YESC Kaizen 0.64 System Sealed (Cable Seal) and 28P
Contents
1. 65 05 065018 14 ON 883 3 8701 84 inued ion Cont t inal Cont 5 3 2 Crimp Tool Geometry Continued ing Spec imp inal Cr Term 5 inued 64mm Female Term 0 3 5 1 viva 16 NSTS30 HI cuim 5 AZMAN A ASOT AEF orto LOT 1 9901 9891 6 15 8401 SES 2278 770 Bs GE 0 9106 KZZOM NEN 01870 6 914 8 8 uv 4 098 022 91120 AN 000 xX 1 130 EC Vv ON dJ 38 1 11 H31N39 Y 40 200 MIHLIA 38 658 Ai 19 H1N3923 Z APA ALARA a da n d Mander Amin qan A4 CY aa ayama 33HYH9 ARIS M T Y T N N 31 I S3LON 90006002 8 CI9 4176 6642 2 So MOY TREES CI lt BR gt 0204 94 ON 931 C 318 39144 _ 8 E inued ion Cont t Ica inal Cont ing Spec imp inal Cr Term 5 inued 64mm Female Term 0 3 5 AHOLOV4 NH d11 93 DIVZVA ETT EES Tom 7 80 07 NE 701 T BAR AS 55 15 ETET Ove 0 9 08 911508 04815 98 0111 5 o De aaa 3817 N31N39 V 30 20 70 MALIA 38 0 AINSI C 0 0 BEEN S310N T C OWEZO2. Jdil Da TEET Sid oOvg lV Ova 0 91Z duvawvis OM 081 8 17 H31N30 Y dO 20 0 Vi ooo 15111118538 5 111018183003 8 M338YH ATLH I IS 80115016081 ON d1 Q lt SILON gt koli z0 0 08 J3 226 43 E HONEY Ha ER Ci 81 GE Cha TEST BS A AWF TAA PIA ww 960 8 M E Cx ib ASAA 57 HU33WVH3 OL 1 FEA amp Wc XA s e me az C amp YAYAY AZA 8 1060 2 9 GST ON 831 378401714 inued ion Cont t Ica inal Cont ing Spec imp inal Cr Term 5 inued 5 3 2 Crimp Tool Geometry Continued 64mm Female Term 0 3 5 IHSVHVAVLT 11 600 89 SH Rai 030939 BONES H 57 P ED Vd VIN SLY HIT 00802 512082966 0 2 82 gt 7 517 ENEE 15 Dax WEE TT EH Au rl se Ma l OI 508 08 LS BS 01 71 8430 386 V ONI 8 en t ANI 83 39 V 30 20 0 NIHLIM 38 GINOHS H33HYH3 A iHBITS 89011101081 ON 410 S3L N MOMYZO 0 090 10 4226 6232 E 182 TRY 1 cai wb ED ON IUS HAYHO
3. If the TPA as improperly inserted by force replace it with new parts Unacceptable Terminal incomplete insertion Figure 7 2B 7 Connector Assembly Continued 7 3 Wire Shield Assembly 1 Move the wire shield in the direction of the arrow shown in Figure 7 3A until an audible click is heard Confirm that both top and bottom locks shown in Figure 7 3B have engaged The wire shield can be routed as shown or 180 deg from the direction shown 2 Once the wire shield is in place a tie strap can be used to secure the wires as shown in Figure 7 3C Figure 7 3A Wire Shield Locking Tabs Figure 7 3B 257 VVire Shield Locks Figure 7 3C Tie Strap VVire Bundle ing Tool for front holder release IC Connector Servi 8 1 Use the des 8 Removal tool 1 35 Figure 8 1A igure 8 1A Part name ignated tool F I removal tools Ina 2 Term 8 see Figure 8 2A Ina ignated tool for 6 3mm termi Use the des gure 8 2A F 8 Connector Servicing Continued 8 2 Terminal Removal Tools Continued Tools necessary to service the 0 64 Terminals are currently available in the GM Service Kit a Terminal Removal Tools 3 Options i GM identified removal tool in GM service kit Part Number J 38125 215 ii Other removal tool with the identified tip geometry Completely remove TPA and use any small size pick to service terminal i
4. Confirm that the insulation barrel remains within the dimension Y Wire seal Scratch or Cut Unacceptable 4 7 No scratch or cut is acceptable 5 Terminal Crimping Specification Continued 5 3 0 64mm Female Terminal continued 5 3 4 Crimped Product Appearance Evaluation Continued Attribute Evaluation Item Terminal Body Deformation Step on the conductor grip 5 Terminal Crimping Specification Continued 5 3 0 64mm Female Terminal Continued 5 3 4 Crimped Product Appearance Evaluation Continued Evaluation Item Terminal Body Deformation 3 P 1 l TI Terminals vvith any deformation detected by visual inspection are unacceptable nappropriate Terminal Feeding Unacceptable Box Defomation Normal Condition Unacceptable Deformation of the area A 6 Handling of Terminated Wire Leads To prevent damage to the terminals on the crimped wire leads the following precautions are recommended a When terminated wires are bundled the number of wires bundled together should be less than 100 Bundles should be bound with elastic bands to prevent separation If more than 100 wires are bundled together they may become entangled with each other deformation or damage may occur or handling may become difficult due to the weight b Do not tap on the tips of the terminals when they are bundled c The terminated wires should be covered with a plastic bag
5. E Figure 10 1A Terminal Spring Test Probe 10 Wire Harness Assembly Continued 10 2 Precautions During Continuity Detection 0 64mm Terminal 1 As shown in the Figures 10 2A and 10 2B below there is a space where a test probe can be inserted The continuity inspection shall be conducted by inserting the probe in this space 2 Parts with visible damage or deformation should be replaced without regard for the severity of the non conformance Test probes Sees Figure 10 2A Terminal Spring Test Probe by 2 Md f 1 0 64mm Cavity Detail Figure 10 2B 11 Wire Harness Packaging Shipping As with many plastic parts the connector may be damaged deformed if excessive external forces are applied to the connector during transportation and or storage To assure damage does not occur it is recommended that the following items be considered when determining the Wire Harness packaging specification 1 When layering the individual Wire Harnesses in the shipping carton it is a recommended that corrugate layer dividers vertical dividers internal supports and or partitions be used to assure the weight of the Wire Harnesses is equally distributed Corrugate Dividers Horizontal Corrugate Dividers Vertical Corrugate Dividers 2 Junction block relay box protectors brackets and any heavy and or bulky item must be placed on the bottom of the car
6. 18111011131 PALIS 10139100000 11121549 CO 000 TXD DMV 077 XL 0 Geld mt 80 01123 10123111500 1199 O dM U9ZIEX 0 0 911 HEZEX XL OMV 81 8011811 ULL ew TEUTUH L 10123111100 VIDEO 0 dM U ZTEY 6020 20 91 TL HEZEX X 073 XL OC CC 0760 ed HEZE A ON HEA HEZEX 1511 SU 101231103 NON 41 4929 0 Attached Sheet 2 m ARID 10102 TXL DMV OI TXS DMV CT YI TXL DAV CI xoeIg 10100 TXD OMY 1 DAV PI n g 10 00 TXD DAV OC 37 0 ee TXL OC JON od ZIS 0 8n q 1 8 10123111100 PALIS 11131546 CO 0006 38 70139000 PALIS urojs S 9 0 0 69 10129uu0 PALIS 1112154 9 Ot IZ ea ITM 10 49000 PALIS 11131545 9 06 2808 851 695 SILA 101231115100 PALIS 11121545 CO 00 714 sureu ued HEZE A ON ued HEZEX Attached Sheet 3 AWARD 1012300 PALIS 11121545 FOO pow 10102 06 06 81 1995 IIM 10129uuo payeas 11121549 79 0 UZY 0 1 TXD DAV OC TXL DAV 81 A210 18 0190 ISNI 10103 TXL OC 22 S ITM 1013310000 PALI 1112155 90 uozie v O8 POSE 8STL aureu ued HEZEX Attached Sheet 4 Note E R e e aa aa 2 2 Q Cmn Yazaki Part No Yazaki part name 7283 9504 30 28P 0 64x24
7. 6 3x4 ABS Hybrid Sealed Connector Female 7134 4489 30 28P 0 64x24 6 3x4 ABS Hybrid Sealed Connector Wire Shield 7134 8582 30 28P 0 64x24 6 3x4 ABS Hybrid Sealed Connector Wire Shield Large
8. GM identified tool Part No J 38125 215 ii Required tip geometry Tool thickness 1 10mm 8 Connector Servicing Continued 8 3 Female Front Holder Release 1 Put a hook tool in one of the areas marked with a teardrop see Figure 8 3A 2 Pull the hook tool in the direction of arrow 1 see Figure 8 3B 3 Move the hook tool to the other area marked with a tear drop and repeat step 2 4 Confirm that the TPA is in pre set position 5 For complete TPA removal put the hook tool in the slot in the top middle of the TPA as shown in Figure 8 3C and pull in the direction of arrow 2 Move hook tool to the bottom slot and pull in the direction of arrow 2 again Repeat until the TPA is removed TEARDROP Figure 8 3A Nut Figure 8 3C Precautions Care shall be taken not to deform the housing Heplace any damaged or deformed components with new ones 8 Connector Servicing Continued 8 4 Female Terminal Removal 6 3mm Female Terminal 1 Confirm the TPA is in the pre set position 2 Place the terminal removal tool see 8 2 along the terminal removal tool guide surface TPA for 6 3mm terminal 3 Push the wire in the direction of arrow 1 and insert the tool straight in the direction of arrow 2 as shown in Figure 8 4A 4 Rotate the tool up in the direction of arrow 3 to release the housing lance and pull the wire lightly in the direction of arrow 4 to remove
9. If ultrasonic welding is used in the termination process of the wire lead it is the user s responsibility to assure no adverse affects result to the terminal and or connector performance 4 Wires which will be taped should be of similar length Taping of leads with different lengths could result in concentration of force on the shortest wire resulting in the potential for terminal pull out Pulled Wire Unacceptable Slack Wire Unacceptable 10 Wire Harness Assembly Continued 10 1 Precautions During Continuity Detection 6 3mm Terminal 1 Jigs used for wire routing and or continuity inspection should be of equal precision to that of the mating component Use of fixtures with greater tolerance variability than the mating component could result in damage to the connector and or terminal 2 Spring loaded pogo pins should be used for continuity detection Recommended spring strength 0 21 at 1mm deflection 3 As shown in the Figures 10 1A and 10 1B below there is a space where a test probe can be inserted The continuity inspection shall be conducted by inserting the probe in this space 4 Parts with visible damage or deformation should be replaced without regard for the severity of the non conformance YY 75 IN ES 7 ve 222 ZC gt gt 7 H H bit Sal 1811 77 probes Es ii zs La UL A Dee M RES
10. 0 09 C10 47 6 63 2 E Rocky fa CN 1 2 ARI D o Via 2 4 Q favi E C 7 _S ok ch WS IST u 0 S Mw Siem 9 d AADA MAMA D Bg ELS KMD R Be 000070 17 ON 8 331 20 M3ARYI or Cred 10 OL fek b 37813550 11 5 Terminal Crimping Specification Continued 5 3 0 64mm Female Terminal Continued 5 3 3 Measurement method for crimp height and width Measure the center of crimp height and wiath of both conductor grip and insulation grip CONDUCTOR GRIP C W INSULATION GRIP C W INSULATION GRIP C H CONDUCTOR GRIP C H Precaution Do not measure C H at the position where there is a difference in level C H Crimp height C W Crimp width Conductor grip Use a micrometer and measure as shown in the illustration below CN C H Insulation grip Use a micrometer and measure as shown in the illustration below 5 Terminal Crimping Specification Continued 5 3 0 64mm Female Terminal Continued 5 3 4 Crimped Product Appearance Evaluation Attribute Evaluation Item Wire Improper uneven cutting of conductor 1 OK 2 NG 3 NG and or insulation Proper Cut Improper Cut Conductor Diagonal cut conductor Improper Cut Conductor Cut Strand s Improper Cut Conductor Damaged Strand s Improper Cut Insulation Diagonal Cut Insulation Improper Cut Insulation Damaged Insulation
11. 0 30 0 80 Bend Down 2 degrees max Cut off Tab 0 30 max Roll Twist 1 degree max Other All Dimensions mm 5 3 2 Crimp Tool Geometry The crimp tool geometry shown on the following pages is representative of the tooling used for determination of the recommended crimp specifications shown in Section 5 1 inued Cont ion 5 3 0 64mm Female Terminal Continued ica ing Spec imp inal Cr Term 5 inued imp Tool Geometry Cont 5 3 2 Cr 1 x 4 Dee j AUOLOVS WHVEIVH AS 912 31 8799 20 28990 UENO i lun S0 1000 1 4 1 38 VAb4 A FL Ad OLE M Y 84606 911 0840449 02 5 X T1v130 GC ONT 4408 AAAA 831439 V 30 20 0 H HL M 38 810085 A112181N3223 C Pee TEE d 338YH2 111849135 NOTIVOIONI ON 3111 minnsta Eech SALON aio ila eet e amp eWfizo 0 08 12 40 642 2 1 T MB 4415 GR 21018337870 q06026 9112 ON 1 1 8831 37188917448 BER 38 506 2 inued ion Cont inued 1 inal Cont ca 5 3 2 Crimp Tool Geometry Continued ing Spec imp I Cr 0 64mm Female Term Termina 5 3 5 2276786 ZZ 6 y0 3 O P E
12. 1938815381 03393H9 aLT 00 SLUYd 4 0 1000 TEREDO 2 NOILV 45 1844 01 027 918068 BEY 014 06 911 48504 5 BB ONL 0 agama lt s EE AR m x iviag ERC V ONT 8 2242 JQNET M31N32 V dO 20 D zl PP er m s NIHLIM 38 0300845 7 Ama n A MM 133NYH9 11 9 115 NOLIVOIONI OH 414 gt 5 317 lt sol EO 0 29 12 2 464 2 ko oy HS CT ta J 0460 2 9 ON 8831 adv inued Cont inued ion 5 3 2 Crimp Tool Geometry Continued icat if inal Cont ing Spec imp inal Cr Term 5 64mm Female Term 0 3 5 22 286 RECETTE ETC 2221 WBS AB 0194 NOLIVAIVAR AMOLOV4 VURSVHM sT ne 1 4711 s 0 S Q3 1 dL S HNe 1 Navid 830182301 03304880103 0 aio 88 8 8 s Ot E Ot j T 4 L AZAR KI EOF 2 0 j tor 1 LIII H ISEE 318709 1 gt 3 NH 122 6 0 AR 7 Te E
13. 2 Precautions during Continuity Detection 11 Wire Harness Packaging Shipping EE 45 46 12 Connector Mating Removal 47 48 12 1 Connector Mating 12 2 Connector Removal Components part list o Attached Sheets 1 to 4 1 Product Specification Reference Housing F l Terminal F 0 64 EREMO Connector PBT 1596 GF Fem Terminal 0 64 Copper Alloy Sn Plate Fem Terminal 6 3 Copper Alloy Sn Plate 40C 125C 145C max temp USCAR Class 3 Operating Temperature Range Sealed Current Capacity See Current Rating Curve Voltage Drop 20milli ohms max crimp to crimp Isolation Resistance 500VDC 20M ohms Dielectric Resistance 1000VAC 1 minute Connector to Connector Retention Current Rating Curve Reference Only Data based on single circuit open air evaluation and should be used for reference purposes only Appropriate de rating should be considered based on specific application requirements 60 pe e TNT 1 EN E SEN Pe 00 h ee L G Be bebes KP Kr w al k ay 1 EH 50 l Es t 45 60 d d I i 202515 E d 45 iee EA
14. 5 Terminal Crimping Specification Continued 5 3 0 64mm female Terminal Continued 5 3 4 Crimped Product Appearance Evaluation Continued Attribute Evaluation Hem Conductor Normal crimping Crimp condition Symmetrical with this line standard E SEC and Twist Unacceptable o Burr should not protrude below this line Conductor fray Terminal with frayed conductor shall not be used 5 Terminal Crimping Specification Continued 5 3 0 64mm Female Terminal Continued 5 3 4 Crimped Product Appearance Evaluation Continued Attribute Evaluation Item Conductor Bell mouth Crimp Top length of conductor Insulation crimped by Conductor barrel 5 Terminal Crimping Specification Continued 5 3 0 64mm Female Terminal Continued 5 3 4 Crimped Product Appearance Evaluation Continued n Confirm that the wire seal lip remains in the dimension Z between the wire barrel and the insulation Insulation Normal crimping Grip condition Wire seal disengage from insulation barrel Cutting tab Confirm that the area A is free of any flaws or cuts 5 Terminal Crimping Specification Continued 5 3 0 64mm Female Terminal Continued 5 3 4 Crimped Product Appearance Evaluation Continued Attribute Evaluation Item Insulation Grip Unacceptable Wire Seal Pinched by Insulation Barrel Unacceptable Wire Seal Position
15. Crimp Height and Width a A stand mounted micrometer should be used for evaluation of the CH and CW dimensions on terminated product b Recommended micrometer anvil and spindles are shown below S A 0 5 Parallel Spindle A Anvil Spindle B Dimensions Conductor Crimp Height Spindle CG TX Q2 gt Spindle A Dimensions Spindle B Conductor Crimp Width Insulation Crimp Height Insulation Crimp Width 5 Terminal Crimping Specification Continued 5 2 6 3mm Female Terminal 5 2 1 Crimping Standards The below crimp specifications have been determined based on Yazaki defined Punch Anvil Tooling Geometries These specifications should be considered reference in that actual performance results may vary based on specific application set up and or processing parameters The user of this product is responsible for 1 Validation of crimp performance 2 Establishment of crimping specifications for wire sizes not listed below Crimping information based on SAE TXL wire EECH Terminal Part i Number Wire Size Cond Wire O D CH CW CH CW Applicable Seal Area 0 05 4 0 1 0 1 0 1 7116 4140 02 20awg 0 508 1 3 7158 3081 50 07 7 0 5812 18850 0 760 4 7 0 8sqmm 0 83 16awg 1 12 1 0sqmm 1 267 7116 4141 02 14awg 1 85 2 10 3 0 1 8 7 158 3082 90 2 0sqmm 2 006 7116 4142 02 12awg 2 91 7158 3083 3 0sqmm 3 163 71
16. the terminal from the cavity see Figure 8 4B Terminal Removal Tool eS ee T a D 1 I DE UT hh Q 2 M Arr daf Ah s 2 Front Holder in Pre set lnc amp 4 YAXA un i ax NNI HH Fm Or s s N ECK e 3 PESE m n ware 3 Pull Terminal After Lance is Deflected Figure 8 4B 8 Connector Servicing Continued 8 4 Female Terminal Removal Continued 0 64mm Female Terminal 1 Place the terminal removal tool along the terminal removal tool guide surface TPA for 0 64mm terminal 2 Push the wire in the direction of arrow 1 similar to Figure 8 4A and insert the tool straight in the direction of arrow 2 as shown in Figure 8 4C below to release the housing lance 3 Holding it in this condition pull the wire lightly to the direction of the arrow 4 and remove the terminal from the cavity similar to Figure 8 4B 4 Holding it in this condition pull the wire lightly to the direction of the arrovv 4 and remove the terminal from the cavity similar to Figure 8 4B 2 m 2 Figure 8 4C lt Precautions gt The terminal removal operation should be performed by trained personnel only Probing of the terminal cavity by technicians not familiar with the removal process could result in damage to the terminal and or conn
17. 16 4143 02 10awg 4 65 3 8 4 05 6 7 7158 3084 40 5 0sqmm 5 066 VVire Strip Length 5 0 5 Bell mouth Front 0 00 0 30 Bend Up 3 degrees max Bell Mouth Rear 0 30 0 80 Bend Down 1 degrees max Cut off Tab 0 30 max Roll Twist 1 degree max Other All Dimensions mm Please reference the Handling Manual for YESC 6 3 System Sealed YPES 15 300 for information regarding the 6 3mm Female Terminal 5 Terminal Crimping Specification Continued 5 3 0 64mm Female Terminal 5 3 1 Crimping Standards The below crimp specifications have been determined based on Yazaki defined Punch Anvil Tooling Geometries These specifications should be considered reference in that actual performance results may vary based on specific application set up and or processing parameters The user of this product is responsible for 1 Validation of crimp performance 2 Establishment of crimping specifications for wire sizes not listed below Terminal Part Nurnber Wire Size Cond Wire O D CH CW CH CW Applicable Seal Area 0 05 0 05 0 05 0 15 7116 3703 02 22awg 0 324 1 50 1 90 1 40 7158 3504 80 0 35sqmm 0 3643 20awg 0 508 1 50 1 90 1 40 0 5sqmm 0 5812 7116 3703 02 20awg 0 508 1 90 2 40 1 40 7158 3505 40 0 5sqmm 0 5812 7116 3704 02 18awg 0 760 1 90 2 40 1 60 2 75 7158 3505 40 07 0 83 Wire Strip Length 5 75 6 25 Bell mouth Front 0 00 0 30 Bend Up 2 degrees max Bell Mouth Rear
18. 3 3 Female Connector Assembly 4 Lever 2 0 64mm Terminal Lance 3 1 Locking Beak 3 2 Lock Sevicing Pad 1 Ww a RS 3 Housing Lock 2 2 Service Operation Tab ao SAAN A 2 1 Locking Beak Lr 1 1 Lock inc Beak AN de 1 2 Service Operation Tab 5 1 8 0 64mn Terminal Cavity LN 5 Front Hol der GEE SAN IBM Wee ee SSS 7 6 am Terminal Cavit Interface Seal 1 6 3mn Terminal Lance Feature name Function 6 3mm a 1 Lock w th fe female terminal Lance u 0 64mm j Lock w ith female 5 2 Lance Service Operation Tab Beak releasing operation _ Lock lever in place Ed ee 77575533757771 Release 09 lock EG Or Belen of terminal incomplete insertion O NOOO DO R ENARA N a SNNN FIN p me EE EE Accommodate the 6 3mm terminal ENSE APP A ee TON ANNE NT AAG A PRON ORRIN AAT 2 Accommodate the 0 64mm terminal 4 Handling of Components 4 1 Receiving Inspection Items The following items should be inspected upon receipt of the parts 1 Terminal a Appropriate Part Number b Parts are free of foreign objects cracks deformation burr rust unclean parts peeling or any other apparent abnormalitie
19. S T 2 ec db in Te 25 s t E ege 20 S EH WE Ld 1 1 i 15 30 Dier Ze He ei t 1 10 55 T T O ame 0j P gt p 1 ts zb 200 M EE 0 9 o 5 10 15 2 25 30 35 5 50 9 1 2 3 4 5 6 7 8 9 10 n 12 13 14 15 6 3mm Terminal System 0 64mm Terminal System Current ampa 2 Associated Components 2 1 Female Connector Sealed Wire Shield Optional 0 64mm Female Terminal 6 3mm Female Terminal Interface Seal Front Holder TPA 3 Components Shape and Function 3 1 6 3mm Female Terminal 7 4 Conductor Grip 5 Insulation Grip D 3 Stabilizer 2 Terminal Locking Point 7 Wire Seal 1 Spring 6 Contact Carrier Contact w ith male terminal Terminal Locking point Lock w ith female housing Prevent improper terminal insertion to housing w rong orientation Conductor Grip Conductor crimping insulation grip insulation crimping Contact carrier Joint of chained terminal Wire Seal Sealing betw een w ire and housing 3 Components Shape and Function Continued 3 2 0 64mm Female Terminal 2 Terminal Locking Point 3 Conductor 4 Insulation Grip 5 Wire Seal Feature Name Function 3 Components Shape and Function Continued
20. YESC Kaizen 0 64 System Sealed Cable Seal and 28P ABS Connector User s Manual Disclaimer The information contained in the manual is for reference purpose only is subject to change without notice and is not guaranteed by Yazaki Corporation Yazaki North America Inc Yazaki Europe Limited or any other Yazaki group company collectively referred to as Yazaki Yazaki makes no warranty as to the completeness or accuracy of the information contained herein and is not responsible for any typographical or printing errors The current specifications for individual products should be obtained by potential customers in connection with placing orders for products with Yazaki The customer among other matters is solely responsible for determining the fitness or suitability of any product of Yazaki for the purpose intended by the customer and for all design and related matters Yazaki makes no warranty expressed or implied with respect to any product referred to in this document except such express warranty If any as may be specifically agreed to by Yazaki in written agreement signed and delivered by an authorized representative of Yazaki for the sale of such product and any such express warranty shall be the sole and exclusive liability of Yazaki Yazaki makes no other warranty Whether express implied statutory or otherwise including but not limited to any warranty of mechantability or fitness for any particular use purpose or other
21. ade reels should be handled with care to prevent damage Packaging configuration should prevent the impact on the components during transportation Care shall be taken not to deform or damage the components during packing Care should be taken to avoid any harsh impact by dropping b Storage Terminals reels should be stored in the box in which they were shipped Specifically parts should be protected from water oil dust and poisonous gas Do not store in an unprotected condition Terminals reels should be stored indoors away from direct sunlight Terminals reels should be stored in an area void of high temperature and humidity 2 Female sub assembly including interface seal TPA matte seal matte seal cover and lever wire seal cavity plug and wire shield a Transportation Packaging configuration should prevent the impact on the components during transportation Care shall be taken not to deform or damage the components during packing Care should be taken to avoid any harsh impact by dropping b Storage Parts should be stored in the box or the plastic bag in which they were shipped Specifically parts should be protected from water oil dust and poisonous gas Do not store in an unprotected condition Pars should be indoors away from direct sunlight Parts should be stored in an area void of high temperature and humidity 5 Terminal Crimping Specification 5 1 Measurement Equipment for
22. e rear end of wire seal is inserted into the cavity aa aae eve 105000 RERUM Per aaperrrrerrrrrrrrrvrvvrrrrrrrepsrv Figure 7 18 7 Connector Assembly 7 1 Female Terminal Installation to Connector Continued Note The 0 64 terminal has a cable seal which consists of two sealing ribs followed by a skirt to prevent water from pooling on the back of the seal While the skirt may protrude from the back of the cavity both sealing ribs must be in contact with the sealing surface of the cavity as shown in Figure 7 1B below Both Sealing ribs must be In contact with cavity wall ur ATE MAAS E LO Figure 7 8 7 Connector Assembly Continued 7 2 Female TPA full lock operation 1 After terminal insertion push the front holder in the direction of arrow 1 shown in Figure 7 2A below 2 Confirm that the TPA is securely locked Figure 7 2A Care shall be taken not to deform the housing Replace any damaged or deformed housing with a new one If the TPA cannot be fully locked to the housing one of the following conditions exists terminal is not fully inserted into the cavity Terminal incomplete insertion See figure 7 2b The terminal is inserted in the wrong orientation Terminal improper insertion
23. ector When the terminal cannot be removed easily repeat the above operation for terminal removal Insert the removal tool straight and do not push too much This may cause damage of the lance Care shall be taken not to deform component parts Replace any damaged or deformed component parts with new ones 8 Connector Servicing Continued 8 5 Wire Shield Servicing 1 Insert a service tool such as a small screwdriver into the service access window shown in Figure 8 5A 2 Push tool between wire shield lock and the lock on the connector as shown in Figure 8 5B until wire shield lock clears the ramp on the connector 3 Repeat on second wire shield lock see Figure 8 5C until shield can be pulled off Wire Shield Service Access Figure 8 5B Figure 8 5C 9 Unused Cavity Precautions 9 1 Dummy Plug Insertion and Removal 1 Insert a dummy plug into every cavity in which a terminal will not be inserted Acceptable Unacceptable 3 Dummy plug removal Pull the dummy plug out from the cavity using fingers or a pair of pliers 10 Wire Harness Assembly 10 1 Precautions during W H Assembly 1 Avoid tangling the leads which could cause the terminals to become deformed and or damaged 2 Cut Leads of inadequate length should be discarded rather than forced into the connector Stretching of the circuit could result in wire strand breakage and or housing terminal damage 3
24. s c Parts display no apparent discoloration and or oxidation Entangled or loosening terminals from reel Q 2 Other Associated Parts a Appropriate Part Number b Parts are free of foreign objects cracks deformation or other apparent abnormalities sink marks short shots etc 4 Handling of Components Continued 4 2 Transportation Storage Handling Precautions The following recommendations should be followed to avoid potential deformation or damage of the product at the W H assembly plant 1 Terminal Specific a Partially used terminal reels should have the carrier strip secured to prevent loosening unwinding or entanglement of the terminal product Utilization of a binding wire or some other form of stopper which would perform a similar function is recommended Binding Wire Binding Wire 4 Handling of Components Continued 4 2 Transportation Storage Handling Precautions Continued b Terminal reels should be handled stored in such a manner that damage to the terminal product is avoided See below illustration Parts wound on paper cardboard reels may require additional care Recommended Practice Reel Maximum recommended stack height 2 reels Poor Practice Reels stacked Vertical storage not recommended not recommended 4 Handling of Components continued 4 2 Transportation Storage Handling Precautions Continued a Transportation Paper m
25. to protect them from dust d Wire bundles should be bound with elastic bands to prevent separation and potential entanglement of terminals e During transportation and storage use a protective cover over the plastic bag to provide further protection until right before insertion into the housing Immediate insertion of the terminated wire into the housing is strongly recommended because it can be easily deformed or damaged f The terminated wires should be transported by a wire hanging stand or a covered container g Do not throw the terminated wires during transportation ire Leads Continued nated W ing of Term Handl 6 Figure A Recommended Crimped Wire Lead Handling Illustration Additional Protective Cover Plastic Bag Recommended ire W Hanging Stand Short Wire Leads Long Wire Leads 7 Connector Assembly 7 1 Female Terminal Installation to Connector 1 Confirm the TPA is in the pre set position f the TPA is not in the pre set condition move the TPA to pre set position before terminal insertion see 8 3 2 Confirm there is no deformation or damage to the wire seals or terminals 3 Place the terminal and the housing as shown in Figure 7 1A below Insert the terminal into the housing An audible clicking sound indicates that the terminal is fully locked to the housing 4 Pull the wire lightly to confirm a secure lock 5 Confirm that th
26. ton or the divider to prevent weight of such item from being applied to the connector as shown below Heavier Harness Component Unacceptable Connector Practice Bottom of Layer Corrugate Connector P Heavier Harness Component Acceptable Practice Bottom of Layer Corrugate 11 Wire Harness Packaging Shipping Continued 3 The connectors should be positioned to the outside or in the center of the W H bundie to prevent the weight of the harness from being transferred to the connector Ex Connectors in Ex Connectors outside center of W H bundle of W H bundle 5 Kee geg TIL 4 The W H bundle size should be compatible with the shipping carton to prevent shifting of the W H during transportation and or storage 5 If the connector housing is taped back on the wire harness bundle assure that the housing lock or other flexible member of the connector is positioned away from the wire harness bundle WIRE BUNDL TAPE HOUSING LOCK Unacceptable HOUSING Acceptable 6 Extra care must be taken to prevent wire harnesses tangling which may cause damage to the connector when the wire harness is removed from the carton at the vehicle assembly 7 After transportation or storage the connector must be checked for damages 12 Connector Mating Removal 12 1 Connector Mating 1 Confirm that the TPA is in full lock position 2 In the orientation shown in the Figure 12 1A belo
27. w push the female connector in the direction of arrow 1 until p is felt click is heard connector will be in pre set position shown in Figure 12 1B below 3 Pull the lever in the direction of arrow 2 shown in Figure 12 1C until lever clicks into the fully mated position shown in Figure 12 1D Housing Lock ABS Interface Figure 12 1A Lever pre set position Final lever position 30 Position Reference Pre set Position Figure 12 1C Figure 12 1B Click Fully Mated Position Figure 12 1D 12 Connector Mating Removal 12 2 Connector Removal 1 Release the housing lock by pushing the operation pad of the housing lock in the direction of arrow 1 see figure 12 2A 2 With the lock deflected push the lever in the direction of arrow 2 see Figure 12 2B until connector is back in the pre set position 3 Rotate the female connector slightly in the direction of arrow 3 then pull the female connector from the interface in the direction of arrow 4 see Figure 12 2C Figure 12 2A Pre set Position Figure 12 2B Figure 12 2C Attached Sheet 1 Sunefd ULL a UU3H EUTULIO L PALIS 1012311110 WASAS CO 0 714 1 XL OAV OT Sunefd ULL 2 12111111131 2321736 1012313150 23155 CO 200521 9174 X DAV CT TXL DMV CI sume q UL IEW 18111111121 PALAS 1013211150 11121549 CO 0011719 TXD PI TXL sumed UL
28. wise with respect to such products Table of Contents 1 Product Specific AN ON ET 3 2 Associated COMPONENTS EE 4 2 1 Female Connector Seated 3 mpon nis Shape and F nclion tnt bei asa yaya O T 3 1 6 3mm Female Terminal 3 2 0 64 Female Terminal 3 3 Female Connector Assembly 4 Handling of Components a ONE 8 11 4 1 Receiving Inspection Items 4 2 Transportation Storage Handling Precautions 5 Terminal Crimping Specification ands a ay alyans s 12 28 5 1 Measurement Equipment for crimp height and vvidth 5 2 6 3mm Female Terminal 5 2 1 Crimping Standards 5 3 0 64mm Female Terminal 5 3 1 Crimping Standards 5 3 2 Crimp Tool Geometry 0 64mm 5 3 3 Measurement method for crimp height and width 5 3 4 Crimped Product Appearance Evaluation 6 Handling of Terminated Wire Leads EEN EE um 9 30 7 CONNEC ele EENEG 7 1 Female Terminal Installation to Connector 7 2 Female Front Holder TPA full lock operation 7 3 Wire Shield Assembly B Connector SERVICING En 8 1 Tool for front hoider release 8 2 Terminal removal tools 8 3 Female Front Holder Release 8 4 Female Terminal Removal 8 5 Wire Shield Servicing 9 Unused Cavity Precautions 828 m 41 9 1 Dummy Plug Insertion amp Removal 10 Wire Harness Assembiy 1 1 1 100000 42 44 10 1 Precautions during W H Assembly 10
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