Mechanical Gas Fuel System G5.9, G8.3, G855 – Master Repair Manual 019-204   Deutsch DRC Connector Series

Pin Replacement

TOC

The Deutsch connector is used to attach the appropriate harness to the ECM.

 
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Replace one contact wire at a time. If more than one wire needs replaced, attach a lettered tag to each wire removed.

Refer to the wiring diagram in Section E for pin locations.

Use the Deutsch extraction tool, listed in the table below, to remove a pin from the connector.

Tool Part Number Wire Size
3824815 20 gauge
3822760 16 gauge
3824816 12 gauge

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Push the tool into the connector approximately 25 mm [1 in] until it bottoms on the terminal flange.

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Hold the tool on the terminal flange and pull the wire and connecting pin out of the connector. Note and record the hole from which the pin is removed.

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NOTE: The repair wire is 127 mm [5 in] long.

Use wire crimping tool, Part Number 3822930, to cut 127 mm [5 in] off the wire and pin.

Use the crimping tool to remove 6 mm [¼ in] of insulation from the wire.

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Refer to the appropriate wiring repair kit in the service tools table in the front of Section 19 for the correct repair wire.

Install the correct repair wire on the bare wire, make sure that the bare wire extends into the splice connector.

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Use the wire crimping tool to crimp the repair wire onto the bare wire.

 
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Use heat gun, Part Number 3822860, or an open flame to heat the shrink tubing around the wire. The tubing will shrink and make the connector waterproof.

 
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Insert the pin into the correct hole of the connector.

The pin must click into place and hold the wire in the connector.

Pull the wire gently to make sure it is seated in the connector.

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 CAUTION 

Use only Cummins recommended lubricant DS-ES, Part Number 3822934. Other lubricants, such as lubricating oil or grease, in the connectors can cause ECM damage, poor engine performance, or premature connector pin wear.

Apply a small amount of lubricant to the connector terminals. Do not fill the entire connector cavity with the lubricant.

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Connector Replacement

TOC

The Deutsch connector is used to attach the appropriate harness to the ECM.

 
SMALL | MEDIUM | LARGE
   


Use the Deutsch extraction tool, listed in the table below, to remove a pin from the connector.

Tool Part Number Wire Size
3824815 20 gauge
3822760 16 gauge
3824816 12 gauge

Replace one wire at a time. Attach a lettered tag to each wire removed.

Refer to the wiring diagram in Section E for pin locations.

SMALL | MEDIUM | LARGE
   


Push the tool into the connector approximately 25 mm [1 in] until it bottoms on the terminal flange.

SMALL | MEDIUM | LARGE
   


Hold the tool on the terminal flange and pull the wire and the connecting pin out of the connector. Note and record the hole from which the pin is removed.

SMALL | MEDIUM | LARGE
   


Before installing the new connector, perform a test fit to make sure the connector is keyed correctly.

Refer to the appropriate wiring repair kit in the service tools table in the front of Section 19 for the correct repair connector.

Refer to the wiring diagram in Section E for pin locations.

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Insert the pins into the correct holes of the replacement connector.

Each pin must click into place and hold the wires in the connector.

Pull each wire gently to make sure it is seated in the connector.

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 CAUTION 

Use only Cummins lubricant DS-ES, Part Number 3822934. Other lubricants such as lubricating oil or grease, in the connectors can cause ECM damage, poor engine performance or premature connector pin wear.

Apply a small amount of lubricant to the connector terminals. Do not fill the entire connector cavity with lubricant.

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Last Modified:  03-Apr-2003