Delphi BTS Series Assembly Manual

Brand
Delphi
Model
BTS Series
Type
Assembly Manual
Connector 6-way
for 150/280 Terminals (BTS and similar)
sealed
Assembly at harness plant
REV 04 - May 2012
ADI-15458155-2
D
2/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant assembly
REV 04 – May 01, 2012
ADI-15458155-2
delphi.com/connectors
TABLE OF CONTENTS
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 information is correct at the time of releasing. Reprinting or translation
is not permitted without written permission from DELPHI.
Copyright 2012 DELPHI. All rights reserved.
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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: electrical and mechanical tests
Requirements for Connector 6-way testing
DISASSEMBLY SEQUENCE:
step D-1: removing cable tie
step D-2: removing Cable Caps
step D-3: unlocking SL
step D-4: removing Female Terminals 280
step D-5: removing Female Terminals 150
Table of tools
Packaging
Revisions
3/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant assembly
REV 04 – May 01, 2012
ADI-15458155-2
delphi.com/connectors
EXPLODED 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
4/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant assembly
REV 04 – May 01, 2012
ADI-15458155-2
delphi.com/connectors
Terminal 280 (BTS and similar): max. 2
LIST OF COMPONENTS
Component
(pre-assembled)
DELPHI
Part-No.
Housing 6-way 15458151 (mixed 1.5/2.8 without CPA, Black) 1
15458152 (mixed 1.5/2.8 without 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)
15427148 (2 cavities closed without CPA)
15458159 (2 cavities closed with CPA)
Terminal 150 (BTS and similar): max. 6
Amount
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
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
7/32
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
CPA locked in pre-
position-windows
CPA locked in end-
position-windows
OK
NOK
CPA DELIVERY STATUS
8/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant assembly
REV 04 – May 01, 2012
ADI-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
9/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant assembly
REV 04 – May 01, 2012
ADI-15458155-2
delphi.com/connectors
INSERTING TERMINAL 280
Correctly 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.
10/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant 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.
11/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant assembly
REV 04 – May 01, 2012
ADI-15458155-2
delphi.com/connectors
NOTE: Validated 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.
12/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant assembly
REV 04 – May 01, 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.
13/32
Assembly Manuals
Connector 6-way for 150/280 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.
14/32
Assembly Manuals
Connector 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.
15/32
Assembly Manuals
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.
16/32
Assembly 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
17/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant assembly
REV 04 – May 01, 2012
ADI-15458155-2
delphi.com/connectors
REQUIREMENTS FOR TESTING CONNECTOR 6-WAY
18/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant assembly
REV 04 – May 01, 2012
ADI-15458155-2
delphi.com/connectors
Coding control required.
Coding 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
REQUIREMENTS FOR TESTING CONNECTOR 6-WAY
19/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant assembly
REV 04 – May 01, 2012
ADI-15458155-2
delphi.com/connectors
Position of connector fixing
A
A
REQUIREMENTS FOR TESTING CONNECTOR 6-WAY
20/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant assembly
REV 04 – May 01, 2012
ADI-15458155-2
delphi.com/connectors
Is required when option is assembled.
A
B
C
REQUIREMENTS FOR TESTING CONNECTOR 6-WAY
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Delphi BTS Series Assembly Manual

Brand
Delphi
Model
BTS Series
Type
Assembly Manual
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