Harley Davidson 2013 Sportster Models. Service Manual — page 32
A.10
DELPHI MICRO 64 SEALED CONNECTOR
DELPHI MICRO 64 SEALED CONNECTOR
REPAIR
TOOL NAME
PART NUMBER
TERMINAL REMOVER
HD-45928
TERMINAL CRIMPER
HD-45929
General
Delphi Micro 64 Sealed connectors are frequently found on
speedometers, tachometers and the ECM of Touring Models.
Separating Pin and Socket Housings
Bend back the external latches slightly and separate the pin
and socket housings.
Mating Pin and Socket Housings
Orient the wire lead colors. Align pin and socket housings.
Push the pin and socket housings of the connector together
until the latches click.
Removing Terminal
1.
See
. Locate the head of the secondary lock
(1) on one side of the connector housing.
2.
Insert the blade of a small screwdriver between the center
ear of the lock and the connector housing and gently pry
out lock. When partially removed, pull lock from connector
housing.
3.
Locate pin hole (2) between terminals on mating end of
connector.
1
2
3
4
5
6
7
8
9 10
11 12
1
6
7
12
1
2
3
sm00047
1. Secondary lock
2. Pin hole
3. Stamped number
Figure A-18. Delphi Micro-64 Sealed Connector: Housing
4.
See
. Obtain the TERMINAL REMOVER (Part
No. HD-45928).
5.
See
. Push the adjacent terminals all the way
into the connector housing and then insert tool into hole
until it bottoms.
6.
Leaving the tool installed, gently tug on wires to pull either
one or both terminals from wire end of connector. Remove
tool.
sm00046
Figure A-19. Terminal Remover (HD-45928)
sm00048
Figure A-20. Delphi Micro-64 Sealed Connector: Insert Tool
and Remove Terminal
2013 Sportster Service: Appendix A Connector Repair A-13
Installing Terminal
1.
Insert terminal into its respective numbered chamber on
wire end of connector. No special orientation of the ter-
minal is necessary.
NOTE
See
. For wire location purposes, the corners of
the socket housing are stamped (3) with the numbers 1, 6, 7
and 12, representing terminals 1-6 on one side, and 7-12 on
the other.
2.
Bottom the terminal in the chamber and then gently tug
on the wire to verify that it is locked in place.
NOTE
Once removed, the terminal may not lock in place when first
installed. Until the lock engages, move the terminal back and
forth slightly while wiggling the lead.
3.
Since the terminal remover tool releases two terminals
simultaneously, repeat step 2 on the adjacent terminal
even if it was not pulled from the connector housing.
4.
With the center ear on the head of the secondary lockpin
facing the mating end of the connector, push secondary
lock in until head is flush with the connector housing.
Preparing Wire Leads for Crimping
Strip 1/8 in (3.0 mm) of insulation from the wire lead.
Crimping Terminals
1.
Inspect
new
socket terminal for bent or deformed contact
and crimp tails. Replace as necessary.
2.
See
. Squeeze the handles of the TERMINAL
CRIMPER (Part No. HD-45929) to cycle the tool to the
fully open position (1).
3.
Raise locking bar and barrel holder by pushing up on
bottom tab with index finger (2).
4.
With the crimp tails facing upward, insert terminal through
locking bar into front hole in barrel holder (20-22 gauge
wire) (3).
5.
Release locking bar to lock position of contact. When
correctly positioned, the locking bar fits snugly in the space
at the front of the core crimp tails and the closed side of
the terminal rests on the outer nest of the crimp tool.
6.
Insert wires between crimp tails until ends make contact
with locking bar. Position wire that the wide pair of crimp
tails squeeze bare wire strands, while the narrow pair folds
over the insulation material.
7.
Squeeze handle of crimp tool until tightly closed (4). Tool
automatically opens when the crimping sequence is com-
plete.
8.
Raise locking bar and barrel holder to remove contact.
Inspecting Crimps
Inspect the quality of the core and insulation crimps. Distortion
should be minimal.
sm00045
Figure A-21. Terminal Crimper (HD-45929)
A-14 2013 Sportster Service: Appendix A Connector Repair
3
1
2
4
sm00049
1. Open position
2. Raising locking bar
3. Insert terminal
4. Crimp terminal
Figure A-22. Delphi Micro-64 Sealed Connector: Terminal
in Crimper
2013 Sportster Service: Appendix A Connector Repair A-15
A.11
DELPHI GT 150 SEALED CONNECTOR
DELPHI GT 150 SEALED CONNECTOR
REPAIR
General
Delphi connectors are embossed with the brand name, Delphi,
on the housing latch or terminal block.
Separating Pin and Socket Housings
See
. Bend back the external latch(es) slightly and
separate pin and socket halves of connector.
Mating Pin and Socket Housings
Push pin and socket halves of connector together until external
latch(es) engage.
Removing Socket Terminals
NOTE
Although the parts of the different Delphi connectors vary in
appearance, the instructions which follow will work for all.
1.
See
. If present, free one side of wire lock (1)
from ear on wire end of socket housing. Release the other
side if necessary. Release wires from channels in wire
lock. Remove from socket housing.
2.
Use a fingernail to pry colored terminal lock (2) loose.
Remove from mating end of socket housing.
3.
Use the thin flat blade from a hobby knife. Gently pry tang
(3) outward away from terminal. Tug on wire to back ter-
minal out wire end of chamber. Do not pull on wire until
tang is released or terminal will be difficult to remove.
Installing Socket Terminals
NOTE
For wire location purposes, alpha or numeric characters are
stamped into the wire end of each socket housing.
1.
Gently push tang on socket housing inward toward
chamber. With the open side of the terminal facing the
tang, push terminal into chamber at wire end of socket
housing.
2.
Gently tug on wire to verify that terminal is locked, pre-
venting it from backing out of chamber. If necessary, use
fingernail to push tang into engagement with terminal.
3.
Install colored terminal lock onto mating end of socket
housing.
4.
If present, seat wires in separate channels of wire lock
and then push channels
inside
chambers at wire end of
socket housing. Fully installed, slot on each side of wire
lock engages ear on socket housing.
sm00014a
Figure A-23. Delphi GT 150 Sealed Connector: Socket
Housing Latch
A-16 2013 Sportster Service: Appendix A Connector Repair
2
3
1
sm00015a
1. Remove wire lock
2. Remove terminal lock
3. Pry tang outward
Figure A-24. Delphi GT 150 Sealed Connector: Removing
Socket Terminals
2013 Sportster Service: Appendix A Connector Repair A-17
A.12
DELPHI GT 280 SEALED 73-TERMINAL ECM
CONNECTOR
DELPHI GT 280 SEALED 73-TERMINAL ECM
CONNECTOR
NOTE
Do not operate latch lever when connector is not mated to
ECU. Damage will occur.
Separating Socket Housing From ECM
See
. Remove strap (1). Press the latch (2). Rotate
lock lever to the released position (3).
Mating Socket Housing To ECM
Push the connector into the ECM. Rotate the lock lever to the
locked position.
Socket Terminal
1.
Cut cable strap to release harness from strain relief collar
of connector housing.
2.
See
. Release latches (4) that retain cover (3)
to housing (2) and remove cover.
3.
Remove and service the Micro-64 terminals. See
A.10 DELPHI MICRO 64 SEALED CONNECTOR
4.
Install connector housing cover. Verify all wires are within
the confines of the cover and that the cover latches are
engaged.
5.
Install
new
cable strap cable to the strain relief of the
connector.
ECM Ground Terminal
1.
See
. Remove secondary lock (1).
2.
See
. Using a thin blade screwdriver, gently
pry ground terminal retainer from connector housing.
3.
See
. Using a thin blade screwdriver, release
latch and pull ground wire, wire seal and terminal from
cover side of housing.
4.
Follow instructions in
to replace the terminal or wire seal.
5.
Push the terminal into place from the cover side of the
connector housing until the latch engages. Pull on wire to
verify terminal is secure.
NOTE
See
. Secondary lock has one short leg and one
long leg. Install as shown.
6.
See
. Install ground secondary lock (5) and
install secondary lock (1) as shown.
3
1
2
sm06098a
1. Strap
2. Latch
3. Lock lever released
Figure A-25. Unlatch ECM Connector
1
2
4
3
5
sm06093
1. Secondary lock
2. Terminal housing
3. Cover
4. Cover latch
5. Ground secondary lock
Figure A-26. Delphi 73-Terminal ECM Connector
A-18 2013 Sportster Service: Appendix A Connector Repair
sm06094a
Figure A-27. Remove Ground Secondary Lock
sm06095a
Figure A-28. Remove ECM Ground Terminal
2013 Sportster Service: Appendix A Connector Repair A-19
A.13
DEUTSCH DT SEALED CONNECTOR
DEUTSCH DT SEALED CONNECTOR
REPAIR
TOOL NAME
PART NUMBER
DEUTSCH TERMINAL REPAIR KIT
HD-41475
FLAT BLADE L-HOOK
HD-41475-100
General
Deutsch DT sealed connectors are colored coded for location
purposes. DT connectors associated with
left
side accessories,
such as the front and rear
left
turn signals, are
gray
. All other
DT connectors are
black
.
NOTE
A DEUTSCH TERMINAL REPAIR KIT (Part No. HD-41475)
contains a selection of seals and seal plugs, locking wedges,
attachment clips and terminals.
Also included is a FLAT BLADE L-HOOK (Part No. HD-41475-
100) used to remove locking wedges, compartmented storage
box and carrying case.
Separating Pin and Socket Housings
See
. To separate the connector halves, Press the
external latch(es) (1) on the socket housing (2) while rocking
the pin (3) and socket housings.
NOTES
•
Generally, the socket housing is found on the accessory
side, while the pin housing is attached to the wiring har-
ness.
•
Six-place and smaller Deutsch connectors have one latch
on the connector.
•
Eight- and twelve-place connectors have a latch on each
side. Simultaneously press both latches to separate the
connector.
Mating Pin and Socket Housings
1.
Align the connectors to match the wire lead colors.
a.
For One External Latch:
Six-place and smaller
Deutsch connectors have one external latch on the
socket housing. To join the housings, align the latch
on the socket side with the latch cover on the pin side.
b.
For Two External Latches:
Align the tabs on the
socket housing with the grooves on the pin housing.
2.
Insert socket housing into pin housing until it snaps or
clicks into place.
NOTE
For Two External Latches: If latches do not click (latch), press
on one side of the connector until that latch engages then press
on the opposite side to engage the other latch.
3.
If necessary, fit the attachment clip to the pin housing.
4.
Place large end of slot on attachment clip over T-stud on
frame. Push assembly forward to engage small end of
slot.
2
3
1
1
sm00017a
1. External latch
2. Socket housing
3. Pin housing
Figure A-29. Deutsch DT Sealed Connector
Removing Socket Terminals
1.
See
. Insert a small screwdriver between the
socket housing and locking wedge in-line with the groove
(in-line with the pin holes if the groove is absent). Turn the
screwdriver 90 degrees to pop the wedge up and remove
the secondary locking wedge.
2.
See
. Use a pick or small screwdriver to press
terminal latches inside socket housing and back out
sockets through holes in rear wire seal.
NOTE
If wire leads require new terminals, see the instructions for
crimping terminals.
Installing Socket Terminals
1.
Match wire lead color to connector cavity.
2.
See
. Fit rear wire seal (1) into back of socket
housing (2), if removed.
3.
Grasp wire lead (3) approximately 1.0 in (25.4 mm) behind
the socket terminal. Gently push socket through hole in
wire seal into its chambers until it clicks in place.
4.
A tug on the wire will confirm that it is properly locked in
place.
NOTE
Install seal plugs (6) into unused chambers. If removed, seal
plugs must be replaced to seal the connector.
5.
Install internal seal (4) on lip of socket housing, if removed.
6.
Insert tapered end of secondary locking wedge (5) into
socket housing and press down until it snaps in place. The
A-20 2013 Sportster Service: Appendix A Connector Repair
wedge fits into the center groove within the socket housing
and holds the terminal latches tightly closed.
NOTES
•
See
. While rectangular wedges do not require
a special orientation, align arrow (1) on conical secondary
locking wedge towards external latch for three-place con-
nectors.
•
If the secondary locking wedge does not slide into position
easily, check the installation of all the terminals. Unseated
terminals prevent the locking wedge from proper installa-
tion.
sm00009a
Figure A-30. Deutsch DT Sealed Connector: Remove
Secondary Locking Wedge
2
1
sm00018
1. Arrow on socket locking wedge
2. Arrow on pin locking wedge
Figure A-31. Deutsch DT Sealed Connector: 3-Place
Locking Wedges
2013 Sportster Service: Appendix A Connector Repair A-21
DEUTSCH
6
1
2
3
4
5
sm00010
1. Wire seal
2. Socket housing
3. Wire lead
4. Internal seal
5. Secondary locking wedge
6. Seal plug
Figure A-32. Deutsch DT Sealed Connector: 2, 3, 4 and
12-Place Socket Housings
Removing Pin Terminals
1.
Use the hooked end of a stiff piece of mechanics wire, a
needle nose pliers or the FLAT BLADE L-HOOK (Part
No. HD-41475-100) to remove the secondary locking
wedge.
2.
Gently press terminal latches inside pin housing and back
out pins through holes in wire seal.
NOTES
•
If wire leads require new terminals, see the instructions
for crimping terminals.
•
The 8-place and 12-place gray and black connectors are
not interchangeable. If replacing both the socket and pin
housings, the black may be substituted for the gray.
•
The socket and pin housings of all other connectors are
interchangeable. Black may be mated with the gray since
the alignment tabs are absent and the orientation of the
external latch is the same.
sm00019
Figure A-33. Deutsch DT Sealed Connector: Press Terminal
Latch and Back Out Pin
Installing Pin Terminals
1.
See
. Fit wire seal (1) into back of pin housing
(2).
2.
Grasp wire lead approximately 1.0 in (25.4 mm) behind
the pin terminal (3). Gently push pin through holes in wire
seal into its respective numbered chamber until it "clicks"
in place.
NOTE
A tug on the wire lead will confirm that a pin is locked in place.
3.
Insert tapered end of secondary locking wedge (4) into
pin housing. Press down until it snaps in place.
NOTES
•
The wedge fits in the center groove of the pin housing and
holds the terminal latches tightly closed.
•
See
. While rectangular wedges do not require
a special orientation, align arrow (1) on conical secondary
locking wedge towards external latch for three-place con-
nectors.
•
If the secondary locking wedge does not slide into position
easily, check the installation of all the terminals. Unseated
terminals prevent the locking wedge from proper installa-
tion.
A-22 2013 Sportster Service: Appendix A Connector Repair
DEUTSCH
1
2
3
4
sm00020
1. Wire seal
2. Pin housing
3. Pin terminal
4. Locking wedge
Figure A-34. Deutsch DT Sealed Connector: 2, 3, 4 and
12-Place Pin Housings
Crimping Terminals
Identify which of the types of Deutsch terminals are used with
the connector. Follow the corresponding crimping instructions.
Refer to
.
Table A-2. Deutsch Connector: Terminal Crimping Instructions
CRIMPING INSTRUCTIONS
TYPE
A.14 DEUTSCH DT SEALED TERMINAL REPAIR
DT Sealed (with crimp tails)
A.16 DEUTSCH DTM SEALED SOLID BARREL MINI TERMINAL REPAIR
DTM Mini Sealed Terminal (solid
barrel)
A.15 DEUTSCH DTM SEALED MINI TERMINAL REPAIR
DTM Mini Sealed Terminal (with crimp
tails)
2013 Sportster Service: Appendix A Connector Repair A-23
A.14
DEUTSCH DT SEALED TERMINAL REPAIR
DEUTSCH DT SEALED TERMINAL CRIMPS
TOOL NAME
PART NUMBER
DEUTSCH TERMINAL CRIMP TOOL
HD-39965-A
Preparing Wire Leads for Crimping
1.
Use a shop gauge to determine gauge of wire lead.
2.
Strip 5/32 in (4.0 mm) of insulation from the wire lead.
Crimping Terminal to Lead
1.
See
. Squeeze the handles of the DEUTSCH
TERMINAL CRIMP TOOL (Part No. HD-39965-A) to open
the jaws. Push the locking bar (1) up.
2.
Match the wire gauge to the crimp tool die. Refer to
.
NOTE
Rest the rounded side of the contact barrel in the nest (concave
split level area) with the crimp tails facing up.
3.
Insert (2) terminal (socket/pin) through hole of the locking
bar.
4.
Release locking bar to lock terminal in die.
NOTE
If the crimp tails are slightly out of alignment, the crimp tool
rotates the terminal to face the tails upward. When positioned,
the locking bar fits snugly in the space between the contact
band and the core crimp tails.
5.
Insert stripped wire core between crimp tails until ends
make contact with locking bar. Position wire that the wide
pair of crimp tails squeeze bare wire strands, while the
narrow pair folds over the insulation material.
6.
Squeeze handle of crimp tool until tightly closed. Tool
automatically opens after the terminal is crimped.
7.
Raise locking bar up to remove wire lead and terminal.
Inspecting Crimps
Inspect the wire core and insulation crimps. Distortion should
be minimal.
Table A-3. Deutsch DT Sealed Terminal Crimp: Wire Gauge
To Die
CRIMP TOOL DIE
WIRE GAUGE (AWG)
Front
20
Middle
16-18
2
5
4
6
1
3
sm00021
4.
1.
Insert stripped lead
Open jaws and raise locking bar
2.
5.
Insert terminal in locking bar
Squeeze crimper
6.
3.
Raise locking bar to remove terminal
Release locking bar to lock terminal in die
Figure A-35. Crimping a Deutsch DT Sealed Terminal
A-24 2013 Sportster Service: Appendix A Connector Repair
A.15
DEUTSCH DTM SEALED MINI TERMINAL
REPAIR
DEUTSCH DTM SEALED MINI TERMINAL
CRIMPS
TOOL NAME
PART NUMBER
PACKARD TERMINAL CRIMPER
HD-38125-7
Preparing Wire Leads for Crimping
Strip 5/32 in (4.0 mm) of insulation from the wire lead.
Crimping a Mini Terminal to Wire Lead
1.
See
. Compress the handles of PACKARD
TERMINAL CRIMPER (Part No. HD-38125-7) until the
ratchet (2) automatically opens.
NOTE
Always perform core crimp before insulation crimp.
2.
Position the core crimp on die E (1) of the crimper. Verify
the core crimp tails are facing the forming jaws.
3.
Gently apply pressure to handles of tool until crimpers just
secure the core crimp tails.
4.
Insert stripped wire core stands between crimp tails. Pos-
ition wire that the short pair of crimp tails squeeze bare
wire strands, while long pair squeeze over the insulation.
5.
Squeeze handle of crimper until tightly closed. Tool auto-
matically opens when the crimping sequence is complete.
NOTE
If the crimper does not open, squeeze the ratchet trigger (2).
6.
Position the insulation crimp on nest C of the crimper.
Verify the insulation crimp tails are facing the forming jaws.
7.
Squeeze handle of crimp tool until tightly closed. Tool
automatically opens when the crimping sequence is com-
plete.
Inspecting Crimps
Inspect the core and insulation crimps. Distortion should be
minimal.
2
1
sm00022
1. E die
2. Crimper ratchet trigger
Figure A-36. Packard Terminal Crimper (HD-38125-7)
2013 Sportster Service: Appendix A Connector Repair A-25
A.16
DEUTSCH DTM SEALED SOLID BARREL MINI
TERMINAL REPAIR
DEUTSCH DTM SEALED SOLID BARREL
TERMINAL CRIMPS
TOOL NAME
PART NUMBER
ELECTRICAL CRIMPER TOOL
HD-42879
Preparing Wire Leads For Crimping
For size 20, 16 and 12 contacts, wire ranges 26-12 AWG.
Strip 1/4 in (6.4 mm) of insulation from the wire lead.
Adjusting Crimper Tool
1.
See
. Squeeze the ELECTRICAL CRIMPER
TOOL (Part No. HD-42879) handles to cycle the crimp
tool to open.
2.
Remove locking pin (1) from selector knob (2).
3.
Raise selector knob. Roate knob until selected wire size
stamped on wheel is aligned with "SEL. NO." arrow (3).
4.
Loosen knurled locknut (4) and turn adjusting screw (5)
clockwise (in) until it stops.
Crimping a Barrel Contact To Wire Lead
1.
See
. Turn tool over and drop contact barrel
(1) into indentor cover (2) hole with the wire end out.
2.
Turn adjusting screw counterclockwise (out) until contact
is flush with bottom of recess in indentor cover. Tighten
knurled locknut.
3.
Slowly squeeze handles of crimp tool until contact centers
between the four indentor points (3).
4.
Insert bare wire core strands of stripped wire lead (4) into
contact barrel. Squeeze handle of crimp tool until tightly
closed. Tool automatically opens when the crimping
sequence is complete.
5.
Remove wire lead with crimped contact from indentor.
NOTE
Adjust the crimper tool for each contact/wire size.
6.
Install pin to lock selector knob.
Inspecting Crimps
Inspect the crimp. All core wire strands are to be crimped in
the barrel.
This
HAND
tool
m
ust
not
be
used
in
an
y
po
w
ered
"PRESS''
as
defined
b
y
OSHA
CFR
1910.211
(46)
2
4
5
1
3
sm00023
1. Locking pin
2. Selector knob
3. SEL. NO. arrow
4. Knurled locknut
5. Adjusting screw
Figure A-37. Electrical Crimper Tool (HD-42879)
A-26 2013 Sportster Service: Appendix A Connector Repair
HDT
- 48
- 00
JDG360-1
HEMET
RYAN
AIRPOR
T, P
.O
. BO
X 878
HEMET
, CA.
92343-0161
(714)
929-1200
INDUSTRIAL
PRODUCTS
DIVISION
HDT
- 48
- 00
JDG360-1
HEMET
RYAN
AIRPOR
T, P
.O
. BO
X 878
HEMET
, CA.
92343-0161
(714)
929-1200
INDUSTRIAL
PRODUCTS
DIVISION
2
1
3
4
3
sm00024
1. Contact barrel
2. Indentor cover
3. Indentor point
4. Stripped wire lead
Figure A-38. Deutsch Solid Barrel
2013 Sportster Service: Appendix A Connector Repair A-27
A.17
JAE MX19 SEALED CONNECTOR
JAE MX19 SEALED CONNECTORS
TOOL NAME
PART NUMBER
TERMINAL EXTRACTOR
B-50085
Connector Housings
Separate Housings:
See
. Press the two release
buttons on each side of the housing to separate the connector.
Connect Housings:
Align housings. Press together until the
locking tabs click.
sm06925
Figure A-39. Release Buttons: JAE MX19 Sealed Connector
Removing Terminals
1.
Modify a TERMINAL EXTRACTOR (Part No. B-50085) by
filing the front edge to 45 degrees.
2.
See
. Insert the extractor (1) into the opening
above the terminal and press the plastic molding (2) up
and out of the way.
3.
Pull the wire lead and terminal out of the back of the
housing.
Installing Terminals
1.
Inspect the plastic molding and replace the connector
housing if necessary.
2.
Orient the terminal to the housing. Push terminal into
housing until it clicks into place.
1
2
2
1
sm06926
1. Extractor
2. Plastic molding
Figure A-40. JAE MX19 Terminal Removal
CRIMPING TERMINALS
TOOL NAME
PART NUMBER
UNIVERSAL CRIMPER SET
HD-50120
HAND CRIMP FRAME
HD-50120-2
JAE DIE
HD-50120-6
1.
Strip the wire insulation to specification. Refer to
2.
Install the JAE DIE (Part No. HD-50120-6) in the handle
of the HAND CRIMP FRAME (Part No. HD-50120-2) of
the UNIVERSAL CRIMPER SET (Part No. HD-50120).
3.
Place the
new
terminal in the specified nest.
4.
Insert the wire to the wire stop. Crimp the terminal.
5.
Inspect the crimped terminal.
Table A-4. JAE MX19 Crimper Die (Part No. HD-50120-6)
NEST
STRIP LENGTH
PART NO.
TERMINAL
mm
in
B
2.0-2.5
0.051-0.098
72910-11
Socket
A
2.0-2.5
0.051-0.098
72909-11
Pin
A-28 2013 Sportster Service: Appendix A Connector Repair
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст