Ampseal 16 Connector Peripheral Seal Servicing{7553} Caterpillar

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Introduction

This Special Instruction describes the procedure that is required to service the peripheral seals of the Ampseal 16 Connector System.

Note: Do not perform any procedure in this Special Instruction until the information has been read and understood.

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Use all cleaning solutions with care and in a well ventilated area. Always wear eye protection when using cleaning solutions. Failure to follow the precautions provided by the manufacturer on using, storing and disposing of any cleaning solution can result in bodily injury.

Peripheral Seal Servicing

Conditions in the field may require that the peripheral seal of the Ampseal 16 plug assembly be serviced. Servicing the connector involves cleaning and lubrication, or replacing the seal when the connector is opened. The following contaminants may require that the seal be serviced.

• Excessive exposure to diesel fuel

• Dust

• Other contaminants

Clean seals that are dirty. Replace seals that are torn or swollen. Refer to Illustration 1 for an example of seal conditions.

Illustration 1	g01288041
Description of Seals for the 12 Pin Connector (1) 1 Hour Unmated (2) Unexposed (3) 48 Hours mated

When Ampseal 16 connectors have been exposed to excessive dust, remating of the serviced connector may be difficult. Clean connectors that have been unmated for service purposes before reconnecting.

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Illustration 2	g01288086

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NOTICE
Many solvents have been found to damage some connector materials. Solvent based cleaners are not recommended. It is important that the connector mating surfaces be clean and dry before remating. If dirt or corrosion cannot be removed from the mating surfaces, the connector and/or terminals must be replaced.

1. Clean the interior mating surfaces. Use a cotton swab and denatured alcohol to clean the surfaces. Refer to Illustration 2. The interior mating surfaces are the following components:
   • Terminals

   • Seals

   • Insulators

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Illustration 3	g01288160

2. Ensure that the surfaces of the connector are dry. Coat a cotton swab with 129-1968 Multipurpose Grease and apply the grease to the surface of the peripheral seal. Applying grease to the connector will allow the connector to mate with decreased resistance. Refer to Illustration 3.

Replacement of the Peripheral Seal

Replace the peripheral seal if the seal is torn or the seal is swollen. Table 1 contains a list of peripheral seal part numbers available for the Ampseal 16 connector.

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Illustration 4	g01288191

1. Separate the connector and remove the Terminal Position Assurance (TPA) from the plug assembly. Use a small flat head screwdriver or an equivalent device. Refer to Illustration 4.

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Illustration 5	g01288396

2. Remove the seal by sliding the seal off the end of the plug housing. Refer to Illustration 5.

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Illustration 6	g01288436

3. Clean the sealing surface of the plug. Remove any dirt, moisture, or debris that may be on the connector assembly. Refer to Illustration 6.

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NOTICE
Care should be taken to ensure that the seal does not roll during installation

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Illustration 7	g01288446

4. Install the new seal on the plug assembly by sliding the seal on the end of the plug housing. Refer to Illustration 7.

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NOTICE
Damaged product should not be used. If a damaged product is evident, it should be replaced with a new one.

5. Reassemble the TPA to the plug housing using the appropriate steps outlined in ""Reassembly of Connector" ".

Reassembly of Connector

Reassembly of the plug after servicing a seal should be performed as follows:

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Illustration 8	g01288449

1. Align the keying features of the TPA with the appropriate features in the plug housing. Refer to Illustration 8.

Note: Single row plug assemblies are keyed by the location of the plug latching fingers. TPA fingers go on top of the contacts. Dual row plug assemblies have a "V" shaped notch inside the housing keys with a matching "V" shaped rib on the bottom of the TPA.

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Illustration 9	g01288448

2. Push the TPA into the fully locked position. Refer to Illustration 9.

3. Tug gently on the wires to ensure that the terminals are fully inserted into the connector. The plug assembly is now ready to be connected to the receptacle.