Assembly of HVA-280 High Voltage Connector #
Note : Each plug connector has the same installation process, but each connector will require a different gauge cable for proper installation
Wire Gauges #
| Connector Output | Item Number | Cable Gauge |
| Key-F | 4-2103177-6 | 14awg |
| Heater 2 | 4-210377-5 | 14awg |
| Charger-D | 4-2103177-4 | 10awg |
| Air Conditioning | 4-2103177-4 | 10awg |
| Heater 1 | 4-210377-1 | 14awg |
Parts #
| 1 | Cable Seal Retainer |
| 2 | Cable Seal |
| 3 | Inner Ferrule |
| 4 | Outer Ferrule |
| 5 | MCP 2.8mm Receptacle Terminal |
| 6 | Plug Connector Assembly |
Assembly #
Step 1 : Assemble Seal #
Assemble (1) cable seal retainer and (2) cable seal in the order and direction shown in the image above.
Note : Circuit numbers are shown on the cable seal retainer. Make sure that the correct cable is inserted into each cavity.
Step 2 : Strip Wire #
With the (1) cable seal retainer and (2) cable seal safely out of the way, strip the outer jacket and braided cable shield off of each cable
Step 3 : Strip Wire Again #
Strip the outer jacket further so that the combined exposed strip length of braided cable shield and conductor insulation matches above
Step 4 : Inner Ferrule #
Insert (3) inner ferrule onto each cable and over the outer jacket as shown in the image above
Step 5 : Fold Braided Cable #
Fold the braided cable shield back over the (3) inner ferrule, taking care to try to keep (3) inner ferrule positioned such that its edge is flush with the stripped edge of the outer jacket as shown in the image above
Step 6 : Strip Wire Again #
Strip the conductor insulation off each cable to the dimension defined by the specific plug connector
Step 7 : Receptacle Terminal #
Apply a (2) receptacle terminal to each cable using the tooling, method, and dimensions necessary for each specific plug connection. The trailing edge of the (2) receptacle terminal box should be located from the stripped edge of the outer jacket to the dimension given (approximately) in the image above
Step 8 : Outer Ferrule #
Insert (4) outer ferrule onto each cable in the orientation shown below and over (3) inner ferrule and folded back braided cable shield
Step 9 : Crimp #
Crimp each (4) outer ferrule using the necessary tool
Recommended Tool : SDE-SA Hand crimping frame assembly : this frame assembly accepts a die assembly designed to crimp the specific outer ferrule. (type 1: 6.80 mm HEX) and (type 2: 7.40 mm HEX) NOT INCLUDED
The distance between the leading edge of the outer ferrule and the trailing edge of the receptacle terminal box must be maintained at the dimension given above
Cable Inspection #
| 1 | Samples match examples shown in the images in this document |
| 2 | Cables are inserted in correct cavity openings in seal retainer |
| 3 | Seal is not rolled or damaged |
| 4 | Outer jacket or conductor is not damaged |
| 5 | No loose or protruding strands from braided cable shield and ferrule crimp |
| 6 | Terminal crimp meets specified requirements |
| 7 | Outer ferrule hex crimp is correct and outer ferrule is not damaged |
Receptical Terminal Installation #
This section contains steps for installing the receptacle terminal into the plug connector
Step 1 : Orient Cable #
Orient the cable assembly so that the bridge feature on the cable seal retainer is aligned with the plug connector
Step 2 : Click Together #
Inset the receptacle terminals into their respective plug connector circuit cavities until they are fully locked, and an audible and tactile ‘click’ is detected
Note : The installation of the ferrule into the contact springs of the connector shield will cause some resistance, so it is important to verify that the receptacle terminals are fully inserted by pulling back lightly on the cables.
Step 3 : Fully Insert #
Fully insert the cable seal until it stops inside the back of the plug connector
Step 4 : Cable Seal Retainer #
Full install the cable seal retainer over the back of the plug connector, making sure that the bridge feature is correctly aligned with the plug connector latch feature. Verify that both locking features are fully engaged
Mating and Un-Mating #
Mating #
Align the plug connector and header assembly
Push the plug connector and header assembly together fully until they stop (two clicks will be heard). Verify that the plug connector and header assembly are fully locked with a light tug and by visually verifying the location of the indicator slot on the floating latch
Un-Mating #
Fully Depress the thumb actuation pad on the plug connector flexible latch (orange).
Pulll the plug connector back (approx. 4.5mm) into the intermediate position. At this point the HVIL circuit has been opened, but the HVIL terminals are still making contact
DO NOT PULL THE CABLES
Fully depress the thumb actuation pad on the floating latch (red)
Pull the plug connector until it is fully separated from the header assembly
