PV776-88975619

Service BulletinMack Trucks, Inc.Greensboro, NC USA Trucks

Date Group No. Release Page

6.2010 371 47 1(11)

Wiring Harness Connector, Replacement

Delphi GT280

Wiring Harness Connector, ReplacementDelphi GT280

W3006952

This service information covers replacement procedures for servicing the Delphi GT280Series connectors.

Content:• “Wire Gauges”, page 2

• “Connector, Replacement”, page 6

Note: Information is subject to change without notice.Illustrations are used for reference only and may differ slightly from the actual vehiclebeing serviced. However, key components addressed in this information are representedas accurately as possible.

PV776-88975619 USA42401

Mack Trucks, Inc. Date Group No. Release PageService Bulletin 6.2010 371 47 2(11)

Wire GaugesAmericanWire Gauge

(AWG)

SAE (mm²) DIN (mm²)

4/0 103.0 120.0

3/0 81.0 95.0

2/0 62.0 70.0

0 50.0 50.0

2 32.0 35.0

4 19.0 25.0

6 13.0 16.0

8 8.0 10.0

10 5.0 4.0

12 3.0 2.5

14 2.0 1.5

16 1.0 1.0

18 0.8 0.75

20 0.5 0.5

22 0.35 0.35

24 0.22 0.22

• AWG: American Wire Gauge (US Standard)

• SAE: Society of Automotive Engineers (US Standard,Metric)

• DIN: Deutsche Industry Norm (European Standard,Metric)

Mack Trucks, Inc. Date Group No. Release PageService Bulletin 6.2010 371 47 3(11)

Special Tools

Hand Crimp Tool Kit (or equivalent)??????????

12094429, Delphi Terminal Removal Tool (or equivalent)???????????

12094430, Delphi Terminal Removal Tool (or equivalent)????????

Note: Tool 85110460 also requires the followingcrimping dies to properly assemble the connectorsin the Delphi Connector and Terminal Kit 85109632:85110461, 85110462, 85110463 and 85110464.

Mack Trucks, Inc. Date Group No. Release PageService Bulletin 6.2010 371 47 4(11)

Other Special Equipment

Delphi Connector and Terminal Kit85109632

Harness Repair Tape20469544

Mack Trucks, Inc. Date Group No. Release PageService Bulletin 6.2010 371 47 5(11)

Terminal Connector, Delphi GT280 Series Connectors

W3006951

1 Terminal

2 Cable

3 Side lock cover (Unsealed Connector Shown)

The GT280 Series connectors are designed for 280(2.80mm width) series blade terminals which give superiorelectrical performance. The 280 series carries up to 25amps. The GT280 Series has one of the lowest connectorengage forces in the industry while being available in; 2, 3,4, 5, 6, 8, 10, 12, 14 & 16-way sealed or unsealed versions.

On most GT280 Series connectors, there will be certainlocks that have to be removed in order to get the terminalsto release from the housing. These lock types are:

• CPA (Connector Position Assurance): Thismechanism is an external lock for the connector whenboth male and female halves are mated. These can beremoved by slightly depressing lock tab and pulling tothe rear.

Note: For Unsealed Connectors

• SLC (Side Lock Cover): This lock is the covering overthe center of the female housing and is a push throughside lock on the male housing. This can be removedfrom the front (female) and sides (male) of the housings.

Note: For Sealed Connectors

• PLR: Primary Lock Reinforcement, this lock is locatedinside the housing for male and female connectors. Itcan be removed from the front side.

Mack Trucks, Inc. Date Group No. Release PageService Bulletin 6.2010 371 47 6(11)

3713-03-03-01Connector, Replacement

You must read and understand the precautions andguidelines in Service Information, group 30, "GeneralSafety Practices, Electrical and Electronics" beforeperforming this procedure. If you are not properly trainedand certified in this procedure, ask your supervisor fortraining before you perform it.

Note: Illustrations are used for reference only and may differslightly from the actual vehicle being serviced. However, keycomponents addressed in this information are representedas accurately as possible.

CAUTION

If you do not have access to the required tools anequivalent, do not attempt to repair connector terminalends. Failure to use the correct tools may lead to poor wirerepairs, which can lead to vehicle component damage.

Also see:

• “Wiring Harness Connector, Replacement”, page 1

Connector Terminal, RemovalSealed1

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1Insert a small pick into the connector and remove thePLR (Primary Lock Reinforcement).

Mack Trucks, Inc. Date Group No. Release PageService Bulletin 6.2010 371 47 7(11)

2

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2Using tool 12094429 (or equivalent), push the retainingclip away from the terminal.

3

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3Using tool 12094429 (or equivalent), push the retainingclip away from the terminal and pull the wire out of theconnector.

44Cut the damaged terminal(s) from the wire(s).

Note: Be sure to cut the wire as close to the originalterminal as possible to avoid shortening the wire toomuch. Extreme shortening of the wire makes re-assemblydifficult.

Mack Trucks, Inc. Date Group No. Release PageService Bulletin 6.2010 371 47 8(11)

Connector Terminal, RemovalUnsealed1

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1Insert tool 12094430 (or equivalent) into the connectorside and push the SLC (Side Lock Cover) out.

2

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2Using tool 12094429 (or equivalent), push the retainingclip away from the terminal.

3

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3Using tool 12894429 (or equivalent), push the retainingclip away from the terminal and pull the wire out of theconnector.

Mack Trucks, Inc. Date Group No. Release PageService Bulletin 6.2010 371 47 9(11)

44Cut the damaged terminal(s) from the wire(s).

Note: Be sure to cut the wire as close to the originalterminal as possible to avoid shortening the wire toomuch. Extreme shortening of the wire makes re-assemblydifficult.

Mack Trucks, Inc. Date Group No. Release PageService Bulletin 6.2010 371 47 10(11)

Connector Terminal, Reassembly1

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1Using tool ST-100, from Kit HC-200 (or equivalent), stripthe wire(s) to the correct length, as indicated by theinformation sheet included with each jaw set.

Note: The tool can be set for different wire coatingthicknesses.

Note: The strip length is set by repositioning the slideon the side of the jaw set.

2

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2Insert the terminal into the crimp die and then insert thewire, (with or without seal), into the rear of the terminal.

Note: Make sure the terminal is matched to the correctslot in the crimp tool. This can be accomplished byreferring to the instruction sheet with each jaw set.

Note: Make sure the seal is located at the edge of thewire insulation before crimping.

Note: Use tool HC-100 (or equivalent), with the propercrimp die, for the best terminal crimp. See the includedleaflet for more information.

3

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3Continue holding the wire steady as the tool jaw closesand the crimp is performed. Close the HC-100 handlegrips all the way until the crimp process is completed.

44Inspect the terminal for sufficient crimp on both the wireand the seal.

Mack Trucks, Inc. Date Group No. Release PageService Bulletin 6.2010 371 47 11(11)

5

W3006923

5Once the terminal repairs have been made, re-insertthe wires into the proper cavities in the connector, firmlyseating the terminal and wire into the connector.

Note: Check that the terminal locked into place bygently pulling on the wire. If the wire is not seatedinto place correctly, a loose connection will result.

66Complete the repair by re-inserting any locks back onthe connector.

77Re-tape the harness after repairing the connector, usingthe harness repair tape (tool 20469544), if needed.

20469544