Connector (Receptacle) 1 (DT12) Brown
32 08192-31100 Connector (Receptacle) 1 DTHD #12
33 08192-41100 Connector (Receptacle) 1 DTHD #8
34 08192-51100 Connector (Receptacle) 1 DTHD #4
35 08192-02200 Connector (Plug) 3 (DTM)
36 08192-12200 Connector (Plug) 3 (DT2)
37 08192-13200 Connector (Plug) 3 (DT3)
38 08192-14200 Connector (Plug) 3 (DT4)
39 08192-16200 Connector (Plug) 3 (DT6)
40 08192-18201 Connector (Plug) 1 (DT8) Grey
41 08192-18202 Connector (Plug) 3 (DT8) Black, standard.
42 08192-18203 Connector (Plug) 1 (DT8) Green
43 08192-18204 Connector (Plug) 1 (DT8) Brown
44 08192-19201 Connector (Plug) 1 (DT12) Grey
45 08192-19202 Connector (Plug) 3 (DT12) Black, standard
46 08192-19203 Connector (Plug) 1 (DT12) Green
47 08192-19204 Connector (Plug) 1 (DT12) Brown
48 08192-31200 Connector (Plug) 1 DTHD #12
49 08192-41200 Connector (Plug) 1 DTHD #8
50 08192-51200 Connector (Plug) 1 DTHD #4
51 08192-22100 Connector (Receptacle: For AEX, AVS0.5) 3 (DT2)
52 08192-23100 Connector (Receptacle: For AEX, AVS0.5) 3 (DT3)

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6-1 Repair kit (A) component list (Part No.: 790-222-4000) (Continued)

No. Part No. Part name Q'ty Remarks

53 08192-24100 Connector (Receptacle: For AEX, AVS0.5) 3 (DT4)
54 08192-26100 Connector (Receptacle: For AEX, AVS0.5) 3 (DT6)
55 08192-28101 Connector (Receptacle: For AEX, AVS0.5) 1 (DT8) Grey
56 08192-28102 Connector (Receptacle: For AEX, AVS0.5) 3 (DT8) Black, standard
57 08192-28103 Connector (Receptacle: For AEX, AVS0.5) 1 (DT8) Green
58 08192-28104 Connector (Receptacle: For AEX, AVS0.5) 1 (DT8) Brown
59 08192-29101 Connector (Receptacle: For AEX, AVS0.5) 1 (DT12) Grey
60 08192-29102 Connector (Receptacle: For AEX, AVS0.5) 3 (DT12) Black, standard
61 08192-29103 Connector (Receptacle: For AEX, AVS0.5) 1 (DT12) Green
62 08192-29104 Connector (Plug: For AEX, AVS0.5) 1 (DT12) Brown
63 08192-22200 Connector (Plug: For AEX, AVS0.5) 3 (DT2)
64 08192-23200 Connector (Plug: For AEX, AVS0.5) 3 (DT3)
65 08192-24200 Connector (Plug: For AEX, AVS0.5) 3 (DT4)
66 08192-26200 Connector (Plug: For AEX, AVS0.5) 3 (DT6)
67 08192-28201 Connector (Plug: For AEX, AVS0.5) 1 (DT8) Grey
68 08192-28202 Connector (Plug: For AEX, AVS0.5) 3 (DT8) Black, standard
69 08192-28203 Connector (Plug: For AEX, AVS0.5) 1 (DT8) Green
70 08192-28204 Connector (Plug: For AEX, AVS0.5) 1 (DT8) Brown
71 08192-29201 Connector (Plug: For AEX, AVS0.5) 1 (DT12) Grey
72 08192-29202 Connector (Plug: For AEX, AVS0.5) 3 (DT12) Black, standard
73 08192-29203 Connector (Plug: For AEX, AVS0.5) 1 (DT12) Green
74 08192-29204 Connector (Plug: For AEX, AVS0.5) 1 (DT12) Brown
75 08192-02300 Wedge (Receptacle) 5 (DTM)
76 08192-12300 Wedge (Receptacle) 5 (DT2)
77 08192-13300 Wedge (Receptacle) 5 (DT3)
78 08192-14300 Wedge (Receptacle) 5 (DT4)
79 08192-16300 Wedge (Receptacle) 5 (DT6)
80 08192-18300 Wedge (Receptacle) 5 (DT8)

3-6 81 08192-19300 Wedge (Receptacle) 5 (DT12) 3-6

82 08192-02400 Wedge (Plug) 5 (DTM)
83 08192-12400 Wedge (Plug) 5 (DT2)
84 08192-13400 Wedge (Plug) 5 (DT3).
85 08192-14400 Wedge (Plug) 5 (DT4)
86 08192-16400 Wedge (Plug) 5 (DT6)
87 08192-18400 Wedge (Plug) 5 (DT8)
88 08192-19400 Wedge (Plug) 5 (DT12)
89 08191-00710 Sealing plug 10 (#20)
90 08191-00770 Sealing plug 10 (#12, #16)
91 08191-00750 Sealing plug 5 (#8)
92 08191-00760 Sealing plug 5 (#4)
93 08193-20012 Clamp 5
94 08193-30012 Clamp 3 Applicable to 8-ways type only
95 799-601-7810 Tool 1 Terminal crimp tool
96 799-601-7820 Tool 3 HD connector pin pull-out tool
97 799-601-7830 Tool 3 HD connector pin pull-out tool
98 799-601-7840 Tool 3 HD connector pin pull-out tool
99 799-601-7850 Tool 3 HD connector pin pull-out tool
100 799-601-7860 Tool 1 HD connector pin pull-out tool
101 799-601-7870 Tool 1 HD connector pin pull-out tool
102 799-601-7880 Tool 1 DT connector pin pull-out tool
103 799-601-7930 Operation Manual 1

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6-2 Repair kit (B) component list (Part No.: 790-222-4100)

No. Part Part name Q'ty Remarks

1 08191-05310 Pin (Nickel-plated) 100 (#20)
2 08191-05320 Pin (Nickel-plated) 50 (#16: AWG16-0)
3 08191-05330 Pin (Nickel-plated) 50 (#16: AWG14-6)
4 08191-05410 Socket (Nickel-plated) 100 (#20)
5 08191-05420 Socket (Nickel-plated) 50 (#16: AWG16-0)
6 08191-05430 Socket (Nickel-plated) 50 (#16: AWG14-6)
7 08192-02100 Connector (Receptacle) 3 (DTM)
8 08192-12100 Connector (Receptacle) 3 (DT2)
9 08192-13100 Connector (Receptacle) 3 (DT3)
10 08192-14100 Connector (Receptacle) 3 (DT4)
11 08192-16100 Connector (Receptacle) 3 (DT6)
12 08192-02200 Connector (Plug) 3 (DTM)
13 08192-12200 Connector (Plug) 3 (DT2)
14 08192-13200 Connector (Plug) 3 (DT3)
15 08192-14200 Connector (Plug) 3 (DT4)
16 08192-16200 Connector (Plug) 3 (DT6)
17 08192-22100 Connector (Receptacle: For AEX, AVS0.5) 3 (DT2)
18 08192-23100 Connector (Receptacle: For AEX, AVS0.5) 3 (DT3)
19 08192-24100 Connector (Receptacle: For AEX, AVS0.5) 3 (DT4)
20 08192-26100 Connector (Plug: For AEX, AVS0.5) 3 (DT6)
21 08192-22200 Connector (Plug: For AEX, AVS0.5) 3 (DT2)
22 08192-23200 Connector (Plug: For AEX, AVS0.5) 3 (DT3)
23 08192-24200 Connector (Plug: For AEX, AVS0.5) 3 (DT4).
24 08192-26200 Connector (Plug: For AEX, AVS0.5) 3 (DT6)
25 08192-02300 Wedge (Receptacle) (For male connector) 5 (DTM)
26 08192-12300 Wedge (Receptacle) (For male connector) 5 (DT2)

3-6 27
28
08192-13300
08192-14300
Wedge (Receptacle) (For male connector)
Wedge (Receptacle) (For male connector)
5 (DT3)
5 (DT4)
3-6

29 08192-16300 Wedge (Receptacle) (For male connector) 5 (DT6)
30 08192-02400 Wedge (Plug) (For female connector) 5 (DTM)
31 08192-12400 Wedge (Plug) (For female connector) 5 (DT2)
32 08192-13400 Wedge (Plug) (For female connector) 5 (DT3)
33 08192-14400 Wedge (Plug) (For female connector) 5 (DT4)
34 08192-16400 Wedge (plug) (For female connector) 5 (DT6)
35 08191-00710 Sealing plug 10 (#20)
36 08191-00770 Sealing plug 10 (#12, #16)
37 08193-20012 Clamp 5
38 799-601-7810 Tool 1 Terminal crimp tool
39 799-601-7820 Tool 3 To pull out HD connector terminal
40 799-601-7830 Tool 3 To pull out HD connector terminal
41 799-601-7840 Tool 3 To pull out HD connector terminal
42 799-601-7850 Tool 3 To pull out HD connector terminal
43 799-601-7860 Tool 1 To pull out HD connector terminal
44 799-601-7870 Tool 1 To pull out HD connector terminal
45 799-601-7880 Tool 1 To pull out DT connector pin
46 799-601-7930 Operation Manual 1

3-6-25