Delphi BTS Series Assembly Manual Download

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Connector 6-way

for 150/280 Terminals (BTS and similar)

sealed

Assembly at harness plant

REV 04 - May 2012
ADI-15458155-2

Summary of Contents for BTS Series

Page 1: ...Connector 6 way for 150 280 Terminals BTS and similar sealed Assembly at harness plant REV 04 May 2012 ADI 15458155 2 D ...

Page 2: ...ll rights reserved 3 4 5 6 7 8 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Components exploded view List of components View of versions Delivery status descriptions ASSEMBLY SEQUENCE step 1 inserting Female Terminals 150 step 2a inserting Female Terminals 280 step 2b inserting Cavity Plug step 3 locking SL step 4 locking Cable Caps step 5 strapping cables step 6 electr...

Page 3: ...D VIEW Female Terminal 150 BTS and similar Female Terminal 280 BTS and similar Receptacle Housing 6 way PART NO see page 4 CPA optional See page 4 Cavity Plug Pictures used in this Assembly Manual and original parts may differ in some details This difference has no influence on the assembly process ATTENTION Optional Cable Caps are not available ...

Page 4: ...ithout CPA Grey 15458153 mixed 1 5 2 8 without CPA Blue 15458163 mixed 1 5 2 8 with CPA Black 15458164 mixed 1 5 2 8 with CPA Grey 15458165 mixed 1 5 2 8 with CPA Blue only 1 5 line without CPA Yellow 15440054 only 1 5 line without CPA Green 15440055 only 1 5 line without CPA Brown 15458160 only 1 5 line with CPA Yellow 15458161 only 1 5 line with CPA Green 15458162 only 1 5 line with CPA Brown 15...

Page 5: ...5 32 Assembly Manuals Connector 6 way for 150 280 Terminals harness plant assembly REV 04 May 01 2012 ADI 15458155 2 delphi com connectors VIEW OF VERSIONS ...

Page 6: ...32 Assembly Manuals Connector 6 way for 150 280 Terminals harness plant assembly REV 04 May 01 2012 ADI 15458155 2 delphi com connectors DELIVERY STATUS PART DESCRIPTIONS PART DESCRIPTIONS DELIVERY STATUS ...

Page 7: ...way for 150 280 Terminals harness plant assembly REV 04 May 01 2012 ADI 15458155 2 delphi com connectors DELIVERY STATUS PART DESCRIPTIONS CPA locked in pre position windows CPA locked in end position windows OK NOK CPA DELIVERY STATUS ...

Page 8: ...I 15458155 2 delphi com connectors Step completed Insert the Terminals 150 or Cavity Plug for 4 way version see page 10 through the cavities by respecting the Terminal polarization INSERTING TERMINAL 150 Correctly locked locking arm one of two Validated up to 4 cycles max for insertion removing Terminal 1 ...

Page 9: ...ectly locked locking arm one of two Insert the Terminals 280 through the 6 way cavities by respecting the Terminal polarization make use of housing shapes similar to terminal crimping area to find the right orientation Only two positions of the Terminal are correct Crimp similar shapes Validated up to 4 cycles max for insertion extraction Terminal 2a Step completed ...

Page 10: ...t assembly REV 04 May 01 2012 ADI 15458155 2 delphi com connectors INSERTING CAVITY PLUG Insert the Cavity Plug into all empty cavities Blank cavities Correctly inserted Cavity Plug Connector 4 way version 2 blank cavities Cavity Plug 210A015019 9628693180 2b Step completed ...

Page 11: ... for 10 cycles opening and closing SL Push the SL until it is correctly locked in the end position LOCKING SL SL in locked position Closing force of SL Terminals in right position 15 F 40 N Terminals in wrong position F 100 N Validated up to 10 cycles max for opening and closing SL SL in pre position Position of the SL closing mechanism 3 Step completed ...

Page 12: ... 2012 ADI 15458155 2 delphi com connectors Insert first the shorter locking arm arrow 1 and press after in the opposite side arrow 2 to lock the Cable Cap TYPE A LOCKING CABLE CAP shorter locking arm longer locking arm ATTENTION CABLE CAP IS NOT AVAILABLE OPTIONAL Cable Cap TYPE A 4a Step completed ...

Page 13: ...80 Terminals harness plant assembly REV 04 May 01 2012 ADI 15458155 2 delphi com connectors LOCKING CABLE CAP or Cable Cap TYPE B shorter locking arm longer locking arm OPTIONAL Cable Cap TYPE B 4b ATTENTION CABLE CAP IS NOT AVAILABLE Step completed ...

Page 14: ...r 6 way for 150 280 Terminals harness plant assembly REV 04 May 01 2012 ADI 15458155 2 delphi com connectors The cables are tightening STRAPPING CABLES ATTENTION CABLE CAP IS NOT AVAILABLE OPTIONAL Cable Cap TYPE A 5a Step completed ...

Page 15: ...uals Connector 6 way for 150 280 Terminals harness plant assembly REV 04 May 01 2012 ADI 15458155 2 delphi com connectors STRAPPING CABLES OPTIONAL Cable Cap TYPE B ATTENTION CABLE CAP IS NOT AVAILABLE 5b Step completed ...

Page 16: ...sembly Manuals Connector 6 way for 150 280 Terminals harness plant assembly REV 04 May 01 2012 ADI 15458155 2 delphi com connectors Apply the electrical test Measurement and assembly controls ELECTRICAL TEST 6 ...

Page 17: ... 1 1 1 1 The maximum Force to 1 5 and 2 8 Terminals is 15 N Maximum contact force 1 4 Test probe dimensions for 1 5 and 2 8 terminals is 0 6 x 4mm FLAT HEAD TOLERANCE 0 02 mm Head dimensions 1 3 Flat head Rectangle Head shape of Test probe 1 2 Position of Test probes 1 1 Data Data Data Data Item Item Item Item Position Position Position Position REQUIREMENTS FOR TESTING CONNECTOR 6 WAY ...

Page 18: ... control via mechanical coding in test holder If version 15458150 Black or 15427143 Violet is used in the production a greyscale sensor is needed distinguish the version because the coding is identically Coding control 2 1 Connector Connector Connector Connector 2 2 2 2 Sicma test probe Design of test probe connection 1 7 Dimension of locked and unlocked terminal 1 6 from 23 08 from 23 08 from 23 ...

Page 19: ...he housing 2 5 Position of switch probe for connector detection in holder The positioning of the connector detection in the test holder symmetry middle of the connector A 11 25 mm Switch Pin Head Ø 3 mm 3 3 3 3 Additional test Additional test Additional test Additional test 3 1 Control Secondary Lock Step1 Check on precense and open position of SL The positioning of the SL detection in the test ho...

Page 20: ... check of cable tie Depend on conditions 3 4 CPA presence check Is required when option is assembled 3 4 1 Position of CPA presence check Position in prototype holder new standard Symetry middle of connector from top Point 1 CPA open Point 2 CPA presence A 13 9 mm B 18 25 mm C 4mm Switch probe head Ø 2 m 4 4 4 4 Test Test Test Test parameter parameter parameter parameter 4 1 Step 1 Check SL on ope...

Page 21: ...21 32 Assembly Manuals Connector 6 way for 150 280 Terminals harness plant assembly REV 04 May 01 2012 ADI 15458155 2 delphi com connectors ...

Page 22: ...150 280 Terminals harness plant assembly REV 04 May 01 2012 ADI 15458155 2 delphi com connectors REMOVING CABLE TIE Remove the plastic tie used to hold the cables ATTENTION CABLE CAP IS NOT AVAILABLE OPTIONAL Cable Cap TYPE A D 1a Step completed ...

Page 23: ...ls Connector 6 way for 150 280 Terminals harness plant assembly REV 04 May 01 2012 ADI 15458155 2 delphi com connectors REMOVING CABLE TIE OPTIONAL Cable Cap TYPE B ATTENTION CABLE CAP IS NOT AVAILABLE D 1b Step completed ...

Page 24: ...12 ADI 15458155 2 delphi com connectors REMOVING CABLE CAP Unlock first longer locking arms side arrows 1 and then remove arrow 2 from the Receptacle Housing 6 way Cable Cap TYPE A longer locking arm shorter locking arm ATTENTION CABLE CAP IS NOT AVAILABLE OPTIONAL Cable Cap TYPE A D 2a Step completed ...

Page 25: ...0 Terminals harness plant assembly REV 04 May 01 2012 ADI 15458155 2 delphi com connectors or Cable Cap TYPE B longer locking arm shorter locking arm REMOVING CABLE CAP OPTIONAL Cable Cap TYPE B ATTENTION CABLE CAP IS NOT AVAILABLE D 2b Step completed ...

Page 26: ...nector 6 way for 150 280 Terminals harness plant assembly REV 04 May 01 2012 ADI 15458155 2 delphi com connectors UNLOCKING SL Using removal tool PN 10804886 unlock SL D 3 Step completed SL in locked position SL in pre position ...

Page 27: ...the front of the cavity Insert operation 1 the hand tool PN 10882549 straight inside the cavity remove the locking arms in order to unlock the Terminal and pull slowly out the cable to remove the Terminal 280 operation 2 from the cavity Primary locking arm of the Terminal D 4 ATTENTION TAKE CARE FOR AVOID CLOSING SL WHILE REMOVING TERMINALS Secondary Lock SL must be in open position Step completed...

Page 28: ...the front of the cavity Insert operation 1 the hand tool PN 10882549 straight inside the cavity remove the locking arms in order to unlock the Terminal and pull slowly out the cable to remove the Terminal 280 operation 2 from the cavity D 5 Primary locking arm of the Terminal Secondary Lock SL must be in open position Step completed ATTENTION TAKE CARE FOR AVOID CLOSING SL WHILE REMOVING TERMINALS...

Page 29: ...or 6 way for 150 280 Terminals harness plant assembly REV 04 May 01 2012 ADI 15458155 2 delphi com connectors TABLE OF TOOLS Item Function Tool PN 1 Removal tool for BTS 150 280 10882549 2 Removal tool for SL unlocking 10804886 2 1 ...

Page 30: ...30 32 Assembly Manuals Connector 6 way for 150 280 Terminals harness plant assembly REV 04 May 01 2012 ADI 15458155 2 delphi com connectors DRAWINGS OF TOOLS ...

Page 31: ...ectors PACKAGING 1 Standard Wrapping in accordance with Standard E73 03 150 G 800 parts per carton GALIA N 12 Packaging weight 9 2 Kg Carton volume 380mm x 280mm x 250mm 2 Storage conditions Storage temperature 5 C to 30 C Storage time unlimited consumption according to first in first out principle 3 Handing Do not throw the cartons ...

Page 32: ... Date REV 01 Initial release Mar 24 2005 REV 02 Updated testing information and added requirements for Connector Family 2 6 way pages 16 20 Mar 28 2006 REV 03 Added new page 9 CPA delivery status Added new page 12 Inserting Cavity Plug Added new pages 32 33 removal tools drawings Dec 13 2006 REV04 Connectors 2 3 way removed New removal tool PN 10882549 was 10803855 May 01 2012 ...

Page 33: ...Mouser Electronics Authorized Distributor Click to View Pricing Inventory Delivery Lifecycle Information Aptiv 15414369 15414438 15414435 15414437 ...

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