Transcription
J-38125TERMINAL REPAIR KITINSTRUCTION MANUAL
TABLE OF CONTENTSITEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE NUMBERGENERAL INSTRUCTIONSDefinition Of Terms And Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Terminal Removal Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Terminal Replacement / Crimping Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Crimp Tool Usage Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Ultratorch Usage Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Visual Product Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Splice Clip Usage And Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15English / Metric Wire Gauge Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Kit Contents, Re-Order Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20CRIMP TOOL / REMOVAL TOOL MATRIXAFL TRAY #21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45DELPHI TRAY #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46DELPHI TRAY #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47DELPHI TRAY #3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48DELPHI TRAY #4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49DELPHI TRAY #5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50DELPHI TRAY #8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51DELPHI TRAY #18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52DELPHI TRAY #19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53DELPHI TRAY #20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54DELPHI TRAY #23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55LEAR TRAY #7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56LEAR TRAY #16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57LEAR TRAY #17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58SUMITOMO TRAY #6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59SUMITOMO TRAY #22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60YAZAKI TRAY #9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61YAZAKI TRAY #10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62YAZAKI TRAY #11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63YAZAKI TRAY #12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64YAZAKI TRAY #13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65YAZAKI TRAY #14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66YAZAKI TRAY #15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
DEFINITION OF TERMSCableAnother term for a bulk length of wire.ConnectorThe molded plastic part which houses one ormore terminals.Connector Position AssuranceA lock designed to retain connectors when mated.CoreConductive portion of a wire, covered with insulationof various types - usually PVC or polyethylene.Crimp & Seal Splice SleeveA crimp only splice with an integral heat shrink shieldused to make a sealed one to one splice.LeadAnother term for a cut length of wire.PickRemoval tool for terminal, TPA, CPA or opening ofsecondary locks.PigtailTerminated wires housed in a connector intended to bespliced into a harness when total harness replacementis not required.Secondary LockProvides terminal retention in addition to lock tang,usually molded as part of the connector.TerminalFormed metal attached to the end of the wire thatprovides electrical connection.Terminal Lock TangsFlexible portion of the terminal that locks terminal intoconnector cavity.Terminal Position AssuranceA loose piece component that snaps on to a connector.It is designed to keep the terminal from backing out ofthe connector.Terminal WingsPortion of terminal that is used for attachment to wire.Typical terminal has core wings, attached to theconductive core of the wire and insulation wings,attached to the outside of the wire for strain relief.Page 2
ABBREVIATIONSACTAdvanced Connection Technology, the next generation metri pack having lowerterminal to terminal engage forceCPAConnector Position Assurance lockMIC/PMicro Pack, a family of sealed and unsealed connection systems used primarily in lowcurrent (signal level) applicationsM/PMetri Pack, a family of sealed and unsealed connection systems of various sizes andcurrent carrying capacitiesP2SPull to Seat, a connection system where the terminal on a wire is actually insertedinto the mating end of the connector, wire first, so that an unseated terminal does notpush out the back of the connector and cause an electrical open circuit.TPATerminal Position Assurance lockW/PWeather Pack, a family of sealed connection systems utilizing a pin andsleeve configurationPage 3
TERMINAL REMOVAL INSTRUCTIONSTerminal retention within the connector generally takes two forms:1. A flexible primary lock, either part of the terminal or part of the connector2. A hinged or loose piece secondary lock. To remove a terminal, both mustbe disengaged or removed.First, locate and remove the secondary lock.1. Most are located in the rear (non-mating end) of the connector. These can generally beremoved using a small screwdriver.2. The new GT series and 100W micropack styles have the secondary lock on the front(mating) end of the connector. 100W can be removed with a screwdriver, the GT requiresthe use of pick #15313892. It will allow you to “hook” the secondary lock and gently liftit out of place.Now remove the terminal by disengaging the primary lock.1. Determine the terminal part number or family, then get the appropriate removal tool usingthe cross reference matrix in the tabbed sections.2. Locate the area of the front of the connector where the removal tool is to be inserted. It willNEVER enter the portion of the terminal where the mating terminal would be located.Inserting the removal tool into this mating area will RUIN the terminal.3. Position the terminal by using the attached wire. For push to seat, slide the terminalforward. For pull to seat, slide it rearward. This allows the lock tang to disengage fromthe lock shoulder.4. Terminal locks which are flexible members in the connector are ACT, GT and 100Wmicropacks. All others have the lock tang as part of the terminal. Using appropriate toolfrom the matrix, flex the plastic lock member, then gently remove the terminal by pushingor pulling on the wire.5. For families with the lock tang on the terminal, gently insert the removal tool and disengagethe lock while holding the terminal in the position from step #3. The terminal can be removedby pushing or pulling on the wire.Page 4
STANDARD TERMINAL REPLACEMENT1CUT OFF TERMINAL BETWEEN CORE ANDINSULATION CRIMP.(MINIMIZE WIRE LENGTH LOSS)2STRIP INSULATION (1/4” LENGTH)CAUTION MUST BE USED NOT TO CUT STRANDS3POSITION WIRE IN TERMINAL AS SHOWN.CAUTION MUST BE USED NOT TO POSITIONSTRIP TOO FAR FORWARD. IT MAY INTERFEREWITH MATING PORTION OF TERMINAL.4HAND CRIMP CORE WINGS FIRST, THENINSULATION WINGS USING ONE OF THEAPPROVED CRIMPING TOOLS. USE CRIMPMATRIX IN THE TABBED SECTIONS TODETERMINE CORRECT TOOL COMBINATION.Page 5
STANDARD TERMINAL REPLACEMENT(cont)5SOLDER ALL HAND CRIMPED TERMINALS.CAUTION: USE EXTREME CARE ON ALLMICRO-PACK AND 150 METRI-PACKTERMINALS. AVOID SOLDER ON INTERFACEOR BOX AREA.6ELECTRICALLY CHECK REPAIRED TERMINALFOR CONTINUITY.USE J-39200-A DVOM OR EQUIVALENT.MAKE SURE TERMINAL IS REPLACED INCORRECT CONNECTOR CAVITY TO ASSUREPROPER INDEXING.Page 6
TERMINAL REPLACEMENT SEALEDWEATHER PACK AND METRI-PACK1CUT OFF TERMINAL BETWEEN CORE ANDINSULATION CRIMP.(MINIMIZE WIRE LENGTH LOSS)REMOVE SEAL2APPLY CORRECT SEAL PER GAUGE SIZE OFWIRE. SLIDE BACK TO ENABLE REMOVAL OFINSULATION. STRIP 1/4” OF INSULATION.CAUTION MUST BE USED NOT TOCUT STRANDS3ALIGN SEAL WITH CABLE INSULATION4POSITION STRIP AND SEAL IN TERMINAL ASSHOWN. CAUTION MUST BE USED NOT TOPOSITION STRIP TOO FAR FORWARD. ITMAY INTERFERE WITH MATING PORTIONOF TERMINAL.Page 7
TERMINAL REPLACEMENT SEALEDWEATHER PACK AND METRI-PACK(cont)5HAND CRIMP CORE WINGS FIRST, THENINSULATION WINGS USING ONE OF THEAPPROVED CRIMPING TOOLS. USE CRIMPMATRIX IN THE TABBED SECTIONS TODETERMINE CORRECT TOOL COMBINATION.6SOLDER ALL HAND CRIMPED TERMINALS.CAUTION: USE EXTREME CARE ON ALLMICRO-PACK AND 150 METRI-PACKTERMINALS. AVOID SOLDER ON INTERFACEOR BOX AREA.7ELECTRICALLY CHECK REPAIRED TERMINALFOR CONTINUITY.USE KENT-MOORE J-39200-A MULTIMETEROR EQUIVALENT.MAKE SURE TERMINAL IS REPLACED INCORRECT CONNECTOR CAVITY TO ASSUREPROPER INDEXING.Page 8
TERMINAL CRIMP 25-642J-38125-643J-38125-101 is used for Delphi 100W round terminals which use crimpjaw “W” in the crimp matrix.J-38125-64 is used for Delphi .64 round terminals which use crimp jaw“M” in the crimp matrix.Both J-38125-641 and J-38125-642 are used for .64 square terminalswith or without cable seals.Page 9
TERMINAL CRIMP TOOL1. COMPRESS HANDLES UNTIL RATCHET AUTOMATICALLY OPENS.2. DETERMINE THE CORRECT HOLDER PER CRIMP MATRIX IN THE TABBED SECTIONS.3. CORE WINGS SHOULD BE CRIMPED FIRST. LAY THE BACK OF THE TERMINALCORE WINGS ON APPROPRIATE ANVIL. BE SURE THE CORE WINGS ARE POINTINGTOWARDS THE FORMING JAWS.4. GENTLY APPLY PRESSURE TO HANDLES UNTIL CRIMPERS SLIGHTLY SECURE THETERMINAL CORE WINGS.5. INSERT STRIPPED CABLE THROUGH CORE CRIMP WINGS OF TERMINAL ANDPOSITION PROPERLY.6. COMPRESS HANDLES UNTIL RATCHET AUTOMATICALLY RELEASES.7. REPEAT STEPS 2 AND 3 FOR INSULATION CRIMP.8. LOOK AT TERMINAL FOR DAMAGE PRIOR TO APPLYING SOLDER. IF TERMINALAPPEARS BENT AFTER CRIMPING, IT SHOULD BE GENTLY STRAIGHTENED BY HAND.Page 10
SPLICE CRIMP TOOLJ-38125-8P/N (F-G) 12085115GREEN FILL / SALMON FILLBLUE FILLYELLOW FILL1. COMPRESS HANDLES UNTIL RATCHET AUTOMATICALLY OPENS.2. DETERMINE THE CORRECT SPLICE HOLDER (NEST) PER SPLICE CRIMP MATRIX.PG. G5.3. GENTLY APPLY PRESSURE TO HANDLES UNTIL CRIMPERS SLIGHTLY SECURE THESPLICE SLEEVE BARREL. NOTE: MUST BE CRIMPED IN TWO STAGES - LEFT AND RIGHT.4. INSERT STRIPPED CABLE THROUGH SLEEVE BARREL UNTIL WIRE HITS THESTOP POSITION.5. COMPRESS THE HANDLES UNTIL RATCHET AUTOMATICALLY RELEASES.6. REPEAT STEPS 3, 4 AND 5.7. GENTLY TUG ON THE WIRES TO MAKE SURE THEY ARE SECURE BEFORE APPLYINGHEAT TO SLEEVE.8. APPLY HEAT FROM CENTER TO OUTSIDE OF SLEEVE.Page 11
ULTRATORCHJ-38125-5P/N 12085116PLEASE READ OPERATING INSTRUCTIONS INCLUDED WITH THE ULTRATORCH. THEFOLLOWING ADDITIONAL INSTRUCTIONS WILL HELP IN MAKING QUALITY APPLICATIONS.1. MAXIMUM SETTING FOR GAS CONTROL LEVER WHEN APPLYING HEAT TO SPLICESLEEVES OR TERMINAL APPLICATIONS IS 3 1/2.2. USE CARE IN CONFINED AREAS SUCH AS ENGINE COMPARTMENT OR NEXTTO ANYTHING THAT CAN EASILY MELT (CARPET, PLASTIC COMPONENTS, ETC.)ADJUST GAS CONTROL LEVER TO APPROXIMATELY 2 TO 2 1/2 SETTING WHENIN CONFINED AREAS.3. WHEN USING THE SOLDERING TIP ATTACHMENT, ALLOW APPROXIMATELY 1 MINUTEFOR TOOL TO HEAT UP. THIS WILL ALLOW THE SOLDER TO FLOW PROPERLY ON THETERMINAL CORE CRIMP.4. USE CARE IN REFILLING TORCH.Page 12
VISUAL STANDARDSTERMINAL APPLICATIONTERMINAL WITH SEAL APPLICATIONSPLICE APPLICATIONCRIMP AND SEAL APPLICATIONPage 13
VISUAL STANDARDSSOLDER APPLICATIONTERMINALSPLICE CLIPGLUED HEAT SHRINK APPLICATIONPage 14
SPLICE CLIPSPLICE CLIP PART NUMBERS — 05297428— 018399061CUT OFF CLIP(MINIMIZE WIRE LENGTH LOSS)2STRIP INSULATION (1/2” LENGTH)CAUTION MUST BE USED NOT TO CUT STRANDS3PREFERRED: LOCATE NEW SPLICE40 MM (1.5”) MINIMUM FROM AN OUTLETOR ANOTHER SPLICE.4DETERMINE PROPER SPLICE CLIP FOR GAUGESIZE OF WIRES.POSITION CLIP ON STRIPS.Page 15
SPLICE CLIP(cont)5HAND CRIMP TO SECURELY CLOSE THEENTIRE CLIP USING CRIMPERS OR PLIERS.6SOLDER SPLICE CLIP7ELECTRICALLY CHECK CONTINUITY.USE J-39200-A MULTIMETER OR EQUIVALENT8COVER ENTIRE SPLICE WITH SPLICE TAPE.TAPE MUST EXTEND ONTO THE INSULATIONON BOTH SIDES OF SPLICE.Page 16
CRIMP AND SEAL SPLICE SLEEVEP/N 12089189, 12089190, 12089191, 889883791CUT OFF CLIP IF APPLICABLE(MINIMIZE WIRE LENGTH LOSS)2STRIP INSULATION. 3/16” LENGTH FOR 10THRU 20 GA, 3/8” FOR 22 GA.CAUTION MUST BE USED NOT TO CUT STRANDS3PREFERRED: LOCATE NEW SPLICE 40 MM(1.5”) MINIMUM FROM AN OUTLET ORANOTHER SPLICE.4DETERMINE PROPER SLEEVE FOR GAUGEOF WIRE.POSITION STRIPPED ENDS OF WIRE INTOSLEEVE UNTIL WIRE HITS THE STOP.Page 17
CRIMP AND SEAL SPLICE SLEEVEP/N 12089189, 12089190, 12089191(cont)5HAND CRIMP USING THE APPROVED CRIMPINGTOOL ON PG. D2. GENTLY TUG ON WIRE TOMAKE SURE THEY ARE SECURE BEFOREAPPLYING HEAT TO SLEEVE.6APPLY HEAT USING ULTRATORCH OR OTHERDEVICE HEATING TO 175 C. REFER TO PG. E1.CAUTION: DO NOT USE MATCH OR OPENFLAME TO APPLY HEAT TO SEAL7ELECTRICALLY CHECK FOR CONTINUITY.USE J-39200-A MULTIMETER OR EQUIVALENTPage 18
SEALED SPLICE CRIMP MATRIX (one to one splice only)Part 089190Blue12089191Yellow0.50.8XX12XX35XXThe unsealed splice clips are designed to be crimped and soldered. Each clip may contain onlya certain combination of wires, expressed in area. Use the table below to determine which clipworks with your combination.Wire size.0220.350.50.81235Area - sq mm0.0510.3080.5490.8051.1771.9473.0194.756Splice clip P/NRecommended area in crimp18399064.00 - 10.85 sq mm52974281.35 - 3.55 sq mmENGLISH/METRIC GAUGE CONVERSION TABLEMETRIC SIZE (SQ MM)0.220.350.50.8123581319SAE SIZE (GAUGE)2422201816141210864Page 19
J-38125-D Essential Tool KitDescriptionPart No.J-NumberTerminal tray #1 (Delphi)12085267J-38125-TRAY1Terminal tray #2 (Delphi)12085266J-38125-TRAY2Terminal tray #3 (Delphi)12188910J-38125-TRAY3Terminal tray #4 (Delphi)12188911J-38125-TRAY4Terminal tray #5 (Delphi)12188912J-38125-TRAY5Terminal tray #6 (Sumitomo)N/AJ-38125-TRAY6Terminal tray #7 (Lear)N/AJ-38125-TRAY7Terminal tray #8 (Delphi)N/AJ-38125-TRAY8Terminal tray #9 (Yazaki)N/AJ-38125-TRAY9Terminal tray #10 (Yazaki)N/AJ-38125-TRAY10Terminal tray #11 (Yazaki)N/AJ-38125-TRAY11Terminal tray #12 (Yazaki)N/AJ-38125-TRAY12Terminal tray #13 (Yazaki)N/AJ-38125-TRAY13Terminal tray #14 (Yazaki)N/AJ-38125-TRAY14Terminal tray #15 (Yazaki)N/AJ-38125-TRAY15Terminal tray #16 (Lear)N/AJ-38125-TRAY16Terminal tray #17 (Lear)N/AJ-38125-TRAY17Terminal tray #18 (Delphi)N/AJ-38125-TRAY18Terminal tray #19 (Delphi)N/AJ-38125-TRAY19Terminal tray #20 (Delphi)N/AJ-38125-TRAY20Terminal tray #21 (AFL)N/AJ-38125-TRAY21Terminal tray #22 (Sumitomo)N/AJ-38125-TRAY22Terminal tray #23 (Delphi)N/AJ-38125-TRAY23Terminal tray SIRN/AJ-38125-SIRRelease Tool - Weather Pack - Yellow12014012-1J-38125-10ARelease Tool - Standard Large - Blue12094430J-38125-11ARelease Tool - Standard Small - Green12094429J-38125-12ARelease Tool - Micro Pack - Red12031876-1J-38125-13ARelease Tool - Micro .64 - 5-33Release Tool - .64 JAE - BlueN/AJ-38125-211Release Tool - Tyco 280 Male JPT - BlackN/AJ-38125-212Release Tool - GrayN/AJ-38125-213Release ToolN/AJ-38125-214Release Tool - Round Hook - TPA Removal Tool - Blue15313892J-38125-552Release Tool - Micro Pack 280,480 - Black15315247J-38125-553Release Tool - .64 MQS Tyco - GreenRelease Tool - Micro Pack 100W - GrayPage 20
J-38125-D Essential Tool Kit (Cont.)DescriptionPart No.J-NumberRelease Tool - Transmission Conn - White12152110J-38125-554Release Tool - 280 Tyco JP/Mini-Timer - Yellow12093624J-38125-556Release Tool - Tyco Mini-Timer - White12122378J-38125-557Release Tool - M/P 800 Maxi Fuse - J-38125-560N/AJ-38125-561Release Tool - Tyco Mini-Timer - Yellow12093647J-38125-556Crimper - 1 thru 512085270J-38125-6Crimper - 6 thru 8N/AJ-38125-641Crimper - A thru E12085271J-38125-7Crimper - F&G - Sealed Splice12085115J-38125-8Crimper - H thru KN/AJ-38125-642Crimper N, 9, PN/AJ-38125-643Crimper - W12125080J-38125-101Crimper - M15397700J-38125-64Ultra Torch12085116J-38125-5Cabinet (Holds 5 trays) 2 eachN/AJ-38125-610Tool TrayN/AJ-38125-615Reference GuideN/AJ-38125-620Pin ViseRelease Tool - Micro .64 Bosch - WhiteRelease Tool - Bosch BSK - WhiteAll components listed above are available from Kent-Moore. Please call (800) 345-2233 for orders.Page 21
Tray #1 Delphi AutomotiveP/N 12085267Part NumberDescriptionQuantity1839906Splice clip - unsealed252962516Pin grip female10297196256 series long male25297321659 series female252984172Ring - straight lock type202984375Ring - straight lock type255297428Splice clip - unsealed258911640Pac/on I female258917528Replaced with 8905087012004996Pac/on II female2512020320Pac/on I male2512020321Pac/on III female2512033816Pac/on I heavy duty male2512034037Printed circuit bow type2512048247Mic/P 100 female2512089189Splice & Seal sleeve - Salmon512089190Splice & Seal sleeve - Blue512089191Splice & Seal sleeve - Yellow512089507Printed circuit edgeboard2512089649Replaced with 1214644801212451556 series female2512124580W/P female sealed2512124582W/P male sealed2512129497M/P 280 series sealed male25Page 22
Tray #2 Delphi AutomotiveP/N 12085266Part NumberDescriptionQuantity12015870M/P 630 series female2512020116M/P 280 series male2512020120M/P 480 series male2512020126M/P 630 series male2512033820M/P 480 series male2512034046M/P 280 series female2512034047M/P 280 series male2512041351M/P 280 and W/P Cable seal - Tan2512045773M/P 150 series male sealed2512047581M/P 150 series male2512047767M/P 150 series female2512048074M/P 150 series female sealed2512048087M/P 150 Cable seal - Blu.2512048159M/P 280 series male sealed2512048441M/P 480 Cable seal - Wht.2512048451M/P 480 series female sealed2512066132Mic/P 100 series female sealed2512066214M/P 280 series female2512077411M/P 280 series female sealed2512084595M/P 480 series female2512089340M/P 150 series female pull to seat2512103881M/P 150 series female pull to seat2512124304M/P 480 series female2512129493M/P 280 series female sealed25Page 23
Tray #3 Delphi AutomotiveP/N 12188910Part NumberDescriptionQuantity12015869M/P 630 series female2512020758Mic/P 100 female2512040502Printed circuit edgeboard female2512048086M/P 150 Cable seal - Dk Red2512040511Printed circuit edgeboard female2512052456M/P 630 series female sealed2512059168M/P 150 Empty cavity plug - Dk Red2512064736M/P 630 series male sealed2512066272Printed circuit bow type pull to seat2512066493M/P 630 series male2512084590M/P 630 series female2512084596M/P 630 series female2512089040W/P pin male sealed2512089188W/P female sealed2512089660Replaced with 12146447012089678M/P 150 Cable seal - Wht.2512103114Mic/P 100 series female gold plated2512103325M/P 630 series female2512146447Mic/P 100 series female2512160551Mic/P 100W series male sealed2512160776Micro .64 female1012176387M/P 280 series female sealed1012191448M/P 480 series female sealed2512191811Replaced with 121918120Page 24
Tray #4 Delphi AutomotiveP/N 12188911Part NumberDescriptionQuantity12015828Replaced with 12015860012015858M/P 280 series female2512015860M/P 480 series female2512033821Replaced with 12015858012048450Replaced with 12048451012077413M/P 280 series female sealed2512084586M/P 280 series male2512103347Replaced with 12066214012103360Replaced with 12077939012110652M/P 280 series busbar female tangless1512110657M/P 280 series busbar female tangless2512110842M/P 280 female tangless2512110844M/P 280 series female tangless2512110845M/P 280 series female tangless sealed2512110846Replaced with 12110847012110847M/P 280 series female tangless sealed2512110853M/P 280 series female tangless sealed2512129409Replaced with 12110845012129424Replaced with 12110842012160643M/P 280 series busbar female2012160644M/P 280 series busbar female2015359541Micro .64 female (Gold)1015366021Cable seal - Wht.2515410621Micro .64 female (Gold) Bosch ECM W/Delphi Conn.10Page 25
Tray #5 Delphi AutomotiveP/N 12188912Part NumberDescriptionQuantity8905087Pac/on I female2512015823Replaced with 12034046012040993M/P 150 series male2512059894Replaced with 12047581012064971M/P 150 series female2512065915M/P 800 series female1012066638Lamp socket wedge base sealed2512084912Mic/P 100W series female sealed2512084913Mic/P 100W series female sealed1512089263Ring - lock type1012089290Replaced with 12103881012089496Ring - lock type1012092344M/P 280 series male ACT2512092345M/P 280 series male ACT2512110063M/P 480 series female ACT2512110064M/P 480 series male ACT2012124075M/P 150.2 series female pull to seat2512124076Replaced with 12124075012124471Lamp socket wedge base sealed2512129373Replaced with 12129484012186456M/P 280 series female ACT2512186457M/P 280 series female ACT2512186458Replaced with 12186457088988379Splice Seal - Green10Page 26
Tray #6 SumitomoPart NumberDescriptionQuantity7160-9465230 TS series cavity plug - Blk.7165-0347480 TS series cable seal - Dk. Grn.7165-0348280 cable seal - Gray7165-0349150 cable seal - Brn.7165-0356480 TS series cable seal - Dk. Blue7165-0395230 TS series cable seal - Dk. Grn.7165-0547.64 cable seal - Orn.7165-0796.64mm TS series cable seal - Orn.7165-0797.64mm TS series cavity plug - Gray7165-0815.64mm TS series cable seal - Dk. Brn.8100-0460150 TS series female sealed8100-0461150 TS series female sealed8100-0468480 TS series female sealed8100-0594150 TS series female sealed8100-1466.64 DL series female sealed8100-1467.64 DL series female sealed8100-1710100 DL series female8100-2493800 TS series female8100-2512100 DL series male8230-4040630 male208230-4282150 male208240-4140630 female208240-4422150 female20Page 27
Tray #7 LearPart NumberDescriptionQuantity1123343-2.64 Multi-Lock female251393364-1.64 GET female201393365-1.64 GET female20154718-3630 Positive Lock female25171631-2180 Econoseal Tab female20171661-2180 Econoseal Tab10172748-1180 empty cavity plug - Blk.25173630-7180 Multi-Lock female20173716-1100 MLC female25184030-1180 070 female25184095-1180 070 female25184139-1180 cable seal - Lt. Blu.25184140-1180 cable seal - Brn.25184141-1180 cable seal - Prp.251-968857-3280 MCP female sealed251-968859-3280 MCP female sealed202-927835-2480 SPT female sealed52-968037-4480 SPT female sealed5771016-HK200280 female20771416-HK200280 female20771816-HK200280 female20280756-4950 Fastin-On female10282224-1180 female sealed25282225-1180 Econoseal female sealed25Page 28
Tray #8 Delphi AutomotivePart NumberDescriptionQuantity12020156M/P 630 series female pull to seat2512033997M/P 630 series female pull to seat2512064734M/P 630 series male sealed1012065197Replaced with 12052172012084449Mic/P 100 series male2512177068280 Mini - Timer female1512177069280 Mini - Timer female2012191818Replaced with 12191819012191819GT 150 series female2515304701Replaced with 15304702015304711GT 280 series female2515304715Replaced with 15304716015304716GT 280 series female sealed2515304717GT 280 series female sealed2515304722GT 280 series male2515304724GT 280 series male2515304727Replaced with 15304728015304728GT 280 series male sealed2515304729GT 280 series male sealed2515304730Replaced with 15304731015304732GT 280 series male sealed2515305171GT 150 cavity plug Grn.2515305174Mic/P 064 female sealed1015326004GT 280 series female sealed15Page 29
Tray #9 YazakiPart NumberDescription7114-4100-08150 system male207114-4101-08150 system male157114-4102-08150 system male sealed157114-4103-08150 system male sealed157114-4110-02280 system male257114-4111-02280 system male257114-4112-02280 system male257114-4120-02630 system male257114-4121-02630 system male257114-4122-02630 system male257114-4150-02280 system male sealed257114-4151-02280 system male sealed257114-4152-02280 system male sealed207116-4100-08150 system female207116-4101-08150 system female157116-4102-08150 system female sealed157116-4103-08150 system female sealed157116-4110-02280 system female257116-4111-02280 system female257116-4112-02280 system female257116-4120-02630 system female207116-4150-02280 system female sealed257116-4151-02280 system female sealed257116-4152-02280 system female sealed25Page 30Quantity
Tray #10 YazakiPart NumberDescriptionQuantity7114-1470180 S-type male257114-1475180 S-type male257114-2875630 M-type male257114-2876630 M-type male257114-2877630 M-type male257114-4020230 090-II male257114-4021230 090-II male257114-4022230 090-II male257114-4140-02630 system male sealed257114-4141-02630 system male sealed257114-4142-02630 system male sealed257116-1470180 Y-type female257116-1473180 S-type female257116-1474180 S-type female257116-2875630 M-type female257116-2876630 M-type female257116-2877630 M-type female257116-3250950 L-type female107116-3251950 L-type female107116-4121-02630 system female207116-4122-02630 system female207116-4140-02630 system female sealed207116-4141-02630 system female sealed207116-4142-02630 system female sealed20Page 31
Tray #11 YazakiPart NumberDescriptionQuantity7114-1170220 type male257114-1238280 S-type male207114-1239280 S-type male257114-4025230 090-II male sealed257114-4026230 090-II male sealed257114-4027230 090-II male sealed257114-4031480 187-type male157114-4032480 187-type male207114-6041800 312-type male207114-6042800 312-type male207116-1180220 type female257116-1181220 type female257116-1342280 S-type female257116-1420220 female sealed257116-4020230 090-II female257116-4021230 090-II female257116-4022230 090-II female257116-4025230 090-II female sealed257116-4026230 090-II female sealed257116-4027230 090-II female sealed257116-4031480 187-type female257116-4032480 187-type female257116-6041800 312-type female257116-6042800 312-type female20Page 32
Tray #12 YazakiPart NumberDescriptionQuantity1 0800 444522280 SLK cable seal - Blu.252 2124 472200150 Female sealed107114-1467-02100 R-type male sealed257114-1468-02100 R-type male sealed257114-1471180 S-type male sealed257114-1472180 S-type male sealed257114-1680-08120 S-type male sealed257116-1343280 S-type female257116-1471180 S-type female sealed257116-1472180 S-type female sealed257116-1557-08280 D-type female sealed57116-1558-08280 D-type female sealed57116-1680-02120 S-type female sealed257116-1767-08100 R-type female sealed57116-1768-08100 R-type female sealed57116-2090600 C-type female257116-2092600 C-type female257116-2095600 C-type female257116-2640630 CN-type female257116-2640-02630 CN-type female257116-2641630 CN-type female257116-2641-02630 CN-type female257116-2642630 CN-type female257116-2642-02630 CN-type female25Page 33
Tray #13 YazakiPart NumberDescriptionQuantity7157-3646220 cable seal - Gry.257157-3852480 cable seal - Blk.257157-3891280 cable seal - Blk./Brn.257157-3920-40100 cable seal - Gry.257157-3950-80120 cable seal - Org./Blk.107157-3976-60100 cable seal - Lt. Grn./Brn.157157-3977-50100 cable seal - Pink/Brn.157157-7811-80180 cable seal - Org./Brn.257157-7812180 cable seal - Blk./Brn.207157-7935280 cable seal - Org./Blk.257158-3006-90230 cable seal - Blu.157158-3007-10230 cable seal - Gry.157158-3008-80230 cable seal - Brn.157158-3030-50150 cable seal - Red257158-3031-90150 cable seal - Blu.257158-3081-50630 cable seal - Red257158-3082-90630 cable seal - Blu.257158-3083630 cable seal - Blk.257158-3111-60280 cable seal - Grn.257158-3112-70280 cable seal - Lt. Org.257158-3113-40280 cable seal - Wht.20Page 34
Tray #14 YazakiPart NumberDescriptionQuantity7114-1050280 PA-type male257114-1257-02100 050-type male257114-3250950 L-type male107114-3251950 L-type male107114-4036480 187-type male sealed207114-4037480 187-type male sealed207114-4060-02100 050-type male sealed257114-4231-08.64 040-lll type male257114-4720-02.64 system male257114-4721-02.64 system male257114-6046800 312-type male sealed207114-6047800 312-type male sealed207116-1257-02100 050-type female257116-4035500 187-type female257116-4036480 187-type female257116-4037480 187-type female257116-4060-02050-type female sealed257116-4231-08.64 040-lll type female257116-4720-02.64 040-lll typ
DEFINITION OF TERMS Cable Another term for a bulk length of wire. Connector The molded plastic part which houses one or more terminals. Connector Position Assurance A lock designed to retain connectors when mated. Core Conductive portion of a wire, covered with insulation of various types - usually PVC or polyethylene. Crimp & Seal Splice Sleeve A crimp only splice with an integral heat shrink .
