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Assembly Manual 

2 Way Unsealed  OCS 1.2 Inline  Connection System  

Female/Male OCS 1.2 Terminal System (Unsealed) 

Contact at CTC Warren: Michelle  Smith +1 (330)  306 1089 
Assembly Manual   - 33286031 

22 

MALE ASSEMBLY 

– COMPLETED HARNESS  ASSEMBLY 

ASSEMBLY 

PERFORM TESTS, APPLY COVERINGS IF REQUIRED.  INSPECT THE ASSEMBLY. 

CONNECTOR HINGE MUST BE COMPLETELY CLOSED  

BEFORE TAPING OR DRESSING WIRES/HARNESS 

Содержание 101

Страница 1: ...rren Ohio STC Saltillo Mex October 2015 2 Way Unsealed OCS 1 2 Inline Connection System Female Male OCS 1 2 Terminal System Unsealed ASSEMBLY MANUALS PRE ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY ASSEMBLY MANUAL 33286031 ...

Страница 2: ...e part of DELPHI All the information is correct at time of releasing Reprinting or translation is not permitted without written permission from DELPHI Copyright 2015 DELPHI All rights reserved Developed by Deniss Guerrero 52 844 438 90 60 Assembly Manual 2 Way Unsealed OCS 1 2 Inline Connection System Female Male OCS 1 2 Terminal System Unsealed ...

Страница 3: ...SSEMBLY SECTION ASSEMBLY OF THE FEMALE HARNESS ASSEMBLY CONNECTOR 10 List of Components Exploded View 11 ASSEMBLY SEQUENCE Step 1 Identify Cavities for Terminals OCS 1 2 or Equivalent 12 Step 2 Align T erminals Female 1 2 and Female Assembly 12 Step 3 Insert Terminals Female OCS 1 2 or Equivalent 13 Step 4 Lock Connector Hinge to Closed Position 14 Harness Assembly Completed 15 ASSEMBLY OF THE MAL...

Страница 4: ...gn Index Features and Mate Female Assembly and Male Assembly Together 26 Step 3 Lock CPA to Full Stage Position 27 Connection System Completed Assembly 28 DISASSEMBLY SECTION DISASSEMBLY OF THE CONNECTION SYSTEM 29 Step 1 Move CPA to Pre Stage Position 30 Step 2 Disconnect 31 Connection System Completed Disassembly 31 REPAIR REPLACEMENT SECTION FEMALE CONNECTOR SUB COMPONENTS 32 TERMINAL F OCS 1 2...

Страница 5: ...ale OCS 1 2 Terminal System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 2 Way Unsealed OCS 1 2 Inline Connection System ASSEMBLY OF THE FEMALE CONNECTOR 5 FEMALE CONNECTOR ASSEMBLY PRE ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY ASSEMBLY ...

Страница 6: ...le Smith 1 330 306 1089 Assembly Manual 33286031 6 VIEW OF VERSIONS ASSEMBLY THIS CONNECTION SYSTEM HAS MULTIPLE CONFIGURATIONS WHICH DIFFER IN THE INDEXING AND COLOR THE METHOD OF ASSEMBLY IS THE SAME FOR ALL CONNECTORS REGARDLESS OF THEIR DIFFERENCES REFER TO LATEST TAXI ASSEMBLY DRAWING FOR DETAILS Type 101 Type 102 Type 103 Type 104 ...

Страница 7: ...en Michelle Smith 1 330 306 1089 Assembly Manual 33286031 7 Pictures used in this Assembly Manual and original parts may differ in some details These differences have no influence on the assembly process ASSEMBLY FEMALE CONNECTOR QUANTITY COMPONENTS 1 FEMALE CONNECTOR 1 CPA LIST OF COMPONENTS LIST OF COMPONENTS EXPLODED VIEW CPA ...

Страница 8: ...t CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 8 STEP 1a Assemble CPA to Pre Stage Position STEP 1b Assemble CPA to Pre Stage Position ASSEMBLY IDENTIFY THE CORRECT ORIENTATIONOF THE CPAAND INSERT IT ONTO THE CONNECTOR VERIFYAUDIBLE CLICK ON BOTH LOCKS CPA IS NOW IN PRE STAGE POSITION SECTION VIEW ...

Страница 9: ...y Unsealed OCS 1 2 Inline Connection System Female Male OCS 1 2 Terminal System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 9 FEMALE CONNECTOR ASSEMBLY COMPLETED ASSEMBLY ASSEMBLY ...

Страница 10: ...Male OCS 1 2 Terminal System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 2 Way Unsealed OCS 1 2 Inline Connection System 10 FEMALE ASSEMBLY PRE ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY ASSEMBLY ASSEMBLY OF THE FEMALE HARNESS ASSEMBLY ...

Страница 11: ...6 1089 Assembly Manual 33286031 11 Pictures used in this Assembly Manual and original parts may differ in some details these differences have no influence on the assembly process ASSEMBLY FEMALE CONNECTOR ASSEMBLY QUANTITY COMPONENTS 1 FEMALE CONNECTOR ASSEMBLY 2 TERMINAL OCS 1 2 LIST OF COMPONENTS EXPLODED VIEW TERMINAL LIST OF COMPONENTS EXPLODED VIEW ...

Страница 12: ...089 Assembly Manual 33286031 12 STEP 1 Identify Cavities for Terminals OCS 1 2 or Equivalent STEP 2 Align Terminals Female 1 2 and Female Assembly ASSEMBLY CAVITY ID NUMBERS LOCATED AT THE BACK OF THE CONNECTOR BACK VIEW INSERT FEMALETERMINALS INTO RECEPTACLEHOUSING ACCORDING TO INSERTION PLAN PROPER ORIENTATIONOF TERMINAL REQUIRED INDEX FEATURE BACK VIEWS ...

Страница 13: ...mbly Manual 33286031 13 STEP 3a Insert Terminals Female OCS 1 2 or Equivalent STEP 3b Insert Terminals Female OCS 1 2 or Equivalent ASSEMBLY TERMINAL FULLYENGAGED UNDER THE FLEX LOCK VERIFY AUDIBLE CLICK 1 2 PUSH THE TERMINAL STRAIGHT INTO THE CAVITY GENTLY PULL ON THE CABLE TO VERIFY THE LOCK SYSTEM 3 USE THE SAME PROCESS TO INSERT THE REST OF THE TERMINALS NEEDED ...

Страница 14: ...TC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 14 STEP 4a Lock Connector Hinge to Closed Position STEP 4b Lock Connector Hinge to Closed Position ASSEMBLY CAREFULLY PUSH THE HINGE FORWARD VERIFY AUDIBLE CLICK DO NOT FORCE THE HINGE IF IT CAN T BE CLOSED REVIEW IF TERMINALS ARE PROPERLYLOCKED LOCKED HINGE ...

Страница 15: ...l System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 15 FEMALE ASSEMBLY COMPLETED HARNESS ASSEMBLY ASSEMBLY PERFORM TESTS APPLY COVERINGS AS REQUIRED INSPECT THE ASSEMBLY CONNECTORHINGE MUST BE COMPLETELYCLOSED BEFORE TAPING OR DRESSING WIRES HARNESS ...

Страница 16: ...e Male OCS 1 2 Terminal System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 2 Way Unsealed OCS 1 2 Inline Connection System 16 MALE ASSEMBLY PRE ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY ASSEMBLY ASSEMBLY OF THE MALE HARNESS ASSEMBLY ...

Страница 17: ...chelle Smith 1 330 306 1089 Assembly Manual 33286031 17 VIEW OF VERSIONS ASSEMBLY THIS CONNECTION SYSTEM HAS MULTIPLE CONFIGURATIONS WHICH DIFFER IN THE INDEXING AND COLOR THE METHOD OF ASSEMBLY IS THE SAME FOR ALL CONNECTORS REGARDLESS OF THEIR DIFFERENCES REFER TO LATEST TAXI DRAWING FOR DETAILS Type 101 Type 102 Type 103 Type 104 ...

Страница 18: ...th 1 330 306 1089 Assembly Manual 33286031 18 Pictures used in this Assembly Manual and original parts may differ in some details these differences have no influence on the assembly process ASSEMBLY MALE CONNECTOR QUANTITY COMPONENTS 1 MALE CONNECTOR 2 TERMINAL OCS 1 2 LIST OF COMPONENTS EXPLODED VIEW LIST OF COMPONENTS EXPLODED VIEW TERMINAL ...

Страница 19: ...06 1089 Assembly Manual 33286031 19 STEP 1 Identify Cavities for Terminals OCS or Equivalent STEP 2 Align Terminals Male 1 2 and Male Assembly ASSEMBLY CAVITY ID NUMBERS LOCATED AT THE BACK OF THE CONNECTOR BACK VIEW INSERT MALE TERMINALS INTO RECEPTACLEHOUSING ACCORDING TO INSERTION PLAN PROPER ORIENTATIONOF TERMINAL REQUIRED INDEX FEATURES BACK VIEWS ...

Страница 20: ...embly Manual 33286031 20 STEP 3a Insert Terminals Male OCS 1 2 or Equivalent STEP 3b Insert Terminals Male OCS 1 2 or Equivalent ASSEMBLY TERMINAL FULLY ENGAGED UNDER THE FLEX LOCK VERIFY AUDIBLE CLICK 1 2 PUSH THE TERMINAL STRAIGHT INTO THE CAVITY GENTLY PULL ON THE CABLE TO VERIFY THE LOCK SYSTEM 3 USE THE SAME PROCESS TO INSERT THE REST OF THE TERMINALS NEEDED ...

Страница 21: ...led Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 21 STEP 4a Lock Connector Hinge to Closed Position STEP 4b Lock Connector Hinge to Closed Position ASSEMBLY VERIFY AUDIBLE CLICK DO NOT FORCE THE HINGE IF IT CAN T BE CLOSED REVIEW IF TERMINALS ARE PROPERLYLOCKED LOCKED HINGE ...

Страница 22: ...al System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 22 MALE ASSEMBLY COMPLETED HARNESS ASSEMBLY ASSEMBLY PERFORM TESTS APPLY COVERINGS IF REQUIRED INSPECT THE ASSEMBLY CONNECTORHINGE MUST BE COMPLETELYCLOSED BEFORE TAPING OR DRESSING WIRES HARNESS ...

Страница 23: ... OCS 1 2 Terminal System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 2 Way Unsealed OCS 1 2 Inline Connection System ASSEMBLY OF THE CONNECTION SYSTEM 23 FEMALE ASSEMBLY MALE ASSEMBLY PRE ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY ASSEMBLY ...

Страница 24: ...6 1089 Assembly Manual 33286031 24 ASSEMBLY MALE ASSEMBLY QUANTITY COMPONENTS OF 2 WAY UNSEALED OCS 1 2 INLINE CONNECTION SYSTEM 1 MALE ASSEMBLY 1 FEMALE ASSEMBLY LIST OF COMPONENTS EXPLODED VIEW Pictures used in this Assembly Manual and original parts may differ in some details These differences have no influence on the assembly process FEMALE ASSEMBLY ...

Страница 25: ...sealed OCS 1 2 Inline Connection System Female Male OCS 1 2 Terminal System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 25 3D MODEL VIEW CLICK IMAGE TO START 3D VISUALIZATION ASSEMBLY ...

Страница 26: ...minal System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 26 STEP 1 Identify Index Features STEP 2a Align Index Features and Mate Female Assembly and Male Assembly Together ASSEMBLY IMPORTANT IF THE INDEXES DON T LINE UP DO NOT CONTINUE FRONT VIEWS ...

Страница 27: ... Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 27 STEP 2b Align Index Features and Mate Female Assembly and Male Assembly Together STEP 3a Lock CPA to Full Stage Position ASSEMBLY VERIFY AUDIBLE CLICK SLIDE THE CPAFORWARD AS SHOWN BELOW TO SECURE THE CONNECTION ...

Страница 28: ...Female Male OCS 1 2 Terminal System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 28 STEP 3b Lock CPA to Full Stage Position CONNECTION SYSTEM COMPLETED ASSEMBLY ASSEMBLY CPA IS NOW IN FULL STAGE POSITION VERIFY AUDIBLE CLICK ...

Страница 29: ...S 1 2 Terminal System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 2 Way Unsealed OCS 1 2 Inline Connection System DISASSEMBLY OF THE CONNECTION SYSTEM 29 FEMALE ASSEMBLY MALE ASSEMBLY DISASSEMBLY PRE ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY ...

Страница 30: ...inal System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 30 STEP 1a Move CPA to Pre Stage Position STEP 1b Move CPA to Pre Stage Position DISASSEMBLY HOLD THE CPA TAB THEN SLIDE BACK THE CPA TO PLACE IT IN PRE STAGE CPA IS NOW IN PRE STAGE POSITION ...

Страница 31: ...CS 1 2 Terminal System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 31 STEP 2 Disconnect CONNECTION SYSTEM COMPLETED DISASSEMBLY DISASSEMBLY LOCATE AND PRESS DOWN THE CONNECTORLOCK 1 WITH THE LOCK DEFLECTED DISENGAGE THE CONNECTORS 2 1 2 ...

Страница 32: ... System Female Male OCS 1 2 Terminal System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 2 Way Unsealed OCS 1 2 Inline Connection System REPAIR REPLACEMENT OF THE FEMALE ASSEMBLY 32 REPAIR REPLACEMENT FEMALE ASSEMBLY ...

Страница 33: ...Assembly Manual 33286031 33 FEMALE TERMINAL OCS 1 2 REPLACEMENT Release Connector Hinge STEP 1a FEMALE TERMINAL OCS 1 2 REPLACEMENT Release Connector Hinge STEP 1b REPAIR REPLACEMENT IDENTIFY THE SIDE OF THE HINGE WITH A CHAMFER THEN INSERT TOOLTBD BETWEEN THE CONNECTORBODY AND HINGE CONNECTOR HINGE RELEASED ROTATE THE TOOLCAREFULLY TOUNLOCK THE CONNECTORHINGE ...

Страница 34: ... Assembly Manual 33286031 34 FEMALE TERMINAL OCS 1 2 REPLACEMENT Remove Terminal STEP 2a FEMALE TERMINAL OCS 1 2 REPLACEMENT Remove Terminal STEP 2b REPAIR REPLACEMENT REMOVE TERMINALS This graph justrepresents how this kind of terminals are removed Removal Window IDENTIFY Removal Window Terminal Mating End Cable End Flex Lock FLEX LOCK TERMINAL REMOVAL WINDOW ...

Страница 35: ...MINAL OCS 1 2 REPLACEMENT Insert Terminal STEP 3 REPAIR REPLACEMENT REFER TO HARNESS ASSEMBLY SECTION REMOVE TERMINALS Locate Removal Window at the front of the Connector Insert Operation 1 tool TBD straight into the window deflect the Flex Lock to unseat the Terminal and gently pull on the cable to remove Operation 2 the Female Terminal from the receptacle OPERATION 1 OPERATION 2 Removal Tool Thi...

Страница 36: ...on System Female Male OCS 1 2 Terminal System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 2 Way Unsealed OCS 1 2 Inline Connection System REPAIR REPLACEMENT OF THE MALE ASSEMBLY 36 REPAIR REPLACEMENT MALE ASSEMBLY ...

Страница 37: ...9 Assembly Manual 33286031 37 MALE TERMINAL OCS 1 2 REPLACEMENT Release Connector Hinge STEP 1a MALE TERMINAL OCS 1 2 REPLACEMENT Release Connector Hinge STEP 1b REPAIR REPLACEMENT IDENTIFY THE SIDE OF THE HINGE WITH A CHAMFER THEN INSERT TOOLTBD BETWEEN THE CONNECTORBODY AND HINGE CONNECTOR HINGE RELEASED ROTATE THE TOOLCAREFULLY TOUNLOCK THE CONNECTORHINGE ...

Страница 38: ...1089 Assembly Manual 33286031 38 MALE TERMINAL OCS 1 2 REPLACEMENT Remove Terminal STEP 2a MALE TERMINAL OCS 1 2 REPLACEMENT Remove Terminal STEP 2b REPAIR REPLACEMENT REMOVE TERMINALS This graph justrepresents how this kind of terminals are removed IDENTIFY Flex Locks Mating End Cable End REMOVAL WINDOW TERMINAL FLEX LOCK Removal Window Terminal Flex Lock ...

Страница 39: ...INAL OCS 1 2 REPLACEMENT Insert Terminal STEP 3 REPAIR REPLACEMENT REFER TO HARNESS ASSEMBLY SECTION REMOVE TERMINALS Locate Removal Window at the front of the Connector Insert Operation 1 tool TBD straight into the window deflect the Flex Lock to unseat the Terminal and gently pull on the cable to remove Operation 2 the Male Terminal from the receptacle OPERATION 1 OPERATION 2 Removal Tool This g...

Страница 40: ...nsealed OCS 1 2 Inline Connection System Female Male OCS 1 2 Terminal System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 40 RECOMMENDED REPAIR TOOLS ITEM DELPHI PART NUMBER 1 2 3 TBD ...

Страница 41: ...onnection System Female Male OCS 1 2 Terminal System Unsealed Contact at CTC Warren Michelle Smith 1 330 306 1089 Assembly Manual 33286031 DATE REV REVISION HISTORY AUTH 09OC15 01 RELEASED 430721 18JA17 02 REVISED PAGES 11 AND 18 435401 41 REVISIONS ...

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