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Delphi HV-2000 Assembly Manual

Delphi HV-2000 Assembly Manual

Right angle bolted connector
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ASSEMBLY MANUALS
CONNECTOR - ASSEMBLY
HARNESS ASSEMBLY
CAR ASSEMBLY
ASSEMBLY MANUAL - 33366036
HV-2000 Right Angle Bolted Connector
Female Power Pack 2000 Terminal System (Sealed)
September 2016
Issued by
CTC Warren, Ohio
STC Saltillo, Mex.

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  • Page 1 ASSEMBLY MANUALS CONNECTOR - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY ASSEMBLY MANUAL - 33366036 HV-2000 Right Angle Bolted Connector Female Power Pack 2000 Terminal System (Sealed) September 2016 Issued by CTC Warren, Ohio STC Saltillo, Mex.
  • Page 2 The information contained in these assembly instructions is subject to alteration without prior notice and does not represent any obligation on the part of DELPHI. All the information is correct at time of releasing. Reprinting or translation is not permitted without written permission from DELPHI. © Copyright 2016 DELPHI. All rights reserved.

  • Page 3: Table Of Contents

    Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) TABLE OF CONTENTS CONNECTOR–ASSEMBLY SECTION ASSEMBLY OF THE FEMALE CONNECTOR List of Components & Exploded View Step 1 – Assembly O-Ring Seal onto Bolt Step 2 – Retain Bolt to Housing with Bolt Retainer Step 3 –...
  • Page 4 Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) TABLE OF CONTENTS CAR ASSEMBLY SECTION ASSEMBLY OF THE CONNECTION SYSTEM List of Components & Exploded View Step 1 – Identify Index Features in both the Mating Interface and Bolted Connector Step 2 –...

  • Page 5: Assembly Of The Female Connector

    Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) ASSEMBLY ASSEMBLY OF THE FEMALE CONNECTOR CONNECTOR - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY HV-2000 Right Angle Bolted Connector FEMALE CONNECTOR ASSEMBLY Contact at CTC Warren: Nicholas Durse +1 (330) 306 12 95 www.delphi.com...

  • Page 6: List Of Components & Exploded View

    Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) ASSEMBLY LIST OF COMPONENTS & EXPLODED VIEW QUANTITY COMPONENTS BOLT RETAINER FACE SEAL INNER CONNECTOR SHUNT HOUSING O-RING SEAL BOLT REFER TO LATEST DRAWING 33352038 FOR PART NUMBERS AND DETAILS...

  • Page 7: Step 1 - Assembly O-Ring Seal Onto Bolt

    Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) ASSEMBLY STEP 1 – Assembly O-Ring Seal onto Bolt INSERT O-RING SEAL ONTO BOLT AND PLACE IT IMPORTANT! VERIFY THAT O-RING SEAL IS NOT UNDERNEATH THE BOLT HEAD...
  • Page 8 Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) ASSEMBLY STEP 2b – Retain Bolt to Housing with Bolt Retainer PLACE BOLT RETAINER ONTO THE BOLT AS SHOWN BELOW, BOLT RETAINER FLAT FACE MUST BE FACING TOWARD THE HOUSING...

  • Page 9: Step 3 - Insert Face Seal Into Housing Shroud

    Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) ASSEMBLY STEP 3a – Insert Face Seal into Housing Shroud INSERT FACE SEAL ONTO ASSEMBLY FIXTURE MAKE SURE THE SEAL MUST IS NOT BUNCHED OR ROLLED SEAL IS ORIENTED WITH THE SEAL RETENTION BUMPS AS SHOWN STEP 3b –...

  • Page 10: Step 4 - Press Shunt Into The Inner Connector

    Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) ASSEMBLY STEP 4a – Press Shunt into the Inner Connector LOCATE THE SLOT TO INSERT THE SHUNT AND PRESS IT INTO THE INNER CONNECTOR STEP 4b – Press Shunt into the Inner Connector...

  • Page 11: Step 5 - Assembly Inner Connector

    Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) ASSEMBLY STEP 5a – Assembly Inner Connector IDENTIFY THE PROPER ORIENTATION OF THE INNER CONNECTOR AND REVIEW THAT ITS SHUNT IS PRESENT AND UNDAMAGED STEP 5b – Assembly Inner Connector...

  • Page 12: Connector Assembly - Completed

    Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) ASSEMBLY STEP 5c – Assembly Inner Connector VERIFY AUDIBLE CLICK ON THE THREE LOCKS INNER CONNECTOR ASSEMBLED FEMALE CONNECTOR ASSEMBLY – COMPLETED Contact at CTC Warren: Nicholas Durse +1 (330) 306 12 95 www.delphi.com...

  • Page 13: Assembly Of The Female Harness Assembly Connector

    Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) ASSEMBLY ASSEMBLY OF THE FEMALE HARNESS ASSEMBLY CONNECTOR - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY HV-2000 Right Angle Bolted Connector Contact at CTC Warren: Nicholas Durse +1 (330) 306 12 95 www.delphi.com...

  • Page 14: List Of Components & Exploded View

    Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) ASSEMBLY LIST OF COMPONENTS & EXPLODED VIEW QUANTITY COMPONENTS FEMALE CONNECTOR ASSEMBLY LOCK TPA/CLIP MOUN SCREW PAN HD FEMALE TERMINAL ASSEMBLY - POWER PACK 2000 REFER TO LATEST DRAWING 33352038 FOR PART NUMBERS AND DETAILS...

  • Page 15: Step 1 - Insert Retainer And Cable Seal Onto Coaxial Cable

    Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) ASSEMBLY STEP 1a – Insert Retainer and Cable Seal onto Coaxial Cable SLIDE RETAINER OVER THE CABLE WITH THE LOCKS FACING TOWARD THE FRONT STEP 1b – Insert Retainer and Cable Seal onto Coaxial Cable...

  • Page 16: Step 2 - Partially Strip The Cables And Remove Stripped Insulation

    Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) ASSEMBLY STEP 2a – Partially Strip the Cables and Remove Stripped Insulation See latest connector assembly drawing for final A and B dimensions STEP 2b – Partially Strip the Cables and Remove Stripped Insulation...

  • Page 17: Step 3 - Insert And Crimp Ferrules

    Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) ASSEMBLY STEP 3a – Insert and Crimp Ferrules SLIDE INNER FERRULE ON CABLE AND PLACE IT OVER THE OUTER JACKET AS SHOWN IMPORTANT! DO NOT REMOVE INNER JACKET FROM THE CORE STEP 3b –...
  • Page 18 Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) ASSEMBLY STEP 3c – Insert and Crimp Ferrules SLIDE OUTER FERRULE ON CABLE AND PLACE IT OVER THE SHIELD AND INNER FERRULE IMPORTANT! DO NOT REMOVE INNER JACKET FROM THE CORE STEP 3d –...

  • Page 19: Step 4 - Sonic Weld Female Terminal

    Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) ASSEMBLY STEP 4a – Sonic Weld Female Terminal REMOVE PARTIALLY STRIPPED INNER JACKET THEN ALIGN AND SONIC WELD THE TERMINAL TO CONDUCTOR; REFER TO LATEST ASSEMBLY DRAWING FOR SONIC WELD DIMENSIONS STEP 4b –...

  • Page 20: Step 1 - Identify Cavities

    Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) ASSEMBLY STEP 5 – Identify Cavities STEP 6a – Align and Insert Terminals Female Power Pack 2000 INSERT FEMALE TERMINAL INTO RECEPTACLE HOUSING ACCORDING TO INSERTION PLAN.
  • Page 21 Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) ASSEMBLY STEP 6b – Align and Insert Terminals Female Power Pack 2000 PUSH THE TERMINAL STRAIGHT VERIFY AUDIBLE CLICK INTO THE CAVITY TERMINAL FULLY ENGAGED UNDER THE FLEX LOCK STEP 6c –...

  • Page 22: Step 3 - Assemble Lock Tpa/Clip

    Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) ASSEMBLY STEP 7a – Assemble Lock TPA/Clip IDENTIFY THE CORRECT ORIENTATION OF THE PLACE LOCK TPA/CLIP ONTO LOCK TPA/CLIP THE TERMINAL FERRULES STEP 7b – Assemble Lock TPA/Clip...

  • Page 23: Step 4 - Insert Cable Seal Into The Housing

    Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) ASSEMBLY STEP 8 – Insert Cable Seal into the Housing PUSH THE CABLE SEALS INTO THE SHROUD, SEALS MUST STAY INSIDE THE SHROUD USE OF A PROPER TOOL IS REQUIRED...

  • Page 24: Harness Assembly - Completed

    Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) ASSEMBLY FEMALE HARNESS ASSEMBLY – COMPLETED PERFORM REQUIRED TESTS PER ASSEMBLY PRINT 33352038, APPLY COVERINGS AS REQUIRED. INSPECT THE ASSEMBLY AS REQUIRED. Contact at CTC Warren: Nicholas Durse +1 (330) 306 12 95 www.delphi.com...
  • Page 25 Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) ASSEMBLY ASSEMBLY OF THE CONNECTION SYSTEM CONNECTOR- ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY HV-2000 Right Angle Bolted Connector Contact at CTC Warren: Nicholas Durse +1 (330) 306 12 95 www.delphi.com...
  • Page 26 Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) ASSEMBLY LIST OF COMPONENTS & EXPLODED VIEW QUANTITY COMPONENTS MATING INTERFACE WITH MALE HEADER HV-2000 RIGHT ANGLE BOLTED CONNECTOR MOUNTING MATING INTERFACE WITH MALE HEADER HV-2000 RIGHT ANGLE...
  • Page 27 Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) ASSEMBLY STEP 1 – Identify Index Features in both the Mating Interface and Bolted Connector STEP 2a – Assembly Bolted Connector onto Mating Interface IMPORTANT! IF THE INDEX FEATURES DO NOT ALIGN DO NOT CONTINUE Contact at CTC Warren: Nicholas Durse +1 (330) 306 12 95 www.delphi.com...
  • Page 28 Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) ASSEMBLY STEP 2b – Assembly Bolted Connector onto Mating Interface INSTALL BY HAND TO START, THE INTERLOCKING PRE-STAGE FEATURES WILL LOCK CONNECTORS IN A PARTIALLY UNMATED POSITION STEP 2c –...
  • Page 29 Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) ASSEMBLY CONNECTION SYSTEM – COMPLETED ASSEMBLY Contact at CTC Warren: Nicholas Durse +1 (330) 306 12 95 www.delphi.com Assembly Manual - 33366036...
  • Page 30 Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) DISASSEMBLY DISASSEMBLY OF THE CONNECTION SYSTEM CONNECTOR- ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY HV-2000 Right Angle Bolted Connector Contact at CTC Warren: Nicholas Durse +1 (330) 306 12 95 www.delphi.com...
  • Page 31 Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) DISASSEMBLY STEP 1 – Disconnect UNSCREW THE BOLT ONCE THE BOLT IS COMPLETELY RELEASED, REMOVE THE BOLTED CONNECTOR CONNECTION SYSTEM – COMPLETED DISASSEMBLY Contact at CTC Warren: Nicholas Durse +1 (330) 306 12 95 www.delphi.com...
  • Page 32 Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) REPAIR / REPLACEMENT REPAIR / REPLACEMENT THE FEMALE ASSEMBLY HV-2000 Right Angle Bolted Connector Contact at CTC Warren: Nicholas Durse +1 (330) 306 12 95 www.delphi.com Assembly Manual - 33366036...
  • Page 33 Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) REPAIR / REPLACEMENT LOCK TPA/CLIP REPLACEMENT (Remove) – STEP 1 UNSCREW THE MOUN SCREW TO RELEASE THEN TAKE THE CLIP OUT OF THE CONNECTOR THE LOCK TPA/CLIP LOCK TPA/CLIP REPLACEMENT (Insert) –...
  • Page 34 Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) REPAIR / REPLACEMENT FEMALE TERMINAL REPLACEMENT (Release Seal Retainer) – STEP 1a INSERT TOOL 12094441 BETWEEN THE DEFLECT THE LOCK TO RELEASE THAT SIDE RETAINER AND CONNECTOR OF THE RETAINER FEMALE TERMINAL REPLACEMENT (Release Seal Retainer) –...
  • Page 35 Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) REPAIR / REPLACEMENT FEMALE TERMINAL REPLACEMENT (Remove Terminal) – STEP 2a TERMINAL FLEX LOCK REMOVE THE TPA/CLIP BEFORE TERMINAL REMOVAL FEMALE TERMINAL REPLACEMENT (Remove Terminal) – STEP 2b REMOVE TERMINALS Locate Terminal Flex Lock at the top of the cavity.
  • Page 36 Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) REPAIR / REPLACEMENT FEMALE TERMINAL REPLACEMENT (Insert Terminal) – STEP 3 REFER TO HARNESS ASSEMBLY SECTION INNER CONNECTOR REPLACEMENT (Remove) – STEP 1 LOCATE THE THREE LOCK ARMS FASTENING...
  • Page 37 Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) REPAIR / REPLACEMENT INNER CONNECTOR REPLACEMENT (Insert) – STEP 2 REFER TO CONNECTOR ASSEMBLY SECTION BOLT REPLACEMENT (Remove) – STEP 1 USE MECHANICAL PRESS TO PUSH THE BOLT OUT OF THE OUTER CONNECTOR; THIS WILL...
  • Page 38 Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) REPAIR / REPLACEMENT BOLT REPLACEMENT (Insert) – STEP 2 REFER TO CONNECTOR ASSEMBLY SECTION Contact at CTC Warren: Nicholas Durse +1 (330) 306 12 95 www.delphi.com Assembly Manual - 33366036...
  • Page 39 Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) RECOMMENDED REPAIR TOOLS ITEM DELPHI PART NUMBER 12094441 Contact at CTC Warren: Nicholas Durse +1 (330) 306 12 95 www.delphi.com Assembly Manual - 33366036...
  • Page 40 Assembly Manual HV-2000 Right Angle Bolted Connector Power Pack 2000 Terminal System (Sealed) REVISIONS DATE REVISION HISTORY AUTH 09SE16 RELEASED 433383 Contact at CTC Warren: Nicholas Durse +1 (330) 306 12 95 www.delphi.com Assembly Manual - 33366036...

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