1. Introduction
This manual provides instructions for the proper use and installation of the JRready Deutsch DT Connector Terminal Kit Size 16. This kit includes 100 male pin contacts (1060-16-0122) and 100 female socket contacts (1062-16-0122), designed for 14-18AWG wire. These contacts are compatible with various Deutsch connector series, including DT, HDP20, HD30, DTHD, HD10, DRC, and Jiffy Splice series.
The terminals are constructed from phosphor bronze for abrasion and corrosion resistance, with tin-plated crimping wings for enhanced weldability. This design ensures reliable electrical connections.
2. Product Components
The kit contains the following components:
- 100x Male Pin Contacts: Part Number 1060-16-0122
- 100x Female Socket Contacts: Part Number 1062-16-0122
Each contact features a wire barrel, insulation barrel, retention shoulder, and a mating end. The socket contacts include a protective sleeve. The retention shoulder secures the contact within the connector housing, preventing accidental dislodgement.
Figure 2.1: Exploded view of Deutsch DT connector components, including pin and socket contacts.
Figure 2.2: Detailed view of Size 16 stamped and formed contacts, showing dimensions and phosphor bronze, tin-plated material.
Note: Connectors (housings and wedgelocks) must be purchased separately.
3. Specifications
| Feature | Specification |
|---|---|
| Model | ST6255-100 |
| Contact Type | Open Barrel, Stamped & Formed |
| Contact Size | Size 16 |
| Wire Gauge Range | 14-18 AWG |
| Maximum Current | 13 Amps |
| Contact Material | Phosphor Bronze |
| Plating | Tin-plated (crimping wings) |
| Maximum Voltage | 24 Volts (DC) |
| Compliance | RoHS |
4. Setup & Installation
4.1 Crimping Process
For optimal performance, use a dedicated crimping tool such as the JRready ACT-LY-16DT. Follow these steps for proper crimping:
- Strip the Wire: Carefully strip approximately 5mm (0.2 inches) of insulation from the end of the wire. Ensure the wire strands are not twisted or damaged.
- Prepare the Crimping Tool: Open the crimping tool jaws and ensure the positioner is correctly set for Size 16 contacts.
- Insert Terminal: Lift the positioner slightly to expose the locating hole. Insert the contact terminal into the hole of the positioner, ensuring it is fully seated at the bottom. Close the handle slightly to hold the terminal in place.
- Insert Wire: Insert the stripped wire into the terminal's wire barrel.
- Crimp: Fully close the crimping tool handles until the ratchet mechanism releases. This ensures a complete and secure crimp.
- Inspect Crimp: Remove the crimped terminal and inspect it for proper formation. The wire strands should be fully captured within the conductor crimp, and the insulation should be spaced appropriately from the crimp area.
Figure 4.1: Step-by-step guide for crimping contacts using a JRready crimping tool.
Figure 4.2: Recommended JRready ACT-LY-16DT crimping tool for professional standard crimping.
4.2 Connector Assembly
After crimping the contacts onto the wires, insert them into the appropriate Deutsch connector housing. Ensure the contacts are fully seated and the wedgelocks are installed to secure them.
Video 4.1: This video demonstrates the crimping process for JRready Deutsch stamped contacts and their insertion into a connector, ensuring a secure and reliable connection.
5. Operating Instructions
Once assembled, the Deutsch DT connectors provide a robust and reliable electrical connection. Ensure that the male and female connector halves are fully mated and the wedgelocks are properly engaged to prevent accidental disconnection and maintain environmental sealing.
Figure 5.1: A fully assembled Deutsch connector, demonstrating a secure connection.
6. Maintenance
Deutsch DT connectors are designed for durability and require minimal maintenance. However, periodic inspection is recommended, especially in harsh environments.
- Visual Inspection: Check for any signs of physical damage, corrosion, or loose connections.
- Cleaning: If necessary, clean the connector surfaces with a non-conductive, residue-free cleaner. Avoid using abrasive materials.
- Re-seating: If a connection appears loose, ensure the contacts are fully seated and the wedgelocks are properly installed.
7. Troubleshooting
If you encounter issues with your Deutsch DT connectors, consider the following:
- Poor Electrical Connection: This is often due to an improper crimp. Ensure the wire is stripped to the correct length (approx. 5mm) and fully inserted into the terminal before crimping. The crimp should capture all wire strands securely.
- Bent or Damaged Terminal: If the terminal appears bent or damaged after crimping, it may indicate incorrect tool usage or improper positioning. Always ensure the terminal is correctly seated in the crimping tool's positioner.
- Terminal Not Seating in Connector: Verify that the terminal is correctly crimped and that there are no obstructions in the connector cavity. Ensure the wire gauge matches the terminal size.
- Connector Disconnection: Confirm that the wedgelocks are fully inserted and locked into place after mating the connector halves.
8. Safety Information
Always observe basic electrical safety precautions when working with electrical components:
- Disconnect power before working on any electrical system.
- Use appropriate personal protective equipment (PPE), such as safety glasses.
- Ensure all connections are secure to prevent short circuits or arcing.
- Do not exceed the specified current (13A) or voltage (24V DC) ratings for these contacts.
9. Warranty & Support
JRready products are backed by a commitment to quality. For any inquiries or support needs, please contact JRready customer service. The product includes a 12-month after-sale service period.