Cummins ISX11.9 CM2250 – Service Manual 019-201   Weather Pak Connector Series

Pin Replacement

TOC

This connector is used to connect many different components to the engine, or other devices. The connector can have many different pin configurations. All types of connectors are repaired in the same manner. The two-way connector is displayed in this procedure.

Before installing the new repair wire, perform a test fit to make sure the wire is the correct size.

Refer to the appropriate wiring repair kit in the service tools table in the front of Section 19 for the correct repair wire. Replace one contact wire at a time. If more than one wire needs replaced, attach a lettered tag to each wire removed.

Refer to the wiring diagram in Section E for pin locations.

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To replace the Weather-Pack terminal (1), pull the locking tabs (3) apart on the wire lock (4).

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NOTE: The wire is held in the connector body by the wire lock (1) and two locking lances (2) on the terminal.

Open the wire lock.

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 CAUTION 

This tool can be easily broken. Care must be taken when using this tool. Do not force the tool into place.

Insert the Weather-Pack extraction tool, Part Number 3822608, over the terminal. Use a twisting motion to push the tool to the bottom of the cavity.

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 CAUTION 

If more than one wire is being repaired, tag each wire and install it in the original location. Electrical problems can occur if wires are switched.

Pull the wire and the terminal out of the connector body.

NOTE: The repair wire and the terminal is 127 mm [5 in] long.

Use crimping tool, Part Number 3822930, to cut 127 mm [5 in] of the terminal wire.

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Use wire crimping tool, Part Number 3822930, to remove approximately 6 mm [¼ in] of insulation from the wire.

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NOTE: The shroud connector bodies (1) use pin terminals (2). The tower connector bodies (3) use socket terminals (4).

Before installing the new repair wire, perform a test fit to make sure the wire is the correct size.

Refer to the appropriate wiring repair kit in the service tools table in the front of Section 19 for the correct repair wire. Replace one contact wire at a time. If more than one wire needs to be replaced, attach a lettered tag to each wire removed.

Refer to the wiring diagram in Section E for pin locations.

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Install the correct repair wire on the bare wire.

Make sure that the bare wire extends into the insulated butt splice connector.

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Use wire crimping tool, Part Number 3822930, to crimp the repair wire on the bare wire.

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Use heat gun, Part Number 3822860, to heat the shrink tubing. The tubing will shrink and make the connection waterproof.

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 CAUTION 

If more than one wire is repaired or if the connector body is replaced, make sure to insert the wires into the same locations as they were in. Electrical problems can occur if wires are switched.

Insert the terminal into the connector body. The terminal locking lances must click and hold the terminal in the body.

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Close and latch the wire on the connector body.

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Insert the two connector halves together.

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Connector Replacement

TOC

The connector is used to connect many different components to the engine, or other devices. The connector can have many different pin configurations. All types of connectors are repaired in the same manner. The two-way connector is displayed in this procedure.

Before installing the new connector, perform a test fit to make sure the connector is keyed correctly.

Refer to the appropriate wiring repair kit in the service tools table in the front of Section 19 for the correct repair connector.

Refer to the wiring diagram in Section E for pin locations.

Replace one contact wire at a time. If more than one wire needs to be replaced, attach a lettered tag to each wire removed.

SMALL | MEDIUM | LARGE
   


To replace the Weather-Pack connector body (2), pull the locking tabs (3) apart on the wire lock (4).

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The wire is head in the connector body by the wire lock (1) and two locking lances (2) on the terminal.

Open the wire lock.

SMALL | MEDIUM | LARGE
   


 CAUTION 

This tool can be easily broken. Care must be taken when using this tool. Do not force the tool into place.

Insert Weather-Pack extraction tool, Part Number 3822608, over the terminal. Use a twisting motion to push the tool to the bottom of the cavity.

SMALL | MEDIUM | LARGE
   


Pull the wire and the terminal out of the connector body.

SMALL | MEDIUM | LARGE
   


Before installing the new connector, perform a test fit to make sure the connector is keyed correctly.

Refer to the appropriate wiring repair kit in the service tools table in the front of Section 19 for the correct repair connector.

Replace one contact wire at a time. If more than one wire needs replaced, attached a lettered tag to each wire removed.

SMALL | MEDIUM | LARGE
   


 CAUTION 

If more that one wire is repaired or if the connector body is replaced, make sure to insert the wires into the same locations as they were in. Electrical problems can occur if wires are switched.

Insert the terminal into the connector body. The terminal locking lances must click and hold the terminal in the body.

SMALL | MEDIUM | LARGE
   


Close and latch the wire lock on the connector body.

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Insert the two connector halves together.

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Last Modified:  09-Oct-2003