Using the U5MK1110 Ampseal Connector Kit for Wiring Harness Repairs on Perkins Engines{7553} Caterpillar

Caterpillar Products: All

Introduction

Important Safety Information

Illustration 1	g02139237
Think Safety

Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the operation, lubrication, maintenance, and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER","WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.

A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.

When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.

Literature Information

This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group

This manual should be stored with the U5MK1110 Connector Repair Kit to service harnesses with Ampseal16 connectors.

Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.

Safety Section

The Safety section lists basic safety precautions.

Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.

General Information Section

The General Information section describes tooling functions and features. The section provides useful information on individual parts, additional tooling, and resources.

Operation Section

The Operation section is a reference for the new operator and a refresher for the experienced operator.

Photographs and illustrations guide the operator through correct procedures for using the tool group.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and tool capabilities.

Maintenance Section

The Maintenance section is a guide to tool inspection, cleaning, storage, and tool disposal

Safety Section

Safety Icon Nomenclature

Personal Protection/Important Information

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Personal Protection/Important Information

Prohibited Action

Do not weld

No smoking

Safety Warnings

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At operating temperature, the hydraulic tank is hot and under pressure. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve pressure.

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Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

General Information Section

Introduction

Illustration 3	g02264033

This manual covers the U5MK1110 Connector Repair Kit .The kit includes plug assemblies, receptacle assemblies, pin contacts, plug contacts, seal plugs, silicone perimeter seals, and a removal tool all in a convenient storage case.

The plug and receptacle assemblies are available in 2, 3, 4, 6, 8, and 12-pin versions, and are intended for wire-to-wire connections. This sealed connector system is mechanically mated and is designed with a lanceless contact system.

Illustration 4	g02268656
CH11155

Note: The U5MK1110 Connector Repair Kit does not contain the CH11155 Crimp Tool . The CH11155 Crimp Tool should be ordered separately.

Materials

The receptacle and plug assemblies are made from glass-filled thermoplastic with silicone rubber seals. Pin contacts are made of brass, and socket contacts are made of copper alloy.

Acceptable Wire Diameters

Plug and receptacle assemblies will accept wires having insulation diameters from 2.24 to 3.94 mm (.09 to .16 in). Only 14, 16, and 18 AWG wires with insulation diameters within the recommended range should be used with the plug and receptacle assemblies in the U5MK1110 Ampseal Connector Kit. Contacts will accept other gauge wires with a wider range of insulation diameters.

Color Code Identification

TPA (terminal position assurance) covers on plug and receptacle assemblies are color coded to indicate mechanical polarization (key).

Illustration 5	g02266193
28170096 8-Pin Plug, Key 1 (TPA Color Red). 28170040 8-Pin Receptacle, Key 1 (TPA Color Red).

Note: Only matching TPA plug and receptacle assemblies can be connected. For example; 28170096 Plug (8 pin, TPA color red, Key 1) with 28170040 Receptacle (8 pin, TPA color red, Key 1).

U5MK1110 Connector Repair Kit (Electrical Connector)

Component Description

Plug and Receptacle Assemblies

Illustration 6	g02266194
(1) Plug Assembly. (5) Circuit Identification Numbers. (6) CPA (Connector Position Assurance) Lock. (2) TPA (Terminal Position Assurance) Cover. (13) Perimeter Seal. (14) Wire Seal Cover. (15) Keys

Plug and receptacle assemblies are available in 2, 3, 4, 6, 8, and 12-pin versions.

Plug assemblies (1) feature a color coded TPA (terminal position assurance) cover (12) that locks the socket contacts in place when in the closed position. Circuit identification numbers (5) are marked on each TPA cover and wire seal cover (14). Plug assemblies have TPA (terminal position assurance) keys (15) that ensure correct plug and receptacle connections. Plug assemblies also feature a CPA (connector position assurance) lock (6) that prevents the unintended separation of plug and receptacle connections. A silicone perimeter seal (13) on each plug assembly helps protect the mated plug and receptacle contact connections from moisture and dirt.

Illustration 7	g02266213
(2) Receptacle Assembly. (5) Circuit Identification Numbers. (12) TPA (Terminal Position Assurance) Cover. (14) Wire Seal Cover. (15) Keys.

Receptacle assemblies (2) feature a color coded TPA (terminal position assurance) cover (12) that locks the pin contacts in place when in the closed position. Circuit identification numbers (5) are marked on each TPA cover and wire seal cover (14). Receptacle assemblies have molded TPA (terminal position assurance) keys (15) that ensure correct plug and receptacle mating connections.

Illustration 8	g02266233
(16) 147-6456 Removal Tool.

A special 147-6456 Removal Tool (16), part of the service kit, is required to unlock and remove TPA covers and remove contacts from plug assemblies and receptacle assemblies.

Illustration 9	g02266235
(1) Plug Assembly. (2) Receptacle Assembly. (14) Wire Seal Cover

Both plug and receptacle assemblies feature a sealed, permanently attached wire seal cover (14) on the wire harness end of the housing.

Illustration 10	g02266255
(1) Loaded Plug Assembly. (2) Loaded Receptacle Assembly. (3) Crimped Socket Contact. (4) Crimped Pin Contact.

A completed connector assembly consists of plug assembly (1 ) loaded with socket contacts (3) (crimped to wires) mated to receptacle assembly (2) loaded with pin contacts (4) (crimped to wires).

Contacts

Illustration 11	g02266256
(3) Socket Contact. (17) Crimp Barrel. (18) Inspection Hole. (37) Retention Shoulder.

Socket contacts (3) are only used in plug assemblies.

Illustration 12	g02266293
(4) Pin Contact. (17) Crimp Barrel. (18) Inspection Hole. (37) Retention Shoulder

Pin contacts (4) are only used in receptacle assemblies.

Illustration 13	g02266313
(7) 126-1768 Connector Socket . (8) 126-1767 Connector Pin .

126-1768 Connector Socket (7) and 126-1767 Connector Pin (8), with a green band (A) on the crimp area of the contact, are used with 14 American Wire Gauge (AWG) wire having an insulation diameter of 2.24 mm (0.09 inch) to 3.94 mm (0.16 inch).

Illustration 14	g02266314
(9) 9X-3402 Connector Socket . (10) 9X-3401 Connector Pin .

9X-3402 Connector Socket (9) and 9X-3401 Connector Pin (10), without color band markings, are used with 16 and 18 AWG wire having an insulation diameter of 2.24 mm (0.09 inch) to 3.94 mm (0.16 inch).

Illustration 15	g02266335
(11) 8T-8737 Seal Plug .

8T-8737 Seal Plug (11) is inserted into unused circuits in plug and receptacle assemblies to seal out dirt and moisture

Plug and Receptacle Assembly

Disconnect

No tools are required to unmate Ampseal connectors.

Illustration 16	g02266376
(1) Plug Assembly. (2) Receptacle Assembly. (6) CPA Tab. (39) Connector Latch.

1. Slide red CPA tab (6) toward the rear (wire end) of plug assembly (1) until the tab clears connector latch (39) pad.

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Illustration 17	g02266378
(1) Plug Assembly. (2) Receptacle Assembly. (39) Connector Latch.

2. To separate the mated connector assembly, depress the end of connector latch (39) near the wire end of plug assembly (1). Continue to squeeze the latch pad while pulling plug assembly and receptacle assembly (2) apart.

Disassemble

The Ampseal connectors use a TPA cover to lock the socket and pin contacts securely in place. The TPA cover must first be removed before contacts are removed from the connector.

Illustration 18	g02266393
(1) Plug (or Receptacle) Assembly. (12) TPA Cover. (16) 147-6456 Wedge Removal Tool . (35) Tool Slot.

1. Insert the notched tip of 147-6456 Wedge Removal Tool (16) into tool slot (35) in plug or receptacle TPA cover (12). Orient the removal tool so the notch is facing the center of the TPA cover. Hook the tool firmly against the edge of the tool slot and slowly pull on the TPA cover until the cover is removed from the plug or receptacle assembly. Retain the TPA cover for reassembly.

2. Record the circuit number location and mark all wires to be removed from plug and receptacle assemblies. This information will be used during assembly.

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Illustration 19	g02266414
(9) Contact. (16) Removal Tool. (42) Contact Retention Finger.

3. Insert the tip of 147-6456 Wedge Removal Tool (16) into the desired contact cavity with the tip of the tool under the lip of contact retention finger (42). Deflect the contact retention finger away from contact (9). Gently pull the wire until the contact is pulled free from the housing

4. Repeat 2 for the remaining contacts to be removed from the plug or receptacle assembly.

5. Service the removed contacts as required. Refer to the ""Crimping a Contact" " section in this manual for contact crimping procedures.

Crimping a Contact

To ensure proper electrical performance, contacts must be crimped using the CH11155 Crimp Tool (ordered separately) and the following procedure. DO NOT solder the wires into the contacts.

1. Cut the end of the 14, 16, or 18 AWG wire square and clean.

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Illustration 20	g02510956
(A) 6.4 - 7.0 mm (.25 - .31in.) (B) 1.5 mm (.06 in)

2. Strip 6.4 mm (0.25 inch) to 7.0 mm (0.28 inch) of insulation from the wire, being careful not to cut or nick the copper wire strands. A properly stripped wire will touch the bottom of crimp barrel (17), with the wire visible through inspection hole (18). The wire insulation will be 1.5 mm (0.06 inch) from the end of the contact

   Note: On the socket contact, the stripped wire is inserted into the end with inspection hole (18) .

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Illustration 21	g02266457
(19) CH1115S Crimp Tool (20) Wire Selector Gauge. (21) Lock Clip. (22) Selector Knob.

3. Make sure wire selector gauge (20) on CH11155 Crimp Tool (19) is set to the wire size being crimped. If the wire selector gauge is properly set, proceed to 4. If the selector gauge setting does not match the wire size being crimped, proceed as follows.

   1. Remove lock clip (21)

   2. Raise selector knob (22) and rotate until the arrow is aligned with the wire size to be crimped

   3. Lower the selector knob and insert the lock clip.

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Illustration 22	g02266633
(23) Locknut. (24) Adjusting Screw.

4. Loosen locknut (23) and turn adjusting screw (24) in until the screw stops.

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Illustration 23	g02266635
(23) Locknut. (24) Adjusting Screw. (25) Contact.

5. Insert contact (25) and turn adjusting screw (24) out until the wire/crimp end of the contact is flush with the tool face. Tighten locknut (23) .

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Illustration 24	g02266675
(26) Crimp Fingers.

6. The contact must be centered between crimp fingers (26). Insert the wire into the contact. Make sure that all wire strands are inside the crimp barrel.

7. Crimp the wire in the contact by squeezing the handles of the crimp tool together until the handle hits the stop and automatically releases.

8. Remove the crimped contact from the CH11155 Crimp Tool .

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Illustration 25	g02266757
(27) Crimp Indent (Correct).

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Illustration 26	g02266758
(27) Crimp Indent (Incorrect).

9. Inspect the contact to make sure that all wire strands are in the crimped barrel and that crimp indent (27) falls in the center of the contact crimp barrel.

10. If crimp indent (27) is not centered, or if wire strands are outside the crimp barrel, cut off the contact and repeat ""Crimping a Contact" " procedure.

Assemble

Illustration 27	g02266913

1. Install TPA covers removed during disassembly.

   1. Align keys of the TPA cover with matching features on the plug or receptacle assembly. Insert extended TPA cover contact retention fingers inside the plug assembly housing.

      Note: Matching keyed features on the TPA cover and plug or receptacle assembly will orient the contact latching fingers in the correct position.

   2. Carefully push the TPA cover to the unlocked position on the plug or receptacle assembly

      Note: Contact retention features in plug and receptacle assemblies will not engage if the contacts are inserted with the TPA cover in the locked position.

2. Verify that the TPA covers are in the unlocked position
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   Illustration 28	g02266916
   (1) Plug Assembly. (29) Plug Flange. (30) 19.9 mm (0.78346 inch) Minimum Distance. (31) Clearance Between Seal and TPA.

   1. On plug assemblies (1), measure the distance from under plug flange (29) to the face of TPA cover (12), as shown. Minimum distance (30) should be 19.9 mm (0.78 inch). There will be clearance (31) visible between the seal and the lip of the TPA.
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   Illustration 29	g02266953
   (2) Receptacle Assembly. (12) TPA Cover. (32) Outer Lip Of Receptacle Assembly. (33) 14mm mm (0.55118 inch) Maximum Distance.

   2. On receptacle assemblies (2), measure the distance from face of TPA cover (12) to outer lip (32) of the receptacle assembly, as shown. Maximum distance (33) should be 14mm (0.55 inch).

3. If a TPA cover is in the locked position, use the following procedure to unlock.
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   Illustration 30	g02266974
   (1) Plug Assembly. (2) Receptacle Assembly. (12) TPA Cover. (16) 147-6456 Wedge Removal Tool (35) Tool Slot.

   1. Insert the notched tip of 147-6456 Wedge Removal Tool (16) into tool slot (35) in the TPA cover of plug or receptacle assembly (1). Orient the tool so the notch is facing the center of the TPA cover. Hook the tool firmly against the edge of the tool slot and slowly pull on the TPA cover until the cover unlocks and moves forward approximately 5 mm (0.20 inch).

      Note: To prevent damage to the TPA cover, orient the removal tool so the notch is facing the center of the TPA cover.

4. If a TPA cover is removed during the unlocking process, reinstall the TPA cover, making sure that the cover is only pushed to the unlocked position.

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Illustration 31	g02266593

5. Grasp the appropriate wire approximately 25 mm (0.98 inch) from the crimped contact. Align the contact with the desired circuit cavity at the rear of the connector. Push the contact straight into the cavity, forcing the contact through the wire seal.

   Note: Socket contacts should only be used in plug assemblies. Pin contacts should only be used in receptacle assemblies.

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Illustration 32	g02266976
(1) Plug (or Receptacle) Assembly. (36) Retention Finger. (37) Socket (or Pin) Contact Shoulder

6. Continue to push the contact straight into the connector until contact retention finger (36) locks in place behind retention shoulder (37) on the contact, as indicated by an audible and tactile "click". A slight tug on the wire will confirm the contact is properly locked in place.

7. When all required contacts have been inserted, complete the assembly by pushing the TPA cover into the fully locked position.
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   Illustration 33	g02267855

   1. Plug assembly TPA covers may be fully locked by holding the rear of the housing and pushing the TPA cover in, until the cover snaps into the locked position.
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   Illustration 34	g02267873

   2. Receptacle assembly TPA covers may be fully locked by holding the rear of the housing while pushing in on the center of the recessed TPA cover with the tip of the 147-6456 Wedge Removal Tool or a number 10 flat blade screwdriver, until the TPA cover snaps into the locked position

      Note: To verify that TPA covers are fully locked, apply pressure to both TPA covers. Install a mating plug to verify that the two assemblies fully engage.

8. Verify that all contacts are locked into place. Pull on each wire with a force of 4.5 N (1.01 lb) to 8 N (1.80 lb).
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   Illustration 35	g02267875
   (1) Plug Assembly. (2) Receptacle Assembly. (11) 8T-8737 Seal Plug . (14) Wire Seal Cover

   1. Insert 8T-8737 Seal Plug (11) into any plug assembly (1) or receptacle assembly (2) circuit without a wire. The seal plug should be pushed in until the flange on the seal plug is firmly against wire seal cover (14) .

Connect Plug and Receptacle Assemblies

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Illustration 36	g02267893
(1) Plug Assembly. (2) Receptacle Assembly. (39) Connector Latch.

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Illustration 37	g02267933
(1) Plug Assembly. (2) Receptacle Assembly. (40) Lock Tab. (41) Plug Assembly Latch Tip.

Note: Plug assembly latch tip (41) must extend past the two small lock tabs (40) on the receptacle assembly and in a horizontal position to be latched.

1. When all contacts have been locked securely in position, complete the assembly of the connector system by mating matching plug assembly (1) and receptacle assembly (2) until connector latch (39) is fully engaged. An audible "click" will be heard.

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Illustration 38	g02267934
(1) Plug Assembly. (2) Receptacle Assembly. (6) CPA Tab. (39) Connector Latch.

2. Securely lock plug assembly (1) and receptacle assembly (2) together by pushing red CPA (connector position assurance) tab (6) inward, sliding CPA under connector latch (39) pad. Push the plug assembly until the CPA "clicks" into position. Once the CPA tab is locked, the connector latch pad cannot be depressed, preventing unintended separation of the plug and receptacle assembly.

Perimeter Seal Replacement

Illustration 39	g02267935
(1) Plug Assembly. (12) TPA (Terminal Position Assurance) Cover. (13) Silicone Perimeter Seal.

Perimeter seal (13) can be replaced on plug assemblies (1) when the connector is separated, using the following procedure.

1. Remove TPA cover (12). Refer to 1 in the ""Disassemble" " section in this manual.

2. Remove perimeter seal (13) by sliding the seal off the plug assembly (1) .

3. Clean the sealing surface on the plug assembly.

4. Install the new perimeter seal by sliding the seal on the plug assembly (1) .

   Note: Make sure that the perimeter seal does not roll during the installation process.

5. Install TPA cover on the plug assembly. Refer to 1.a in the ""Assemble" "section in this manual

Maintenance Section

Storage

Store connector assemblies, contacts, and other components in the shipping containers until ready for use, to prevent deformation and contamination. Use contacts on a first in, first out basis to avoid storage contamination that can adversely affect signal transmissions.

Alkalies, Amines, Ammonia, Carbonates Citrates, Nitrates, Phosphates Citrates, Sulfides Nitrates, Sulfur Compounds and Tartrates

Additional Contact Information

For additional product support questions concerning this tool, contact the Caterpillar Dealer Service Tools Hotline at: