ASSEMBLY INSTRUCTIONS GT MIXED 150/280 SEALED CONNECTION SYSTEM

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1 ASSEMBLY INSTRUCTIONS GT MIXED 150/280 SEALED CONNECTION SYSTEM NOTE: PLEASE CONTACT YOUR DELPHI SALES REPRESENTATIVE WITH ANY QUESTIONS OR COMMENTS CONCERNING THESE ASSEMBLY INSTRUCTIONS. COMPONENT P/N S AND REPAIR TOOL P/N S ARE AVAILABLE FROM YOUR DELPHI SALES ENGINEER. Delphi Connections Systems Page 1 of 11 11/19/99

2 FEMALE GT MIXED 150/280 CONNECTOR COMPONENTS CONNECTOR BODY SEAL LEVER LOCK TPA Delphi Connections Systems Page 2 of 11 11/19/99

3 ASSEMBLY INSTRUCTIONS FEMALE GT MIXED 150/280 CONNECTOR STEP 1: ASSEMBLE SEAL TO CONNECTOR BODY. APPLY TO OUTSIDE WALL OF TERMINAL TOWER USING REPAIR TOOL GM OR EQUIVALENT. STEP 2: BUILD LEVER LOCK TO CONNECTOR. A. HOLD CONNECTOR MATING SIDE AWAY FROM HAND AND HOLD LEVER LOCK FLAT SIDE UP (WITH EXTENSIONS TOWARD CONNECTOR) B. PLACE SMALL DIAMETER HOLE ON LEVER LOCK OVER SMALL PEG ON CONNECTOR BODY AND SNAP INTO PLACE. POSITION LARGE DIAMETER HOLE ON LEVER LOCK OVER LARGE PEG ON OPPOSITE SIDE OF CONNECTOR BODY AND SNAP INTO PLACE. LOCK LEVER INTO OPEN POSITION BY PULLING LEVER TOWARDS PLUGGING END OF CONNECTOR UNTIL IT STOPS. STEP 3: PLUG LEADS TO CONNECTOR ASSEMBLY PER PRINT. STEP 4: AFTER ALL LEADS ARE PLUGGED, BUILD ONE TERMINAL POSITION ASSURANCE (TPA), AT A TIME TO CONNECTOR ASSEMBLY. LINE UP WIRE GROOVES ON TPA WITH CORRESPONDING WIRE CAVITIES AND VERIFY ONE LEAD PER GROOVE. APPLY PRESSURE WITH FINGERS TO LOCK INTO PLACE. Delphi Connections Systems Page 3 of 11 11/19/99

4 ASSEMBLY INSTRUCTIONS FOR FEMALE GT MIXED 150/280 CONNECTOR CONNECTOR BODY SEAL STEP 1: ASSEMBLE SEAL TO CONNECTOR BODY. FULLY SEAT SEAL TO OUTSIDE WALL OF TERMINAL TOWER (UNTIL SEAL BOTTOMS OUT) USING REPAIR TOOL GM OR EQUIVALENT. USE CARE DURING SEAL INSTALLATION TO ELIMINATE THE RISK OF DAMAGING THE SEAL. COMPLETED STEP 1 Delphi Connections Systems Page 4 of 11 11/19/99

ASSEMBLY INSTRUCTIONS FEMALE GT MIXED 150/280 CONNECTOR Connection Systems CONNECTOR STEP 2: BUILD LEVER

HOLD CONNECTOR MATING SIDE AWAY FROM HAND AND HOLD LEVER LOCK FLAT SIDE UP (WITH EXTENSIONS TOWARD

PLACE SMALL DIAMETER HOLE ON LEVER LOCK OVER SMALL PEG ON CONNECTOR BODY AND SNAP INTO PLACE.

5 ASSEMBLY INSTRUCTIONS FEMALE GT MIXED 150/280 CONNECTOR Connection Systems CONNECTOR STEP 2: BUILD LEVER LOCK TO CONNECTOR. A. HOLD CONNECTOR MATING SIDE AWAY FROM HAND AND HOLD LEVER LOCK FLAT SIDE UP (WITH EXTENSIONS TOWARD CONNECTOR). LEVER LOCK STEP 2: B. PLACE SMALL DIAMETER HOLE ON LEVER LOCK OVER SMALL PEG ON CONNECTOR BODY AND SNAP INTO PLACE. POSITION LARGE DIAMETER HOLE ON LEVER LOCK OVER LARGE PEG ON OPPOSITE SIDE OF CONNECTOR BODY AND SNAP INTO PLACE. LOCK LEVER INTO OPEN POSITION BY PULLING LEVER TOWARDS PLUGGING END OF CONNECTOR UNTIL IT STOPS. COMPLETED STEP 2 Delphi Connections Systems Page 5 of 11 11/19/99

ASSEMBLY INSTRUCTIONS FEMALE GT MIXED 150/280 CONNECTOR STEP 3: PLUG

TPA s STEP 4: AFTER ALL LEADS ARE PLUGGED, BUILD ONE TERMINAL POSITION

LINE UP WIRE GROOVES ON TPA WITH CORRESPONDING WIRE CAVITIES AND VERIFY

6 ASSEMBLY INSTRUCTIONS FEMALE GT MIXED 150/280 CONNECTOR STEP 3: PLUG LEADS TO CONNECTOR ASSEMBLY PER PRINT. TPA s STEP 4: AFTER ALL LEADS ARE PLUGGED, BUILD ONE TERMINAL POSITION ASSURANCE (TPA), AT A TIME TO CONNECTOR ASSEMBLY. LINE UP WIRE GROOVES ON TPA WITH CORRESPONDING WIRE CAVITIES AND VERIFY ONE LEAD PER GROOVE. APPLY PRESSURE WITH FINGERS TO LOCK INTO PLACE. COMPLETED STEP 4 Delphi Connections Systems Page 6 of 11 11/19/99

7 MALE GT MIXED 150/280 CONNECTOR COMPONENTS CONNECTOR BODY TPA STABILIZER Delphi Connections Systems Page 7 of 11 11/19/99

8 ASSEMBLY INSTRUCTIONS FOR MALE GT MIXED 150/280 CONNECTOR STEP 1: APPLY STABILIZER TO CONNECTOR BODY. SLIDE STABILIZER INTO MATING END OF CONNECTOR AND SEAT USING FINGERS. STEP 2: PLUG LEADS TO ASSEMBLY PER PRINT. STEP 3: AFTER ALL LEADS ARE PLUGGED, BUILD ONE TERMINAL POSTION ASSURANCE (TPA), AT A TIME TO CONNECTOR BODY. LINE UP GROOVES ON TPA WITH CORRESPONDING WIRE CAVITIES AND VERIFY ONE LEAD PER GROOVE. APPLY PRESSURE WITH FINGERS TO LOCK INTO PLACE. Delphi Connections Systems Page 8 of 11 11/19/99

SLIDE STABILIZER INTO MATING END OF CONNECTOR AND SEAT USING FINGERS.

9 ASSEMBLY INSTRUCTIONS FOR MALE GT MIXED 150/280 CONNECTOR CONNECTOR BODY STABILIZER STEP 1: APPLY STABILIZER TO CONNECTOR BODY. SLIDE STABILIZER INTO MATING END OF CONNECTOR AND SEAT USING FINGERS. (STABILIZER WILL SNAP INTO PLACE). COMPLETED STEP 1 STEP 2: PLUG LEADS TO CONNECTOR ASSEMBLY PER PRINT. Delphi Connections Systems Page 9 of 11 11/19/99

LINE UP GROOVES ON TPA WITH CORRESPONDING WIRE CAVITIES AND VERIFY ONE LEAD PER GROOVE.

10 ASSEMBLY INSTRUCTIONS FOR MALE GT MIXED 150/280 CONNECTOR CONNECTOR BODY TPA s STEP 3: AFTER ALL LEADS ARE PLUGGED, BUILD ONE TERMINAL POSTION ASSURANCE (TPA), AT A TIME TO CONNECTOR BODY. LINE UP GROOVES ON TPA WITH CORRESPONDING WIRE CAVITIES AND VERIFY ONE LEAD PER GROOVE. APPLY PRESSURE WITH FINGERS TO LOCK INTO PLACE. COMPLETED STEP 3 Delphi Connections Systems Page 10 of 11 11/19/99

PULL CAM LEVER TOWARDS THE MALE CONNECTOR UNTIL COMPONENTS ARE COMPLETELY SEATED TOGETHER.

11 FINAL ASSEMBLY INSTRUCTIONS FOR FEMALE & MALE GT MIXED 150/280 CONNECTORS FINAL ASSEMBLY MATE PARTS TOGETHER TO PRE- STAGE POSTION; LEVER WILL RELEASE. PULL CAM LEVER TOWARDS THE MALE CONNECTOR UNTIL COMPONENTS ARE COMPLETELY SEATED TOGETHER. (CAM LEVER MUST SNAP INTO PLACE. CONNECTION IS NOW LOCKED INTO ITS FINAL POSITION) COMPLETED FINAL ASSEMBLY of the Mated Parts Delphi Connections Systems Page 11 of 11 11/19/99

2-6-way Connector Family for GT 150 Terminal System

2-6-way Connector Family for GT 150 Terminal System SEALED Assembly / Disassembly D REV 04, May 2013 15326959 15326960 15326962 TABLE OF CONTENTS Exploded view List of components View of versions FEMALE