Delphi BTS Series 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

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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

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Assembly Manuals

Connector 6-way for 150/280 Terminals – harness plant assembly

REV 04 – May 01, 2012
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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

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Assembly Manuals

Connector 6-way for 150/280 Terminals – harness plant assembly

REV 04 – May 01, 2012
ADI-15458155-2

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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

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Assembly Manuals

Connector 6-way for 150/280 Terminals – harness plant assembly

REV 04 – May 01, 2012
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VIEW OF VERSIONS

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Assembly Manuals

Connector 6-way for 150/280 Terminals – harness plant assembly

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DELIVERY STATUS, PART DESCRIPTIONS

PART DESCRIPTIONS

DELIVERY STATUS

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Connector 6-way for 150/280 Terminals – harness plant assembly

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DELIVERY STATUS, PART DESCRIPTIONS

CPA locked in pre­position-windows

CPA locked in end­position-windows

OK

NOK

CPA DELIVERY STATUS

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Assembly Manuals

Connector 6-way for 150/280 Terminals – harness plant assembly

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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

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Assembly Manuals

Connector 6-way for 150/280 Terminals – harness plant assembly

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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.

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Assembly Manuals

Connector 6-way for 150/280 Terminals – harness plant assembly

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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.

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Assembly Manuals

Connector 6-way for 150/280 Terminals – harness plant assembly

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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.

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Assembly Manuals

Connector 6-way for 150/280 Terminals – harness plant assembly

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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.

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Assembly Manuals

Connector 6-way for 150/280 Terminals – harness plant assembly

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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.

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Assembly Manuals

Connector 6-way for 150/280 Terminals – harness plant assembly

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The cables are tightening ...

STRAPPING CABLES

ATTENTION !

CABLE CAP IS NOT AVAILABLE

OPTIONAL (Cable Cap TYPE A)

5a

Step completed.

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Assembly Manuals

Connector 6-way for 150/280 Terminals – harness plant assembly

REV 04 – May 01, 2012
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STRAPPING CABLES

OPTIONAL (Cable Cap TYPE B)

ATTENTION !

CABLE CAP IS NOT AVAILABLE

5b

Step completed.

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Assembly Manuals

Connector 6-way for 150/280 Terminals – harness plant assembly

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Apply the electrical test. Measurement and assembly controls

ELECTRICAL TEST

6

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Connector 6-way for 150/280 Terminals – harness plant assembly

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Test Probes

Test ProbesTest Probes

Test Probes1111

The maximum Force to 1.5 and 2.8 Terminals is 15 NMaximum contact force1.4

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 RectangleHead shape of Test

probe

1.2

Position of Test probes1.1

Data

DataData

DataItem

ItemItem

ItemPosition

PositionPosition

Position

REQUIREMENTS FOR TESTING CONNECTOR 6-WAY

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Assembly Manuals

Connector 6-way for 150/280 Terminals – harness plant assembly

REV 04 – May 01, 2012
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less than 23.08

less than 23.08less than 23.08

less than 23.08

mm (terminal 1.5) in reference to the Reference Plane

(see position 1.1)

Tightening area and position
of connector

2.2

?Clamping Force2.3

Data

DataData

DataItem

ItemItem

ItemPosition

PositionPosition

Position

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

2.1

Connector

ConnectorConnector

Connector2222

Sicma test probeDesign of test probe

connection

1.7

Dimension of locked and
unlocked terminal

1.6

from 23.08

from 23.08 from 23.08

from 23.08

mm (terminal 1.5)

to 23.88

to 23.88to 23.88

to 23.88

mm (terminal 2.8) in reference

to the Reference Plane (see position 1.1)

Position tolerance of
terminal cavity of
correctly seated terminal

1.5

REQUIREMENTS FOR TESTING CONNECTOR 6-WAY

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Connector 6-way for 150/280 Terminals – harness plant assembly

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Position

PositionPosition

Position Item

ItemItem

Item Data

DataData

Data

2.4

Position of connector fixing

The positioning of the connector fixing in the test holder is on the
left and right side of the connector on the symmetry middle of the
connector. Clamping only on the 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

3333 Additional test

Additional testAdditional 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 holder symmetry
middle of the connector.
A = 2,25 mm, Switch Pin Head = Ø 1 mm

3.1.1 Define maximum force to close SL15 N < F < 40N

3.1.2 Define maximum travel way to
close SL

3,5mm

A

A

REQUIREMENTS FOR TESTING CONNECTOR 6-WAY

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Assembly Manuals

Connector 6-way for 150/280 Terminals – harness plant assembly

REV 04 – May 01, 2012
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Position

PositionPosition

Position Item

ItemItem

Item Data

DataData

Data

3.1.3 Position of the SL closing
mechanism

see page

11

1111

11

3.1.4 Control Secondary Lock on close
(Step5)

The locking position of the PLR (SL) is checked by the end
position of the SL closing mechanism

3.2 Leak test Leak Test required

3.2.1 Test parameter Test realization = Pressure

Nominal Pressure = 300m Bar
Limits Good = 200 mBar < P < 500 mBar

3.3 Presence and position 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

4444 Test

TestTest

Test parameter

parameterparameter

parameter

4.1 Step 1 Check SL on open

4.2 Step 2 Execute push test

4.3 Step 3 Check connection

4.4 Step 4 Close SL

4.5 Step 5 Control if SL is closed

4.6 Step 6 Execute leak test

4.7 Step 7 Check lock of cable tie

4.8 Step 8 (optional) Check color of SL to distinguish Black/ Violet SL

4.9 Step 9 (optional) Check presence and position of CPA

4.10 Step 10 (optional) Check Cover

A

B

C

REQUIREMENTS FOR TESTING CONNECTOR 6-WAY

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Assembly Manuals

Connector 6-way for 150/280 Terminals – harness plant assembly

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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.

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Assembly Manuals

Connector 6-way for 150/280 Terminals – harness plant assembly

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REMOVING CABLE TIE

OPTIONAL (Cable Cap TYPE B)

ATTENTION !

CABLE CAP IS NOT AVAILABLE

D-1b

Step completed.

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Assembly Manuals

Connector 6-way for 150/280 Terminals – harness plant assembly

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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.

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Assembly Manuals

Connector 6-way for 150/280 Terminals – harness plant assembly

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... 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.

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Assembly Manuals

Connector 6-way for 150/280 Terminals – harness plant assembly

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UNLOCKING SL

Using removal tool PN 10804886 unlock SL.

D-3

Step completed.

SL in locked position

SL in pre-position

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Assembly Manuals

Connector 6-way for 150/280 Terminals – harness plant assembly

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REMOVING TERMINAL 280

Find the two primary locking arms on 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.

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Connector 6-way for 150/280 Terminals – harness plant assembly

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REMOVING TERMINAL 150

Find the two primary locking arms on 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

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Connector 6-way for 150/280 Terminals – harness plant assembly

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TABLE OF TOOLS

Item Function Tool PN.

1 Removal tool for BTS 150/280 10882549

2 Removal tool for SL unlocking 10804886

2

1

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DRAWINGS OF TOOLS

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Assembly Manuals

Connector 6-way for 150/280 Terminals – harness plant assembly

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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.

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Assembly Manuals

Connector 6-way for 150/280 Terminals – harness plant assembly

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REVISIONS

Revision Change description 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

Mouser Electronics

Authorized Distributor

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