Service Parts Replacement
© 2019 EMP, Inc. 16
The R20C 10-way connectors can be replaced using EMP kit 1370106126. For the mating connector, cut the
old connector off and crimp new pins on the wires. Use the appropriate Apex crimper designed for use with Apex
2.8mm components. Insert the newly pinned wires into the appropriate cavity in the connector housing. Cavity
plugs are included in the kit for the unused positions.
To replace the component connector, cut off and replace the harness:
1. Cut/remove any zip ties that are securing the component.
2. Disconnect the component connector.
NOTE: To avoid damaging the wires and/or pin connections, do not pull back using the wire harness to
disconnect the connection. Wiggling the connector body will help in freeing the connection.
NOTE: Ensure the harness connector electrical sockets remain free of dirt to ensure a solid electrical
connection when reconnecting to the components.
3. Using a pair of wire cutters, cut the component wires off leaving at least 5 inches. One-by-one, cut the wires
at staggered lengths. Staggering the wire lengths spaces out the butt splices. The repaired harness should
maintain the length of the component lead.
4. Using a pair of wire strippers, strip 3/8” of the protective wire coating off of the component wires and the
connector replacement wires ensuring not to cut through the wires.
5. Examine the wires to ensure no corrosion. If corrosion is present, cut the wire back further toward the
component. Corrosion that has carried through the wires into the component indicates that corrosion is likely
present on the controller board as well and the life of the controller may be compromised.
6. Fully insert the component wire into the proper butt connector and inspect to ensure there are no wire
strands protruding outside the connector.
7. With the wires fully inserted, crimp the wires in place using a compatible crimper.
8. Cut the replacement harness wires to match the staggered cuts made on the component wires so that the
overall lengths of each lead are approximately equal.
9. Fully insert the matching replacement harness wire into the proper butt connector and inspect to ensure
there are no wire strands protruding outside the connector.
10. With the wires fully inserted, crimp the wires in place using a compatible crimper.
11. Gently tug on both sides of the connector to make sure it will not be shaken easily loose.
NOTE: If it does shake loose, you will have to repeat the instructions and install a new Molex butt connector,
as this type of butt connector is one use only.
12. Examine to ensure the wires are fully inserted into the Molex butt connector and that there aren’t any wire
strands protruding outside of the butt connector. If the wires are not fully inserted or if there are wire strands
protruding outside of the butt connector, then you will have to repeat the instructions and install a new Molex
butt connector, as these types of butt connectors are one use only.
13. Using a heat gun, apply heat to the butt connectors until the glue protrudes outside of the connector on both
ends.
14. Pull the protective sheathing back down.
15. Test for proper function.
16. Replace any zip ties cut in step 1.
To Next Page
Loading...
