TE CONNECTIVITY S CYLINDER HEAD WIRING SOLUTIONS FOR INDUSTRIAL & COMMERCIAL VEHICLES

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1 TE CONNECTIVITY S CYLINDER HEAD FOR INDUSTRIAL & COMMERCIAL VEHICLES WE GO TO EXTREMES TO MAKE EVERY CONNECTION COUNT INDUSTRIAL & COMMERCIAL TRANSPORTATION /// CYLINDER HEAD

2 FOR INDUSTRIAL & COMMERCIAL VEHICLES INDUSTRIAL & COMMERCIAL TRANSPORTATION (ICT), WHICH IS PART OF TE CONNECTIVITY (TE), OFFERS A FULLY COMPREHENSIVE RANGE OF CONNECTORS AND CABLE ASSEMBLY PRODUCTS AND SOLUTIONS FOR CYLINDER HEAD WIRING. Coupled with our continuously expanding range of capabilities, we are providing the commercial transportation market with highly integrated systems and cost effective solutions. We at TE Connectivity are working with our customers providing them turnkey solutions by integrating all of TE s key technologies of electrical interconnect, sealing capabilities, Raychem wires and fuel injectors interconnect. This extensive experience in connectors and cable assembly enables TE to provide its customers with: Turnkey Solutions High Performance Solutions Cost Competitive Solutions TE Connectivity is developing cylinder head wiring for heavy duty diesel engines with cable channels and pass-through connectors. Cylinder head wiring assemblies are designed to withstand a highly dynamic temperature range, which is caused by a massive thermocycling, substantial vibration load by the engine and overspray of engine oil. Cylinder head wiring assemblies have proven themselves in a variety of engines in truck, agricultural, and construction applications under harsh environment applications. INDUSTRIAL & COMMERCIAL TRANSPORTATION /// CYLINDER HEAD

3 TURNKEY ENGINEERING SOLUTIONS TE Connectivity offers fully tested custom designs to the OEM s specifications utilising not only connectors and wires but also the design of brackets, cable arrangements and cable channels and a selection of related materials. The OEM is only required to design the required opening in the cylinder head and /or valve cover. Product Portfolio Single Cylinder MECHANICAL Amount of positions: 2 24 pos. Two Cylinder Three Cylinder Four Cylinder Six Cylinder and more. Applications Heavy Duty Diesel Motors Common Rail Engines Pump Nozzle Engines Operating temperature: -40 C to 140 C Mating Force: max. 10 N (2 pos.) Nm (6-24 pos.) Mating Cycles: max. 50 (silver plated terminals) Vibration: ISO , Test VI ELECTRICAL Withstanding Voltage: max. 36 VDC (at sea level) Insulation Resistance: > 107 Ω (at 500 VDC) Harness System Undervalve Cover for Injector Sensors to Cylinder Head Exit Connection PRODUCT PORTFOLIO Key features Cylinder head wiring includes electrical connections for injectors, glow plugs, sensors and actuators Oil tight pass-through connectors range based on different interfaces, like DT, AMPSEAL 16, AMP MCP and Circular Connectors Connectors accept multiple terminals including circular or flat, stamped and formed or screw machine terminals Leakage check on the interface connector Polarization, mechanical, color coded keying options Ring tongue solutions for injector terminations Captured screw designs for cable channel fixation Cable support channel design Cable protection solutions High temperature wires Push back test of terminals Integrated secondary locking device delivered in pre-locked position Capability for fully tested design according to OEM specifications 100% tested harness with electrical end of line check Cleanliness requirements according to OEM PAGE 3

4 COST COMPETITIVE SOLUTIONS The combination of cable support channels, high temp. wires and oil tight connectors not only helps the customers to have high performance customized solution at low costs, but it also supports the reduction of the total installed cost of a Cylinder Head Wiring. Oil tight connectors enable installation cost reduction, reliable sealing and connection by accepting non-oil blocking, high temperature wires up to 200 C. The support channel simplifies installation, avoids additional cable ties and fixation. The self-finding guides for the injector reduce significant handling time, avoid mismatching of ring terminals and make motor installation easy and cost effective. Benefits of Cylinder Head Wiring Less Damage Risk wires withstand high temp. up to 200 C, mechanical protection of wiring, oil blocking connectors Easy Service clear handling of cable assembly for cylinder head Easy Handling motor installation time reductions by simplicity of designs and routing Less time in Assembly cable guide aligns with fixing points Secured Assembly the captured parts are prepositioned according to the requirements of the cylinder head Reliability components designed and tested for the application, wires guided inside the engine components designed for the application qualified CHW interfaces and components adaptable for various applications, e.g. engine sensors, gear box applications, etc. Cost saving INDUSTRIAL & COMMERCIAL TRANSPORTATION /// CYLINDER HEAD

5 HIGH PERFORMANCE CABLE SOLUTIONS 200 C rated T6 Class F Thin Wall and Ultra Thin Wall wires are used for Cylinder Head Wiring. TE Connectivity provides customers with high performance cables at a lower price. Using tough advanced TE Raychem radiation cross-linked fluoropolymer insulation offers exceptional high temperature performance and resistance to hot surface damage. It also increases safety in case of accidental contact with hot surfaces, with a lower unit cost compared to alternative fluoropolymer solutions. The tough mechanical characteristics also allows TE Connectivity under the trademark Raychem to produce these wires in thin-wall constructions, providing superior harness shop processing as well as significant space and weight savings, whilst offering the opportunity to remove overprotection. Benefits Lower unit cost at true T6 performance level. Designed to be compatible with typical wire handling equipment used in harness shops. Smaller, lighter wires with the same temperature performance. Thin-wall designs providing improved handling, space savings and miniaturized connector compatibility benefits. Improved mechanical and abrasion performance compared to PTFE and FEP. Irradiation cross-linked insulation does withstand termocycling and oil overspray. Offers the opportunity to remove costly overprotection. PAGE 5

6 HIGH PERFORMANCE OIL TIGHT CONNECTORS The oil tight connector system offers receptacle and pin housings with capability for waterproofing and resistance to conditions of extreme vibration. The system is designed for electronic and electrical applications in motor vehicles, where vibrations and mechanical stress, in the long term, can affect the quality on the contact system. Designed to the specific needs of the cylinder head wiring, installations and motor design a choice of oil tight connectors based on various product family interfaces. 2 Position Connector MCON 1.2 LL PN (2 pos. Receptacle Housing) Feed through hole: Ø 12 x 16mm Interface drawing: on request Up to 6 Positions Connector 1.5mm diameter circular terminals ISO style PN (up to 6 pos. Receptacle Housings) PN (Right-angle Backshell) PN (Vertical Backshell) Feed through hole: Ø 30mm Interface drawing: Up to 16 Positions Connector AMP MCP 1.5 Bayonet Style Connector PN (up to 14 pos. Receptacle Housings) PN (up to 16 pos. Connector Housings) PN (Right-angle Backshell) Feed through hole: Ø 32mm Interface drawing: Up to 24 Positions Connector AMP MCP 1.5 Bayonet Style Connector PN (up to 24 pos. Receptacle Housings) PN (Right-angle Backshell) Feed through hole: Ø 36,4mm Interface drawing: INDUSTRIAL & COMMERCIAL TRANSPORTATION /// CYLINDER HEAD

7 HIGH PERFORMANCE OIL TIGHT CONNECTORS Features High reliability status supported for long term use High vibration level supported Design to avoid quality problems, reduce manufacturing and service cost Integrated secondary locking device delivered in pre-locked position Wire-to-Wire sealed Polarisation, several keyings options Locking mechanism for smaller connectors/mating aid for higher numbers of ways Oil tight connectors 4 Position DEUTSCH Connector DTP Series Size 12 circular terminals PN DTP06-4S Feed through hole Ø 22mm. Interface drawing on request 4 Position DEUTSCH Connector DT Series Size 16 circular terminals PN DT06-4S PN (180 Backshell) Feed through hole Ø24.93mm. Interface Drawing on request Up to 8 Positions Connector AMPSEAL 16 Connectors Size 16 circular terminals PN (Up to 8 positions receptacle housing) Feed through hole: Ø32mm. Interface Drawing on request Contacts The AMP MCP 1.5, MCON 1.2, round 1.5mm 2 and size 16 contact systems are mainly used in the cylinder head wiring. Each contact consists of a flat or a round receptacle, which mates with a flat or round tab. Every contact has a steel spring and a copper alloy body. The two-piece contact design means that the electrical and mechanical properties are separated. PAGE 7

8 Tyco Electronics AMP GmbH, a TE Connectivity Ltd. company AMPèrestrasse D Bensheim Germany Phone: +49 (0) Fax: +49 (0) Tyco Electronics AMP GmbH certified acc. ISO and ISO/TS 16949: TE Connectivity family of companies. All rights reserved. AMP MCP, AMPSEAL, AMPSEAL 16, DEUTSCH, MCON, Raychem, TE, TE Connectivity, and TE connectivity (logo) are trademarks. TE s only obligations are those stated in TE s General Terms and Conditions of Business ( TE expressly disclaims any implied warranty regarding the information contained herein, including, but not limited to, the implied warranties of merchantability or fitness for a particular purpose Issued M ST INDUSTRIAL & COMMERCIAL TRANSPORTATION /// CYLINDER HEAD