APPLICATION SPECIFICATION VALUSEAL SEALED CONNECTOR SYSTEM

APPLICATION SPECIFICATIONVALUSEAL SEALED CONNECTOR SYSTEMWIRE TO WIRE – 1x2 CKTREVISION ECR/ECN INFORMATIONA1EC No:110733DATE:30/11/2016DOCUMENT NUMBER:AS-172877-0001SHEET No.Application SpecificationValuseal sealed connector system1 of 16CREATED / REVISED BY:CHECKED BY:APPROVED BY:Ishwar GIshwar GKPTEMPLATE FILENAME: CRIMP SPEC[SIZE A](V.1).DOC

APPLICATION SPECIFICATIONSCOPEThis specification covers the requirements for the application of Valuseal wire to wire sealedconnector system.TABLE OF CONTENTS Section 1: Product IntroductionSection 2: Product SummarySection 3: Plug connector AssemblySection 4: Receptacle connector AssemblySection 5: Cavity plug AssemblySection 6: WTW Connector AssemblySection 7: Service InstructionsSection 8: Connector/Cable ClampingSection 9: General application notesSection 1: Product IntroductionProduct DescriptionPlug Housing with Integrated sealReceptacle Housing with Integrated sealMale crimp terminalFemale crimp terminalVoid plugREVISION ECR/ECN INFORMATIONA1EC No:110733DATE:30/11/2016DOCUMENT NUMBER:AS-172877-0001Series number172877172878173041173042173061SHEET No.Application SpecificationValuseal sealed connector system2 of 16CREATED / REVISED BY:CHECKED BY:APPROVED BY:Ishwar GIshwar GKPTEMPLATE FILENAME: CRIMP SPEC[SIZE A](V.1).DOC

APPLICATION SPECIFICATIONSection 2: Product Summary1. Plug assembly detailsPlug housingMale TerminalsMatt sealMale Terminal for Plug HousingREVISION ECR/ECN INFORMATIONA1EC No:110733DATE:30/11/2016DOCUMENT NUMBER:AS-172877-0001SHEET No.Application SpecificationValuseal sealed connector system3 of 16CREATED / REVISED BY:CHECKED BY:APPROVED BY:Ishwar GIshwar GKPTEMPLATE FILENAME: CRIMP SPEC[SIZE A](V.1).DOC

APPLICATION SPECIFICATION2. Receptacle assembly detailsRing sealReceptacle housingTerminalsFemale Terminal for Receptacle housingREVISION ECR/ECN INFORMATIONA1EC No:110733DATE:30/11/2016DOCUMENT NUMBER:AS-172877-0001SHEET No.Application SpecificationValuseal sealed connector system4 of 16CREATED / REVISED BY:CHECKED BY:APPROVED BY:Ishwar GIshwar GKPTEMPLATE FILENAME: CRIMP SPEC[SIZE A](V.1).DOC

APPLICATION SPECIFICATIONSection 3: Plug connector AssemblyMale Terminal Insertion1. Place the plug housing on the flat surface and hold by left hand as shown in figure 1.Fig 12. Hold male terminal in vertical position with right hand.Hold the terminal at a distance of 10-15 mm from insulation crimped area as shown in fig 2.No orienation isneeded duringterminal assemblyinto housing (terminalcan be inserted in360 direction)Fig 2REVISION ECR/ECN INFORMATIONA1EC No:110733DATE:30/11/2016DOCUMENT NUMBER:AS-172877-0001Fig 3SHEET No.Application SpecificationValuseal sealed connector system5 of 16CREATED / REVISED BY:CHECKED BY:APPROVED BY:Ishwar GIshwar GKPTEMPLATE FILENAME: CRIMP SPEC[SIZE A](V.1).DOC

APPLICATION SPECIFICATION3. Insert the terminal gently into the housing as shown in fig 3. (Change the finger position after intialinsertion to press the terminal further inside)4. Push the terminal into the hole till the terminal reaches the dead end position (till it bottoms out) in thehousing. Pull the terminal back gently to ensure that terminal is seated properly in the housing as shownin fig 4.Fig 45. Insert terminals into both circuits and complete the insertion as shown in fig 5.Fig 56. Reverse the assembled housing and carry out the visual inspection for terminal position, skiving etc REVISION ECR/ECN INFORMATIONA1EC No:110733DATE:30/11/2016DOCUMENT NUMBER:AS-172877-0001SHEET No.Application SpecificationValuseal sealed connector system6 of 16CREATED / REVISED BY:CHECKED BY:APPROVED BY:Ishwar GIshwar GKPTEMPLATE FILENAME: CRIMP SPEC[SIZE A](V.1).DOC

APPLICATION SPECIFICATIONSection 4: Receptacle connector AssemblyFemale Terminal Insertion1. Place the receptacle housing on the flat surface and hold by left hand as shown in figure 6.Fig 62. Hold female terminal in vertical position with right hand.Hold the terminal at a distance of 10-15 mm from insulation crimped area per figure 7.Fig 7REVISION ECR/ECN INFORMATIONA1EC No:110733DATE:30/11/2016DOCUMENT NUMBER:AS-172877-0001Fig 8SHEET No.Application SpecificationValuseal sealed connector system7 of 16CREATED / REVISED BY:CHECKED BY:APPROVED BY:Ishwar GIshwar GKPTEMPLATE FILENAME: CRIMP SPEC[SIZE A](V.1).DOC

APPLICATION SPECIFICATION3. Insert the terminal gently into the housing as shown figure 8.No terminal orienation is needed to the assembly(terminal can be iserted in 360 direction)(Change the finger position after intial insertion to press the terminal further inside)Fig 94. Push the terminal into the hole till the terminal reaches the dead end position in the housing as shown infigure 9. Pull the terminal back gently to ensure that terminal is seated properly in the housing as shownin figure 10.Fig 10REVISION ECR/ECN INFORMATIONA1EC No:110733DATE:30/11/2016DOCUMENT NUMBER:AS-172877-0001SHEET No.Application SpecificationValuseal sealed connector system8 of 16CREATED / REVISED BY:CHECKED BY:APPROVED BY:Ishwar GIshwar GKPTEMPLATE FILENAME: CRIMP SPEC[SIZE A](V.1).DOC

APPLICATION SPECIFICATION5. Insert terminals into both circuits and complete the insertion as shown in fig 11.Fig 116. Reverse the assembled housing and carry out the visual inspection for terminal position, skiving etc Section 5: Cavity plug installation1. Place the plug/receptacle housing on the flat surface as shown in fig 12.Hold cavity plug in vertical position with right hand & align the cavity plug into the housing hole asshown in fig 13.Fig 12REVISION ECR/ECN INFORMATIONA1EC No:110733DATE:30/11/2016DOCUMENT NUMBER:AS-172877-0001Fig 13SHEET No.Application SpecificationValuseal sealed connector system9 of 16CREATED / REVISED BY:CHECKED BY:APPROVED BY:Ishwar GIshwar GKPTEMPLATE FILENAME: CRIMP SPEC[SIZE A](V.1).DOC

APPLICATION SPECIFICATION2. Press the cavity plug into the housing slot till the plug fits into its position.Fig 143. Above procedure to be followed wherever void positions are identified. Cavity plug insertion procedureis same for both plug and receptacle housing.Section 6: WTW Connector Assembly1. Hold the plug connector assembly and receptacle connector assembly as shown in fig 15.Align connector system latch features and begin mating process along the same axis.Fig 15REVISION ECR/ECN INFORMATIONA1EC No:110733DATE:30/11/2016DOCUMENT NUMBER:AS-172877-0001SHEET No.Application SpecificationValuseal sealed connector system10 of 16CREATED / REVISED BY:CHECKED BY:APPROVED BY:Ishwar GIshwar GKPTEMPLATE FILENAME: CRIMP SPEC[SIZE A](V.1).DOC

APPLICATION SPECIFICATION2. Press the receptacle housing latch until the latch locks (observe for “CLICK” sound)Fig 16Fig 17REVISION ECR/ECN INFORMATIONA1EC No:110733DATE:30/11/2016DOCUMENT NUMBER:AS-172877-0001SHEET No.Application SpecificationValuseal sealed connector system11 of 16CREATED / REVISED BY:CHECKED BY:APPROVED BY:Ishwar GIshwar GKPTEMPLATE FILENAME: CRIMP SPEC[SIZE A](V.1).DOC

APPLICATION SPECIFICATIONSection 7: Service instructionsA. Connector unmating instructions1. Press the latch lever on receptacle assembly to disengage the latch and pull the plug assembly asshown in fig 18 and fig 19.Fig 18Fig 19REVISION ECR/ECN INFORMATIONA1EC No:110733DATE:30/11/2016DOCUMENT NUMBER:AS-172877-0001SHEET No.Application SpecificationValuseal sealed connector system12 of 16CREATED / REVISED BY:CHECKED BY:APPROVED BY:Ishwar GIshwar GKPTEMPLATE FILENAME: CRIMP SPEC[SIZE A](V.1).DOC

APPLICATION SPECIFICATIONB. Male Terminal removal1. Using the extractor tool # 11030002, insert the extractor tool into the male terminal to be serviced.2. Push extractor tool straight down gently and apply pressure to release locking tabs. This motion willrelease the locking tabs. Pull the terminal gently by supporting the finger at the bottom face ofconnector.Pull the terminal gently until the front portion of the terminal protrudes from connector bottom face asshown in below fig 20Fig 203. Extracted terminal should be removed from the housing and replace with new crimp terminal in samecircuit.REVISION ECR/ECN INFORMATIONA1EC No:110733DATE:30/11/2016DOCUMENT NUMBER:AS-172877-0001SHEET No.Application SpecificationValuseal sealed connector system13 of 16CREATED / REVISED BY:CHECKED BY:APPROVED BY:Ishwar GIshwar GKPTEMPLATE FILENAME: CRIMP SPEC[SIZE A](V.1).DOC

APPLICATION SPECIFICATIONC. Female Terminal removal1. Using the extractor tool # 11030002, insert the extractor tool into the male terminal to be serviced.2. Push extractor tool straight down gently and apply pressure to release locking finger. This motion willrelease the locking finger. Pull the terminal gently by supporting the finger at the bottom face ofconnector. Pull the terminal gently until the front portion of the terminal protrudes from connectorbottom face as shown in fig 21Fig 213. Extracted terminal should be removed from the housing and replace with new crimp terminal in samecircuit.REVISION ECR/ECN INFORMATIONA1EC No:110733DATE:30/11/2016DOCUMENT NUMBER:AS-172877-0001SHEET No.Application SpecificationValuseal sealed connector system14 of 16CREATED / REVISED BY:CHECKED BY:APPROVED BY:Ishwar GIshwar GKPTEMPLATE FILENAME: CRIMP SPEC[SIZE A](V.1).DOC

APPLICATION SPECIFICATIOND. Cavity/Void plug removal1. Using the extractor tool # 11030002, insert the extractor tool into the cavity/void plug to be serviced.2. Push extractor tool straight down gently and apply pressure to release locking steps in cavity plug. Pullthe Cavity / Void plug gently by supporting the finger at the bottom face of connector. Pull the cavityplug gently until the front portion of the cavity plug protrudes from connector bottom face as shown infig 22 & 23.Fig 22Fig 233. Cavity plug removal / Extraction procedure is same for both plug and receptacle housing.REVISION ECR/ECN INFORMATIONA1EC No:110733DATE:30/11/2016DOCUMENT NUMBER:AS-172877-0001SHEET No.Application SpecificationValuseal sealed connector system15 of 16CREATED / REVISED BY:CHECKED BY:APPROVED BY:Ishwar GIshwar GKPTEMPLATE FILENAME: CRIMP SPEC[SIZE A](V.1).DOC

APPLICATION SPECIFICATIONSection 8: Connector/Cable Clamping30-60 mm40.030-60 mmFig 22It is recommended to tie the cables (both side) at a distance of approximately 30-60 mm from thehousing surface and cable should be straight to avoid the strain at sealing area per the fig 22.Section 9: General application notesAppearance: Parts conform to class "C" requirements of cosmetic specification PS-45499-002REVISION ECR/ECN INFORMATIONA1EC No:110733DATE:30/11/2016DOCUMENT NUMBER:AS-172877-0001SHEET No.Application SpecificationValuseal sealed connector system16 of 16CREATED / REVISED BY:CHECKED BY:APPROVED BY:Ishwar GIshwar GKPTEMPLATE FILENAME: CRIMP SPEC[SIZE A](V.1).DOC

APPLICATION SPECIFICATION REVISION Application ECR/ECN INFORMATION Specification Valuseal sealed connector systemA1 SHEET No. EC No: 110733 6 of 16 DATE: 30/11 /2016 DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY: AS-172877-0001 Ishwar G Ishwar G KP TEMPLATE FILENAME: CRIMP_SPEC[SIZE_A](V.1).DOC 3.