Delphi HV-2000 User manual

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

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.
Developed by : Deniss Guerrero [phone]
Assembly Manual
HV-2000 Right Angle Bolted Connector
Power Pack 2000 Terminal System (Sealed)

Assembly Manual
HV-2000 Right Angle Bolted Connector
Power Pack 2000 Terminal System (Sealed)
Contact at CTC Warren: Nicholas Durse [phone]
| www.delphi.com |
Assembly Manual - 33366036
TABLE OF CONTENTS
3
CONNECTOR–ASSEMBLY SECTION
ASSEMBLY OF THE FEMALE CONNECTOR
5
List of Components & Exploded View
6
Step 1 –Assembly O-Ring Seal onto Bolt
7
Step 2 –Retain Bolt to Housing with Bolt Retainer
7
Step 3 –Insert Face Seal into Housing Shroud
9
Step 4 –Press Shunt into the Inner Connector
10
Step 5 –Assembly Inner Connector
11
Connector Assembly –Completed
12
HARNESS ASSEMBLY SECTION
ASSEMBLY OF THE FEMALE HARNESS ASSEMBLY CONNECTOR
13
List of Components & Exploded View
14
Step 1 –Insert Retainer and Cable Seal onto Coaxial Cable
15
Step 2 –Partially Strip the Cables and Remove Stripped Insulation
16
Step 3 –Insert and Crimp Ferrules
17
Step 4 –Sonic Weld Female Terminal
19
Step 1 –Identify Cavities
20
Step 2 –Align and Insert Terminals Female Power Pack 2000
20
Step 3 –Assemble Lock TPA/Clip
22
Step 4 –Insert Cable Seal into the Housing
23
Step 5 –Install Seal Retainers
23
Harness Assembly –Completed
24

Assembly Manual
HV-2000 Right Angle Bolted Connector
Power Pack 2000 Terminal System (Sealed)
Contact at CTC Warren: Nicholas Durse [phone]
| www.delphi.com |
Assembly Manual - 33366036
TABLE OF CONTENTS
4
CAR ASSEMBLY SECTION
ASSEMBLY OF THE CONNECTION SYSTEM
25
List of Components & Exploded View
26
Step 1 –Identify Index Features in both the Mating Interface and Bolted Connector
27
Step 2 –Assembly Bolted Connector onto Mating Interface
27
Connection System –Completed Assembly
29
DISASSEMBLY SECTION
DISASSEMBLY OF THE CONNECTION SYSTEM
30
Step 1 –Disconnect
31
Connection System –Completed Disassembly
31
REPAIR SECTION
FEMALE CONNECTOR SUB COMPONENTS:
32
LOCK TPA/CLIP Replacement –Step 1 (Remove)
33
Step 2 (Insert)
33
FEMALE TERMINAL Replacement –Step 1 (Release Seal Retainer)
34
Step 2 (Remove Terminal)
35
Step 3 (Insert Terminals)
36
INNER CONNECTOR Replacement –Step 1 (Remove)
36
Step 2 (Insert)
37
BOLT Replacement –Step 1 (Remove)
37
Step 2 (Insert)
38
Recommended Repair Tools
39
REVISIONS
40

Assembly Manual
HV-2000 Right Angle Bolted Connector
Power Pack 2000 Terminal System (Sealed)
Contact at CTC Warren: Nicholas Durse [phone]
| www.delphi.com |
Assembly Manual - 33366036
HV-2000 Right Angle Bolted Connector
ASSEMBLY OF THE
FEMALE CONNECTOR
5
FEMALE CONNECTOR
ASSEMBLY
CONNECTOR - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY
ASSEMBLY

Assembly Manual
HV-2000 Right Angle Bolted Connector
Power Pack 2000 Terminal System (Sealed)
Contact at CTC Warren: Nicholas Durse [phone]
| www.delphi.com |
Assembly Manual - 33366036 6
Pictures used in this Assembly Manual and original parts may differ in some
details. These differences have no influence on the assembly process.
ASSEMBLY
QUANTITY COMPONENTS
1 BOLT RETAINER
1 FACE SEAL
1 INNER CONNECTOR
1 SHUNT
1 HOUSING
1 O-RING SEAL
1 BOLT
LIST OF COMPONENTS & EXPLODED VIEW
O-RING SEAL
FACE SEAL
BOLT
RETAINER
INNER CONNECTOR
HOUSING
BOLT
REFER TO LATEST DRAWING 33352038 FOR PART NUMBERS AND DETAILS
SHUNT

Assembly Manual
HV-2000 Right Angle Bolted Connector
Power Pack 2000 Terminal System (Sealed)
Contact at CTC Warren: Nicholas Durse [phone]
| www.delphi.com |
Assembly Manual - 33366036 7
STEP 1 –Assembly O-Ring Seal onto Bolt
STEP 2a –Retain Bolt to Housing with Bolt Retainer
ASSEMBLY
INSERT O-RING SEAL ONTO BOLT AND PLACE IT
UNDERNEATH THE BOLT HEAD IMPORTANT! VERIFY THAT O-RING SEAL IS NOT
ROLLED OR DAMAGED DURING THE INSERTION
O-RING SEAL INSERTED
IMPORTANT! USE OF PROPER LUBRICANT IS
REQUIRED FOR O-RING SEAL ASSEMBLY
INSERT THE BOLT ASSEMBLY INTO THE
HOUSING HOLE ONCE THE BOLT HAS BEEN INSERTED, PLACE THE HOUSING ONTO THE ASSEMBLY FIXTURE

Assembly Manual
HV-2000 Right Angle Bolted Connector
Power Pack 2000 Terminal System (Sealed)
Contact at CTC Warren: Nicholas Durse [phone]
| www.delphi.com |
Assembly Manual - 33366036 8
STEP 2b –Retain Bolt to Housing with Bolt Retainer
STEP 2c –Retain Bolt to Housing with Bolt Retainer
ASSEMBLY
BOLT RETAINER INSERTED
PLACE BOLT RETAINER ONTO THE BOLT AS SHOWN BELOW,
BOLT RETAINER FLAT FACE MUST BE FACING TOWARD THE HOUSING
IMPORTANT! BOLT RETAINER ORIENTATION IS CRITICAL TO ACHIEVE THE CORRECT FUNCTION OF THE BOLT
PRESS THE BOLT RETAINER DOWN UNTIL IT SURPASSES THE BOLT NOTCH,
VISIBLE CRACKS ARE NOT PERMITTED AFTER BEING ASSEMBLED

Assembly Manual
HV-2000 Right Angle Bolted Connector
Power Pack 2000 Terminal System (Sealed)
Contact at CTC Warren: Nicholas Durse [phone]
| www.delphi.com |
Assembly Manual - 33366036 9
STEP 3a –Insert Face Seal into Housing Shroud
STEP 3b –Insert Face Seal into Housing Shroud
ASSEMBLY
FACE SEAL INSERTED
IMPORTANT! VERIFY THAT FACE SEAL IS EVENLY
ASSEMBLED AND NOT BUNCHED OR ROLLED DURING
THE INSERTION
INSERT FACE SEAL ONTO ASSEMBLY FIXTURE MAKE SURE THE SEAL MUST IS NOT BUNCHED
OR ROLLED
PRESS THE SEAL INTO THE HOUSING SHROUD
SEAL IS ORIENTED WITH THE SEAL RETENTION BUMPS
AS SHOWN

Assembly Manual
HV-2000 Right Angle Bolted Connector
Power Pack 2000 Terminal System (Sealed)
Contact at CTC Warren: Nicholas Durse [phone]
| www.delphi.com |
Assembly Manual - 33366036 10
STEP 4a –Press Shunt into the Inner Connector
STEP 4b –Press Shunt into the Inner Connector
ASSEMBLY
LOCATE THE SLOT TO INSERT THE SHUNT AND PRESS IT INTO THE INNER CONNECTOR
PUSH INNER CONNECTOR INTO THE HOUSING SHROUD
SHUNT INSERTED

Assembly Manual
HV-2000 Right Angle Bolted Connector
Power Pack 2000 Terminal System (Sealed)
Contact at CTC Warren: Nicholas Durse [phone]
| www.delphi.com |
Assembly Manual - 33366036 11
STEP 5a –Assembly Inner Connector
STEP 5b –Assembly Inner Connector
ASSEMBLY
IDENTIFY THE PROPER ORIENTATION OF THE INNER CONNECTOR
AND REVIEW THAT ITS SHUNT IS PRESENT AND UNDAMAGED
PUSH INNER CONNECTOR INTO THE HOUSING SHROUD

Assembly Manual
HV-2000 Right Angle Bolted Connector
Power Pack 2000 Terminal System (Sealed)
Contact at CTC Warren: Nicholas Durse [phone]
| www.delphi.com |
Assembly Manual - 33366036 12
STEP 5c –Assembly Inner Connector
FEMALE CONNECTOR ASSEMBLY –COMPLETED
ASSEMBLY
VERIFY AUDIBLE CLICK ON THE THREE LOCKS
1
2 3
INNER CONNECTOR ASSEMBLED

Assembly Manual
HV-2000 Right Angle Bolted Connector
Power Pack 2000 Terminal System (Sealed)
Contact at CTC Warren: Nicholas Durse [phone]
| www.delphi.com |
Assembly Manual - 33366036
HV-2000 Right Angle Bolted Connector
13
CONNECTOR - ASSEMBLY HARNESS ASSEMBLY CAR ASSEMBLY
ASSEMBLY
ASSEMBLY OF THE
FEMALE HARNESS ASSEMBLY

Assembly Manual
HV-2000 Right Angle Bolted Connector
Power Pack 2000 Terminal System (Sealed)
Contact at CTC Warren: Nicholas Durse [phone]
| www.delphi.com |
Assembly Manual - 33366036
QUANTITY COMPONENTS
1 FEMALE CONNECTOR ASSEMBLY
1 LOCK TPA/CLIP
1 MOUN SCREW PAN HD
2 FEMALE TERMINALASSEMBLY - POWER PACK 2000
14
Pictures used in this Assembly Manual and original parts may differ in some
details, these differences have no influence on the assembly process.
ASSEMBLY
MOUN SCREW PAN HD
LIST OF COMPONENTS & EXPLODED VIEW
LOCK TPA/CLIP
FEMALE CONNECTOR ASSEMBLY
FEMALE TERMINAL
ASSEMBLY
REFER TO LATEST DRAWING 33352038 FOR PART NUMBERS AND DETAILS

Assembly Manual
HV-2000 Right Angle Bolted Connector
Power Pack 2000 Terminal System (Sealed)
Contact at CTC Warren: Nicholas Durse [phone]
| www.delphi.com |
Assembly Manual - 33366036 15
STEP 1a –Insert Retainer and Cable Seal onto Coaxial Cable
STEP 1b –Insert Retainer and Cable Seal onto Coaxial Cable
ASSEMBLY
SLIDE RETAINER AND SEAL FAR ENOUGH TO PREVENT ANY INTERFERENCE WITH THE REST OF THE PROCESS,
LEAVE A GAP BETWEEN STRAIN RELIEF AND CABLE SEAL (A TOOL WILL BE PLACED THERE FOR SEAL ASSEMBLY)
RETAINER & CABLE
SEAL INSERTED
IMPORTANT! VERIFY THAT CABLE SEAL IS NOT ROLLED OR DAMAGED DURING THE INSERTION
SLIDE RETAINER OVER THE CABLE WITH THE LOCKS FACING TOWARD THE FRONT
SLIDE CABLE SEAL OVER CABLE

Assembly Manual
HV-2000 Right Angle Bolted Connector
Power Pack 2000 Terminal System (Sealed)
Contact at CTC Warren: Nicholas Durse [phone]
| www.delphi.com |
Assembly Manual - 33366036 16
STEP 2a –Partially Strip the Cables and Remove Stripped Insulation
STEP 2b –Partially Strip the Cables and Remove Stripped Insulation
ASSEMBLY
0.0
A
B
See latest connector assembly drawing for
final A and B dimensions
REMOVE OUTER JACKET AND BRAID, THE CORE STAYS COVERED WITH THE PARTIALLY
STRIPPED INNER JACKET
CORE BRAID
OUTER JACKET
INNER JACKET

Assembly Manual
HV-2000 Right Angle Bolted Connector
Power Pack 2000 Terminal System (Sealed)
Contact at CTC Warren: Nicholas Durse [phone]
| www.delphi.com |
Assembly Manual - 33366036 17
STEP 3a –Insert and Crimp Ferrules
STEP 3b –Insert and Crimp Ferrules
ASSEMBLY
IMPORTANT! DO NOT REMOVE INNER JACKET FROM THE CORE
SLIDE INNER FERRULE ON CABLE AND PLACE IT OVER THE OUTER JACKET AS SHOWN
IMPORTANT! DO NOT REMOVE INNER JACKET FROM THE CORE
FLARE SHIELD AND FOLD IT BACK TO COVER THE INNER FERRULE

Assembly Manual
HV-2000 Right Angle Bolted Connector
Power Pack 2000 Terminal System (Sealed)
Contact at CTC Warren: Nicholas Durse [phone]
| www.delphi.com |
Assembly Manual - 33366036 18
STEP 3c –Insert and Crimp Ferrules
STEP 3d –Insert and Crimp Ferrules
ASSEMBLY
IMPORTANT! DO NOT REMOVE INNER JACKET FROM THE CORE
SLIDE OUTER FERRULE ON CABLE AND PLACE IT OVER THE SHIELD AND INNER FERRULE
IMPORTANT! DO NOT REMOVE INNER JACKET FROM THE CORE
AFTER THE FERRULES ARE CORRECTLY POSITIONED, CRIMP THEM TO THE CABLE,
HEXAGONAL STYLE CRIMP WITH INDENTS IS REQUIRED;
REFER TO LATEST ASSEMBLY DRAWING FOR FINAL DIMENSIONS AND DETAILS

Assembly Manual
HV-2000 Right Angle Bolted Connector
Power Pack 2000 Terminal System (Sealed)
Contact at CTC Warren: Nicholas Durse [phone]
| www.delphi.com |
Assembly Manual - 33366036 19
STEP 4a –Sonic Weld Female Terminal
STEP 4b –Sonic Weld Female Terminal
ASSEMBLY
REMOVE PARTIALLY STRIPPED INNER JACKET THEN ALIGN AND SONIC WELD THE TERMINAL TO
CONDUCTOR; REFER TO LATEST ASSEMBLY DRAWING FOR SONIC WELD DIMENSIONS
TERMINAL CENTERLINE MUST ALIGN WITH FERRULE CRIMP CENTERLINE AND INDENTS
See latest connector assembly drawing for
Sonic Weld final dimensions and details

Assembly Manual
HV-2000 Right Angle Bolted Connector
Power Pack 2000 Terminal System (Sealed)
Contact at CTC Warren: Nicholas Durse [phone]
| www.delphi.com |
Assembly Manual - 33366036 20
STEP 5 –Identify Cavities
STEP 6a –Align and Insert Terminals Female Power Pack 2000
ASSEMBLY
INSERT FEMALE TERMINAL INTO RECEPTACLE HOUSING ACCORDING TO INSERTION PLAN.
- PROPER ORIENTATION OF TERMINAL REQUIRED -
INDEX
FEATURES