DSP-161311 Handling Manual SRV 2 - Mouser Electronics€¦ · April 15, 2016 File No. DSP-161311 Revision 0 November 22, 2016 The Quality Connection HANDLING MANUAL of SRV CONNECTION

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AEC-037-R2 J.S.T Corporation Confidential April 15, 2016

File No. DSP-161311

Revision 0

November 22, 2016

The Quality Connection

HANDLING MANUAL of

SRV CONNECTION SYSTEM

J.S.T. Corporation 37879 Interchange Drive Farmington Hills, MI 48335 Tel. 248-324-1957 Fax. 248-324-1775

Approved by Checked by Checked by Prepared by

K.F. S.N Z.W. M.G.

CO

NF

IDE

NT

IAL

& P

RO

PR

IET

AR

Y

Copying, re-printing, or disclo

sure to any third party strictly prohib

ited with

out prior w

ritten consent.

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Table of Contents 1. Introduction ..................................................................................................................................................... 3

2. Components ..................................................................................................................................................... 3

2.1.Connector Keying Options ........................................................................................................................ 6

3. Inspection of Connector Assembly and Components ....................................................................................... 7

4. Storage ............................................................................................................................................................. 7

5. Applicable Terminals, Cables, and Seals ........................................................................................................ 7

6. Harness Assembly Process .............................................................................................................................. 8

6.1.Verification of TPA Pre-Set Positions in Unmated Connectors..................................................................8

6.2.Verification of CPA Pre-Set Position in Unmated Connectors ............................................................... 10

6.3.Moving TPA to Pre-Set Position .............................................................................................................. 11

6.4.Connector Circuit Numbering ................................................................................................................. 13

6.5.Terminal Orientation Feature ................................................................................................................. 13

6.6.Terminal Installation ............................................................................................................................... 14

6.7.Engaging the TPA to Final-Lock Position ............................................................................................... 15

6.8.Miss-Insertion Detection ......................................................................................................................... 16

6.8.1.Detection Methods ........................................................................................................................... 16

6.8.2.Failure Modes .................................................................................................................................. 16

7. Mating and Un-mating the Female and Male Connector .............................................................................. 18

7.1.Mating the Female Connector to the Male Connector ............................................................................ 18

7.1.1.Connector Orientation Features ...................................................................................................... 18

7.1.2.Mating the Connectors..................................................................................................................... 19

7.2.Un-mating the Connectors ....................................................................................................................... 20

8. Serviceability ................................................................................................................................................. 21

8.1.Disengaging TPA to Pre-Set Position...................................................................................................... 21

8.2.Terminal Removal .................................................................................................................................... 21

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1. Introduction This manual provides information and requirements for handling of the SRV Connector System. 2. Components In handling and processing the connector assembly and components, understand each feature and the corresponding name identified in tables 2-1, 2-2, 2-3, and 2-4. Table 2-1 Female Assembly

Circuit No. Key

Code Part Number Component Color Material

5 A SRVPB-A05-H

HOUSING LT. GRAY PBT-GF15

TPA RED PBT-GF15

BACK COVER LT. GRAY PBT-GF15

MATTE SEAL GREEN SILICONE

5 D SRVPB-D05-K

HOUSING BLACK PBT-GF15

TPA RED PBT-GF15

BACK COVER BLACK PBT-GF15


4 B SRVPB-B04-S

HOUSING NATURAL PBT-GF15

TPA RED PBT-GF15

BACK COVER NATURAL PBT-GF15


3 C SRVPB-C03-N

HOUSING BROWN PBT-GF15

TPA RED PBT-GF15

BACK COVER BROWN PBT-GF15


2 D SRVPB-D02-K

HOUSING BLACK PBT-GF15

TPA RED PBT-GF15

BACK COVER BLACK PBT-GF15


Table 2-2 Applicable Female Terminals and Wires NO. TERMINAL* PART NUMBER WIRE TYPE WIRE SIZE

5 1.2 FEMALE TERMINAL (Sn) 1670144-1 1534594-1

FLRY B 18-20 AWG (0.5mm²-0.75mm²)

22 AWG (0.35mm²)

* MCON 1.2 TERMINALS OR AUTHORIZED EQUIVALENTS

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Table 2-3 SRV Male Assembly

Circuit No. Key

Code Part Number Component Color Material

5 A SRVWSB-05A-AH

HOUSING LT. GRAY PBT-GF15 TPA RED PBT-GF15

BACK COVER LT. GRAY PBT-GF15 RETAINER CLIP NATURAL PBT-GF15

CPA RED PBT-GF15 MATTE SEAL GREEN SILICONE RING SEAL GREEN SILICONE

5 D SRVWSB-05A-DK

HOUSING BLACK PBT-GF15 TPA RED PBT-GF15

BACK COVER BLACK PBT-GF15 RETAINER CLIP NATURAL PBT-GF15


4 B SRVWSB-04A-BS

HOUSING NATURAL PBT-GF15 TPA RED PBT-GF15

BACK COVER NATURAL PBT-GF15 RETAINER CLIP NATURAL PBT-GF15


3 C SRVWSB-03A-CN

HOUSING BROWN PBT-GF15 TPA RED PBT-GF15

BACK COVER BROWN PBT-GF15 RETAINER CLIP NATURAL PBT-GF15


2 D SRVWSB-02A-DK

HOUSING BLACK PBT-GF15 TPA RED PBT-GF15

BACK COVER BLACK PBT-GF15 RETAINER CLIP NATURAL PBT-GF15


Table 2-4 Applicable Male Terminals and Wires NO. TERMINAL* PART NUMBER WIRE TYPE WIRE SIZE

13 1.2 MALE TERMINAL (Sn) 1718350-1 1718348-1

FLRY B 18-20 AWG (0.5mm²-0.75mm²)

22 AWG (0.35mm²)

* MCON 1.2 TERMINALS OR AUTHORIZED EQUIVALENTS

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Figure 1: Female Connector Assembly Components

Figure 2: Male Connector Assembly Components

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2.1. Connector Keying Options Connector system keying options A, B, C & D are shown in Figure 3.

Figure 3: Key Options

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3. Inspection of Connector Assembly and Components

Check all components in the assembly for the following conditions:

Table 3-1 Connector Assembly Inspection Items:

Items Acceptance Criteria Measure

Appearance

No Burrs, transformation, and discoloration Visual Inspection

No Cracks, chips, or nicks Visual Inspection

Ring Seal is correctly positioned Visual Inspection

Back Cover is installed and latched Visual Inspection

Performance

Post Assembly Inspection

TPA in pre-set position (1) CPA in pre-set position (2) Back cover secured in final-lock position Retention Clip secured in final-lock position

Manual and Visual Inspection

(1) Refer to Section 6.1 to confirm the TPA is in pre-set position prior to terminal installation.

(2) Refer to Section 6.2 to confirm the CPA in pre-set position prior to terminal installation. 4. Storage

All JST products are controlled according to JST quality control regulations. All records for manufacturing, inspection, delivery, and any other required procedures are traceable.

Female and male connector assemblies are stacked in a box and transported in such a way to keep parts from moving into the locked or partially locked conditions during shipping and handling. The connector assemblies should be kept in the box as shipped and stored in appropriate containers until needed for assembly.

All parts shall be stored in a clean and normal environment. (Recommended condition: 5~35°C / 45~85% RH) 5. Applicable Terminals and Wires, General Motors has approved and specified terminals and wires for use in the SRV Connection System. Refer to Table 2-2 and Table 2-4 for applicable terminals and wires. Follow specifications set by General Motors and/or terminal suppliers for any handling, storage, or assembly issues associated with wires, cables, terminals, or terminal components. Crimped terminal leads must comply with SAE/USCAR-21 performance specification for cable to terminal electrical crimps.

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6. Harness Assembly Process

6.1. Verification of TPA Pre-Set Positions in Unmated Connectors Verify the location of the TPA to ensure that it is in pre-set position (male: 17.0 mm; female: 1.8mm) as shown in Figure 4 and Figure 5.

A TPA must be in pre-set position to correctly perform the terminal installation process as shown in Figure 4 and Figure 5.

Figure 4: TPA in Pre-Set Position (Male)

Figure 5: TPA in Pre-Set Position (Female)

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Figure 6 depicts variations of TPA locations in unmated connectors. The TPA is improperly positioned if it is partially or fully inserted into the final-lock position within an unmated connector.

Male Connector

Female Connector

Figure 6: Variations of Positioned TPAs in Unmated Connectors

Note: Mishandling may cause the TPA to be become partially or fully pushed into the final-lock position. If the TPA is improperly positioned as shown in Figure 6, follow steps in Section 6.3 to properly position the TPA.

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6.2. Verification of CPA Pre-Set Position in Unmated Connectors

Verify the location of the CPA to ensure that it is in pre-set position as shown in Figure 7. The CPA must be set in its Pre-set position in order to properly perform the connector installation process

Figure 7: CPA in Pre-Set position (Male Assembly Only) Figure 8 depicts a variation of an improperly located CPA in an unmated male connector. The CPA is improperly positioned when it is partially or fully inserted into the final-lock position.

Figure 8: Improperly Positioned CPA in Unmated Male Connector (Final-Lock Position)

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6.3. Moving TPA to Pre-Set Position Female Connector Assembly Step 1 – Insert Tool into TPA Disengage Slot Position tool (2mm flathead screwdriver) against female TPA as shown in Figure 9. Step 2 – Moving the Female TPA from Final-Lock to Pre-Set Position: Push the tool against the TPA to move the TPA from final-lock to pre-set position as shown in Figure 9. The TPA is in pre-lock position when its position matches that of the TPA shown in Figure 5.

Figure 9: Moving the Female TPA to Pre-Set Position

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Male Connector Assembly Step 1 – Insert the Tool into the TPA Disengage Opening Insert hook tool (GM tool) into TPA as shown in Figure 10. Ensure care is taken to not damage the silicone ring seal.

Figure 10: Moving the Male TPA to Pre-Set Position

Step 2 – Disengaging the Male TPA: Pull the hook tool to move the TPA from final-lock to pre-set position. The TPA is in pre-set position when its position matches that of the TPA shown in Figure 4.

Figure 11: Moving the Male TPA to Pre-Set Position (Top View)

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6.4. Connector Circuit Numbering

The circuit locations of the SRV Connection System are configured as shown in Figure 12. The two views depict male and female back covers sharing the same circuit number identification scheme.

Figure 12: Circuit Numbering

6.5. Terminal Orientation Feature Figure 13 depicts terminal orientation features designed to prevent misaligned insertion of a terminal into the connector.

Figure 13: Orientation Features of Male and Female Terminals

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6.6. Terminal Installation This section describes installation of the male and female terminals. JST recommends installing components in the sequence detailed below and shown in Figure 14. These installation instructions apply to all SRV Connection System options. Step 1 –Terminal Orientation Each terminal shall be oriented correctly prior to installation into the connector. Correct orientations of the terminals to the connectors are shown in Figure 14.

Step 2 – Terminal Insertion Hold the crimped terminal lead at the wire insulation and push the terminal into the connector as shown in Figure 14. An audible click should be heard indicating the terminal is fully-inserted and locked in place by the housing locking feature. Performing a slight pull of the wire is required to confirm the terminal is properly seated and locked into position.

Figure 14: Inserting Terminals into the Male & Female Connector Assemblies

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6.7. Engaging the TPA to Final-Lock Position

Once all circuit locations are populated with terminals, apply force to the TPA to move it into the final-lock position as shown in Figure 15 and Figure 16. A flat head screw driver (2-2.5 mm blade) is required to move the male TPA into final-lock position. The force required to move a TPA into final-lock position should not exceed 30N.

IMPORTANT NOTE: Should any difficulty be encountered moving the TPA into its final-lock position, refer to Section 6.8: Terminal Miss-Insertion Detection.

TPA in final-lockposition is flush withhousing surface

Figure 15: Moving the Male TPA the Final-lock Position

TPA in final-lockposition is flush withhousing surface

Figure 16: Moving the Female TPA to the Final-lock Position

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6.8. Miss-Insertion Detection An incorrectly (miss-inserted) inserted terminal failure can be detected during harness assembly by using several methods. The following methods aid in detecting miss-inserted terminals in Female and Male Connector Assemblies

6.8.1. Detection Methods

Detection Method

Indicator of properly inserted terminal Indicator of improperly inserted terminal

DM1 Terminal can be easily inserted and locked.

Terminal requires more than 15N of force to insert and/or insulation crimp of terminal can be seen outside of connector housing.

DM2 An audible click is heard during terminal insertion.

Terminal can be removed with less than 30N of force.

DM3 Terminal feels secure; it cannot be easily moved by pushing or pulling the wire lead.

Terminal can be removed with less than 30N of force.

DM4 TPA can be easily seated flush with housing into its final-lock position.

The TPA cannot be seated flush with housing with less than 30N of force

6.8.2. Failure Modes

Failure Mode 1) Partial Terminal Insertion – Terminal Does Not Engage Housing Lock

Figure 17: Failure Mode 1

Detection Method:

DM1) Terminal is difficult to insert DM1) Insulation crimp is visible DM2) No audible click is heard DM3) Terminal can be easily removed

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Failure Mode 2) Partial Terminal Insertion – Terminal is Half-Engaged with Housing Lock


Detection Methods:

DM1) Terminal is difficult to insert DM2) No audible click is heard DM3) Terminal can be easily removed DM4) TPA cannot be easily seated

Note: In case of a half-inserted terminal as shown in Figure 18, the locking feature of the terminal may be deformed as the TPA is pushed in. Replacement of the terminal is recommended if any deformation has occurred.

Failure Mode 3) Miss-Inserted Terminal (Terminal Rotated 180°)


Detection Methods:

DM1) Terminal is difficult to insert DM1) Insulation crimp is visible DM2) No audible click is heard DM4) TPA cannot be easily seated

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7. Mating and Un-mating the Female and Male Connector 7.1. Mating the Female Connector to the Male Connector

7.1.1. Connector Orientation Features

Both female and male connectors have orientation features designed to prevent miss-mating, as shown in Figure 20 and Figure 21.

Figure 20: Female Connector Orientation Features

Figure 21: Male Connector Orientation Feature

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7.1.2. Mating the Connectors This section describes the method of mating and securing the female and male connectors. JST recommends the sequence detailed in the steps below and shown in Figure 22, Figure 23, and Figure 24. These installation instructions apply to all SRV Connection System options. Step 1 – Connector Orientation:

Orient the female connector relative to the male connector as shown in Figure 22. Refer to Section 7.1.1 for detailed descriptions of the orientation features.

Step 2 – Connector Mating:

Push the female connector toward the male connector until it engages with the male connector as shown in Figure 22. An audible click will be heard when the two components lock together. Figure 23 depicts the correct position of the female connector relative to the male connector after mating.

Figure 22: Connector Orientation Prior to Mating

Figure 23: Connector Positions after Mating

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Step 3 – Engage the Connector Position Assurance Feature (CPA):

Figure 24: Engaging the CPA

Figure 25: Connectors Secured by CPA

7.2. Un-mating the Connectors

Step 1 – Disengage the Connector Position Assurance Feature (CPA): Using a tool or finger, move the CPA to its pre-lock position as shown in Figure 26. A flat head screw driver (2- 5mm blade) can be used.

Figure 26: CPA in Pre-Set Position

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Step 2 – Unlock the Connectors: Fully depress the lock release feature located on the connector housing as shown in Figure 27 to unlock the male connector. While depressing the lock release, pull the female connector away from the male connector to extract and fully un-mate it.

Figure 27: Un-mating the Connectors

8. Serviceability During harness assembly, device assembly, and servicing of the connector system, proper care and usage of the connectors must be observed. The following processes should be followed when manipulating the TPA.

8.1. Disengaging TPA to Pre-Set Position

Follow the steps in Section 6.3 to move the TPA from final-lock position to pre-set position.

8.2. Terminal Removal Follow these steps to disengage and remove the terminals from the connector:

Step 1 – Use a Tool to Deflect the Terminal Locking Feature of the Housing: Using the GM Standard Tool P/N J-38125-215A, position the flat head of the tool into the TPA disengage slot as shown in Figure 28. Press the tool into the space between the terminal body and the terminal locking feature of the housing to deflect and disengage the locking feature as shown in Figure 29 and Figure 30.

Figure 28: Positioning the Tool to deflect the Terminal Locking Feature of the Housing

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Figure 29: Deflecting the Terminal Locking Feature of the Male Housing

Step 2 – Terminal Removal: While the terminal locking feature is deflected, pull the terminal by the wire to extract the terminal from the connector housing as shown in Figure 29 and Figure 30. A maximum force of 30N should be required to remove the crimped terminal and wire from the connector.

Figure 30: Deflecting the Terminal Locking Feature of the Female Housing

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Modification Record of the SRV Handling Manual

No, DSP-161311 Product Name SRV Assemblies

Note

Rev. No,

Reason Place Date Engineer

0 Initial release 11/22/2016 Z.W.

Documents

DSP-161311 Handling Manual SRV 2 - Mouser Electronics€¦ · April 15, 2016 File No. DSP-161311 Revision 0 November 22, 2016 The Quality Connection HANDLING MANUAL of SRV CONNECTION