Removing pins from engine wiring harness.

[piperca]

I hope I'm posting this in the correct forum.

I need to remove the connector from the end of a Volvo diesel wiring harness, so that I can pull it from the engine to the helm. There is not enough room for the connector to pass into the flybridge and I am unable to cut the opening larger to make it pass. Can someone tell me if this is possible and, if so, instruct me on how it's done. Here are a couple of photos of the connector:

 

[Thalasso]

How about pulling from the helm to the engine

 

[piperca]

How about pulling from the helm to the engine

Either way, the connector is a smidge too large to pass. I've tried wedging the walls of the flybridge open to try and make the darn thing pass, but no dice! I had to cut off the connector for the old engines' harnesses, just to pull them out. I'm not sure how the boat manufacturer got them in there. They must have ran the wiring before the boat was complete.

 

[piperca]

I've got to get this done this weekend. Please don't tell me I have to cut it and crimp it back together ... I'd prefer not to do that.

 

[sam am I]

Back in the day, we used a lot of connectors(primarily D.G. Obrien and the like) that a fair amount had pinning that went together and came apart like this.......

http://mdfavionics.com/wire/front.html

and this

http://mdfavionics.com/wire/rear.html

It looks to me that that thing is similar and should de-pin one way or another..i.e., the pins don't look to be potted/fused glass/hermetic........pressure bulk head types. Are the pins sorta loose/wiggly or otherwise, can they rotate around a bit axially in their seats? If so, yer gonna need a plastic or metal insertion/extraction tool....GL

 

[Bondo]

I've got to get this done this weekend. Please don't tell me I have to cut it and crimp it back together ... I'd prefer not to do that.

Ayuh,.... Looks like yer 2 choices are widenin' the raceway to clear the plug,...
Or,...
Cut it off, 'n butt conect it back together,.... if ya do, stagger the cuts, 'n connectors to leave a smaller sore after taped up,...

 

[piperca]

Are the pins sorta loose/wiggly or otherwise, can they rotate around a bit axially in their seats? If so, yer gonna need a plastic or metal insertion/extraction tool

Where would I find one of those tools, locally?

Bondo ... I hope you're wrong, but I'm guessing you know your stuff!

 

[sam am I]

Ummmm..........good question. Probably not had "locally" per-se, of course depending on where is local..........



Digi-key, Newark, Mouser would be best best.....

http://www.digikey.com/product-detai...8SP-ND/1242532

http://www.newark.com/webapp/wcs/sto...owResults=true

https://www.google.com/webhp?sourcei...73351553542897

https://www.google.com/shopping/prod...d=0COQBEKYrMAk


Note that the above links are just examples of some whats and wheres, you will have to of course find the right size extractors for the right types of pins. Some of these places have tech support, they might be of some help to identify the OEM manu of that thing and help you help them get what ya need.

If the pins are loose'ish in their seats, they can be un-pinned.......

 

[NYBo]

Would cutting off that flange give you enough clearance?

 

[piperca]

Would cutting off that flange give you enough clearance?

Unfortunately not. The flange has flat sides that are the same width as the threads. I will persevere in my search and leave the installation until next week. Thanks all!

 

[piperca]

Okay, well perseverance paid off!

The connector is an AMP CPC (Circular Plastic Connector) Series 1. The extraction tool is conveniently available at Fry's Electronics:

http://www.frys.com/product/7829639?site=sr:SEARCH:MAIN_RSLT_PG

The replacement pins are too:

http://www.frys.com/product/1938490?site=sr:SEARCH:MAIN_RSLT_PG

So, hopefully, this information will help another in the future. This pertains to the helm to engine harness for all 31, 41, etc. Volvo diesel engines.

Thanks everyone for you input. I'll let you know how it works out.

 

[NYBo]

Good stuff! Thanks for closing the loop.

 

[sam am I]

Cool, hope it de-pins out the back eh?







Edit..Yep, yer good as Gold!!....


Use a tad bit of *silicone grease too on the tool/wire entries/seals, it helps the tool slide around in those tight spots much better and thus easier to feel your way to the releases as you work the tool in and down along side the wires as you push it down in. You'll get the hang of it after the first or second pin pops out.....Just go easy on it, it takes very little force to get them out and you'll not need any new pins........BONUS!!!

* http://www.oreillyauto.com/site/c/de...0941&ppt=C0139

 

[ssobol]

Okay, well perseverance paid off!

The connector is an AMP CPC (Circular Plastic Connector) Series 1. The extraction tool is conveniently available at Fry's Electronics:

http://www.frys.com/product/7829639?site=sr:SEARCH:MAIN_RSLT_PG

The replacement pins are too:

http://www.frys.com/product/1938490?site=sr:SEARCH:MAIN_RSLT_PG

So, hopefully, this information will help another in the future. This pertains to the helm to engine harness for all 31, 41, etc. Volvo diesel engines.

Thanks everyone for you input. I'll let you know how it works out.

You should also get the appropriate crimper for the pins as well.

 

[sam am I]

You should also get the appropriate crimper for the pins as well.

I think his hopes are to de-pin it out the back side (see above), set the too big to fit connector body aside, feed the wire just w pins through a small area, re-pin the body w existing crimped pins once in place........not cut them off!.

Of course if he breaks any de-pinning it, you make a good point.

He best be marking/noting their positions as well eh?

 

[piperca]

The tool worked like a charm. The pins extracted very easily and no damage was done. I used a wiring numbering kit to assure proper replacement.

Now that I have the tool and access to the pins, I am most likely going to make a couple of custom lengths to finish the run to the engines, instead of bundling up the excess in the engine room ... it'll be much cleaner.