Delphi BTS Series Assembly Manual
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Delphi BTS Series Assembly Manual

Delphi BTS Series Assembly Manual

Connector 6-way for 150/280 terminals (bts and similar)
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Connector 6-way
for 150/280 Terminals (BTS and similar)
sealed
Assembly at harness plant
REV 04 - May 2012
D
ADI-15458155-2

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Summary of Contents for Delphi 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...

  • Page 2: 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.

  • Page 3: Components (Exploded View)

    PART-NO. see page 4 CPA (optional) See page 4 Pictures used in this Assembly Manual and original parts may differ in some details, This difference has no influence on the assembly process . delphi.com/connectors REV 04 – May 01, 2012 3/32 ADI-15458155-2...

  • Page 4: List Of Components

    Assembly Manuals Connector 6-way for 150/280 Terminals – harness plant assembly LIST OF COMPONENTS Component DELPHI (pre-assembled) Part-No. Amount Housing 6-way 15458151 (mixed 1.5/2.8 without CPA, Black) 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)

  • Page 5: View Of Versions

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

  • Page 6: Delivery Status, Descriptions

    Assembly Manuals Connector 6-way for 150/280 Terminals – harness plant assembly DELIVERY STATUS, PART DESCRIPTIONS DELIVERY STATUS PART DESCRIPTIONS delphi.com/connectors REV 04 – May 01, 2012 6/32 ADI-15458155-2...
  • Page 7 Assembly Manuals Connector 6-way for 150/280 Terminals – harness plant assembly DELIVERY STATUS, PART DESCRIPTIONS CPA DELIVERY STATUS CPA locked in pre- position-windows CPA locked in end- position-windows delphi.com/connectors REV 04 – May 01, 2012 7/32 ADI-15458155-2...

  • Page 8: Assembly Sequence

    Insert the Terminals 150 (or Cavity Plug for 4-way version - see page 10) through the cavities by respecting the Terminal polarization. Correctly locked locking arm (one of two) Step completed. delphi.com/connectors REV 04 – May 01, 2012 8/32 ADI-15458155-2...
  • Page 9 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). Correctly locked locking arm (one of two) Step completed. delphi.com/connectors REV 04 – May 01, 2012 9/32 ADI-15458155-2...
  • Page 10 Connector 6-way for 150/280 Terminals – harness plant assembly INSERTING CAVITY PLUG Connector 4-way version Cavity Plug: 210A015019 (2 blank cavities) 9628693180 Blank cavities Insert the Cavity Plug into all empty cavities. Correctly inserted Cavity Plug Step completed. delphi.com/connectors REV 04 – May 01, 2012 10/32 ADI-15458155-2...

  • Page 11: Step 3: Locking Sl

    F > 100 N SL in pre-position Push the SL until it is correctly locked in the end position. SL in locked position NOTE: Validated for 10 cycles opening and closing SL! Step completed. delphi.com/connectors REV 04 – May 01, 2012 11/32 ADI-15458155-2...
  • Page 12 Insert first the shorter locking arm (arrow 1), and press after in the opposite side (arrow 2) to lock the Cable Cap TYPE A ..Step completed. delphi.com/connectors REV 04 – May 01, 2012 12/32 ADI-15458155-2...
  • Page 13 Connector 6-way for 150/280 Terminals – harness plant assembly LOCKING CABLE CAP OPTIONAL (Cable Cap TYPE B) ATTENTION ! CABLE CAP IS NOT AVAILABLE shorter longer locking arm locking arm ... or Cable Cap TYPE B Step completed. delphi.com/connectors REV 04 – May 01, 2012 13/32 ADI-15458155-2...

  • Page 14: Step 5: Strapping Cables

    Assembly Manuals Connector 6-way for 150/280 Terminals – harness plant assembly STRAPPING CABLES OPTIONAL (Cable Cap TYPE A) ATTENTION ! CABLE CAP IS NOT AVAILABLE The cables are tightening ... Step completed. delphi.com/connectors REV 04 – May 01, 2012 14/32 ADI-15458155-2...
  • Page 15 Assembly Manuals Connector 6-way for 150/280 Terminals – harness plant assembly STRAPPING CABLES OPTIONAL (Cable Cap TYPE B) ATTENTION ! CABLE CAP IS NOT AVAILABLE Step completed. delphi.com/connectors REV 04 – May 01, 2012 15/32 ADI-15458155-2...
  • Page 16 Assembly Manuals Connector 6-way for 150/280 Terminals – harness plant assembly ELECTRICAL TEST Apply the electrical test. Measurement and assembly controls delphi.com/connectors REV 04 – May 01, 2012 16/32 ADI-15458155-2...

  • Page 17: Requirements For Connector 6-Way Testing

    T h e m a x i m u m F o r c e t o 1 . 5 a n d 2 . 8 T e r m i n a l s i s 1 5 N delphi.com/connectors REV 04 –...
  • Page 18 T i g h t e n i n g a r e a a n d p o s i t i o n 2 . 2 o f c o n n e c t o r 2 . 3 C l a m p i n g F o r c e delphi.com/connectors REV 04 – May 01, 2012 18/32 ADI-15458155-2...
  • Page 19 3 . 1 . 2 D e f i n e m a x i m u m t r a v e l w a y t o 3 , 5 m m c l o s e S L delphi.com/connectors REV 04 – May 01, 2012 19/32...
  • Page 20 C h e c k p r e s e n c e a n d p o s i t i o n o f C P A 4 . 1 0 S t e p 1 0 ( o p t i o n a l ) C h e c k C o v e r delphi.com/connectors REV 04 – May 01, 2012 20/32...

  • Page 21: Disassembly Sequence

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

  • Page 22: Step D-1: Removing Cable Tie

    Connector 6-way for 150/280 Terminals – harness plant assembly REMOVING CABLE TIE OPTIONAL (Cable Cap TYPE A) ATTENTION ! CABLE CAP IS NOT AVAILABLE Remove the plastic tie used to hold the cables …. D-1a Step completed. delphi.com/connectors REV 04 – May 01, 2012 22/32 ADI-15458155-2...
  • Page 23 Assembly Manuals Connector 6-way for 150/280 Terminals – harness plant assembly REMOVING CABLE TIE OPTIONAL (Cable Cap TYPE B) ATTENTION ! CABLE CAP IS NOT AVAILABLE D-1b Step completed. delphi.com/connectors REV 04 – May 01, 2012 23/32 ADI-15458155-2...
  • Page 24 Unlock first longer locking arms side (arrows 1) and then remove (arrow 2) from the Receptacle Housing 6-way Cable Cap TYPE A... D-2a Step completed. delphi.com/connectors REV 04 – May 01, 2012 24/32 ADI-15458155-2...
  • Page 25 Connector 6-way for 150/280 Terminals – harness plant assembly REMOVING CABLE CAP OPTIONAL (Cable Cap TYPE B) ATTENTION ! CABLE CAP IS NOT AVAILABLE longer shorter locking arm locking arm ... or Cable Cap TYPE B. D-2b Step completed. delphi.com/connectors REV 04 – May 01, 2012 25/32 ADI-15458155-2...

  • Page 26: Step D-3: Unlocking Sl

    Assembly Manuals Connector 6-way for 150/280 Terminals – harness plant assembly UNLOCKING SL SL in locked position Using removal tool PN 10804886 unlock SL. SL in pre-position Step completed. delphi.com/connectors REV 04 – May 01, 2012 26/32 ADI-15458155-2...
  • Page 27 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. ATTENTION: TAKE CARE FOR AVOID CLOSING SL WHILE REMOVING TERMINALS Step completed. delphi.com/connectors REV 04 – May 01, 2012 27/32 ADI-15458155-2...
  • Page 28 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. ATTENTION: TAKE CARE FOR AVOID CLOSING SL WHILE REMOVING TERMINALS Step completed. delphi.com/connectors REV 04 – May 01, 2012 28/32 ADI-15458155-2...

  • Page 29: Table Of Tools

    Assembly Manuals Connector 6-way for 150/280 Terminals – harness plant assembly TABLE OF TOOLS Item Function Tool PN. Removal tool for BTS 150/280 10882549 Removal tool for SL unlocking 10804886 delphi.com/connectors REV 04 – May 01, 2012 29/32 ADI-15458155-2...
  • Page 30 Assembly Manuals Connector 6-way for 150/280 Terminals – harness plant assembly DRAWINGS OF TOOLS delphi.com/connectors REV 04 – May 01, 2012 30/32 ADI-15458155-2...

  • Page 31: Packaging

    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. delphi.com/connectors REV 04 – May 01, 2012 31/32 ADI-15458155-2...

  • Page 32: Revisions

    - Added new page 12 - Inserting Cavity Plug Dec 13, 2006 - Added new pages 32, 33 - removal tools drawings Connectors 2-, 3-way removed REV04 May 01, 2012 New removal tool PN 10882549 was 10803855 delphi.com/connectors REV 04 – May 01, 2012 32/32 ADI-15458155-2...
  • Page 33 Mouser Electronics Authorized Distributor Click to View Pricing, Inventory, Delivery & Lifecycle Information: Aptiv 15414369 15414438 15414435 15414437...

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