Es Bu5t 14a121 Aa [PDF]

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Engineering Specification ES-BU5T-14A121-AA PART NAME:

PART NUMBER: ES-BU5T-14A121-AA

SPECIFICATION – WIRING ASSEMBLY AND CABLE INDEX LET

F

F

F

F

F

F

F

F

h

F

F

F

K

G

G

G

G

G

G

J

G

G

G

FR

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

LET

G

G

G

G

G

G

L

L

H

H

FR

24

25

26

27

28

29

30

31

32

33

DATE

LET

SECT

7-22-2016 08-04-2016

F1

27

F2

4,20,22

F3

19

04-04-2018

REVISED FIGURE 2 AND NOTE

RR

RR

CHECKED BY:

UPDATED SDS REQUIREMENT REFERENCES

RR

RR

R. W. Reini

CLARIFIED TAPE SPEC REFERENCE

RR

RR

DETAILED BY: (TYPE NAME HERE)

REVISED SECTION 5.2

RR

RR

REFERENCE:

G2

15

ADDED SECTION 5.3

RR

RR

(ES-F65B-14A121-AA

AELE-E-12982958-314 H1

9

REViSED SECTOR 2.4

RR

RR

H2

13

REVISED SECTION 4.4.2, OPTION F

RR

RR

APPROVAL

H3

32-34

ADD APPENDIX A

RR

RR

DESIGN ENG. SUPERVISOR:

H4

23

REVISED SECTION 13.0

RR

RR

M. C. Brabant

AELE-E-12982958-403 J1

20

REVISED SECTION 9.1

DESIGN ENG. MANAGER: RR

RR

AELE-E-12982958-478

T. D. DeWitt OTHER (AS REQUIRED):

K1

13

REVISED SECTION 4.4.1 OPTION A

RR

RR

K2

13

REVISED SECTION 4.4.2

RR

RR

RR

RR

02-16-2018 04-04-2018

R. W. Reini

14

08-03-2017 02-16-2018

PREPARED BY:

G1

03-30-2017 08-03-2017

CK

AELE-E-12982958-237

12-13-2016 03-30-2017

DR

REDRAWN AFTER CHANGE E4

08-04-2016 12-13-2016

REVISION

(TYPE NAME HERE)

AELE-E-12982958-585 L1

30-31

REVISED TABLE 1 AELE-E-12982958-621

STANDARD NOTES: FOR CURRENT RELEASE STATUS, SEE WERS ENGINEERING NOTICE. CONTROL ITEM –IDENTIFIES CRITICAL CHARACTERISTICS DESIGNATED BY THE CROSS FUNCTIONAL TEAMS DEVELOPING THE PRODUCT. THESE, AND ADDITIONAL CRITICAL CHARACTERISTICS IDENTIFIED BY PROCESS REVIEWS, MUST APPEAR ON THE CONTROL PLANS ACCORDING TO ISO/TS 16949. THESE CONTROL PLANS REQUIRE PRODUCT ENGINEERING APPROVAL.

Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

FRAME 1 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA Section Title Page 1.0 Scope ...................................................................................................................4 2.0 Termination Requirements (Crimping Terminals to Wire) ....................................4 Crimp Specification .........................................................................................4 Application of Terminals .................................................................................4 Termination Quality.........................................................................................5 Tooling Certification ...................................................................................5 Material .......................................................................................................5 Conductor crimp width C.C.W ...................................................................5 Conductor crimp height C.C.H. ...................................................................5 Strip end of insulation..................................................................................5 Wire strand ends ..........................................................................................5 Insulation crimp width I.C.W. .....................................................................6 Insulation crimp height I.C.H. .....................................................................6 Terminal Bend.............................................................................................6 Conductor Crimp Roll .................................................................................7 Fractures......................................................................................................7 Bellmouth (Flare) ........................................................................................7 Cut-off Tab..................................................................................................8 Missing or Broken strands ...........................................................................8 Individual Wire Seal and Mat Seals (Terminal pushed through seal)............8 Pull Testing .................................................................................................8 Cut or pierced insulation ..............................................................................8 Termination Sensors ....................................................................................9 Eyelet Crimp Sealing or Insulating...................................................................9 3.0 Soldering Requirements .......................................................................................9 Dip Soldering...................................................................................................9 Re-flow Soldering .......................................................................................... 10 Spot Soldering ............................................................................................... 10 4.0 Splicing.............................................................................................................. 10 Requirements ................................................................................................. 10 Splice Pull Test .............................................................................................. 10 Splice Peel Testing......................................................................................... 10 Insulation ....................................................................................................... 12 Location......................................................................................................... 13 5.0 Outer Covering................................................................................................... 13 Tape............................................................................................................... 13 Taping to the back of connectors .................................................................... 15 6.0 Molding/Insulation ............................................................................................. 15 Durometer...................................................................................................... 15 Coloring......................................................................................................... 15 Grommet Pull Test ......................................................................................... 16 7.0 Dimensioning and Tolerancing........................................................................... 16 Single Wire .................................................................................................... 16 Multiple Wire ................................................................................................ 16 Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

FRAME 2 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA Tape Ties ....................................................................................................... 17 Retainers and Other Components ................................................................... 17 Retainer Pull Force Requirement.................................................................... 16 Wire Harness Neatness .................................................................................. 16 8.0 Section Removed ............................................................................................... 18 9.0 Shielding Composition ....................................................................................... 19 General .......................................................................................................... 19 Shielded Drain Wire ...................................................................................... 20 10.0 Sealed Connectors ............................................................................................ 20 Mat Seals ....................................................................................................... 20 Individual Wire Seals ..................................................................................... 21 Cavity Plugs .................................................................................................. 18 11.0 Terminal Secondary Locks (a.k.a. TPA) ........................................................... 21 Terminal Push-out Testing ............................................................................. 21 12.0 Electrical Requirements.................................................................................... 21 Fixtures Which Contact Terminals ................................................................. 22 Electrical Control/Maintenance Plans............................................................. 22 Diodes ........................................................................................................... 22 Similar Terminals in the Same Connector ...................................................... 23 13.0 Identification .................................................................................................... 23 Label Characteristics ...................................................................................... 23 Printing Method ............................................................................................. 23 Design and Proportions .................................................................................. 24 Single Wire and Rip Cord .............................................................................. 24 14.0 Shipping Requirements .................................................................................... 25 15.0 Black Box Components .................................................................................... 25 Attachments Fully Taped Bundle Dressed Connector Taping Takeout Dimensioning Cumulative Limit Example Tolerance Example #1 Tolerance Example #2 Cavity Plug Seating Tests that qualify as PV and IP

Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Table 1

FRAME 3 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA

1.0

Scope This specification applies to electrical wiring assemblies, cables, and wiring pigtails/flyleads and details of their construction including wires, terminals, connectors, individual wire seals, etc., as called out on wiring assembly drawings. This specification supersedes all previous versions and wiring harness-manufacturing specifications. This specification outlines the minimum inspection criteria to be utilized in the inspection process at the harness or pigtail/flylead manufacturing location and other associated facilities. Ongoing process capability must be demonstrated and documented for all requirements identified in this specification.

2.0

Termination Requirements (Crimping Terminals to Wire) 2.1

Crimp Specification All terminal to wire crimps supplied to Ford Motor Company and its affiliates must have documented compliance to Requirement EL-0038 (RQT-180107-008676) for wires 8 mm2 and less and Requirement EL-0176 (RQT-180107-008728) for wires larger than 8 mm2, both of which reference the USCAR crimp specification (USCAR-21). Testing must be done using bare wire to optimize the crimp parameters even if a tin plated wire is used in production. Timing for documenting compliance is at the milestone for GPDS programs. EL-0038/EL-0176 testing may be referenced from another supplier, such as the terminal manufacturer, but the documented evidence must identify the crimp tool geometry, wire construction, and application parameters used to demonstrate compliance. The terminal to wire crimp process used by the harness manufacturer must be traceable to that which was validated. Eyelets where the wires are ultrasonically welded must comply with USCAR-38. Spot soldering per section 3.7 is allowed as a temporary method for using terminal/wire applications with crimps that do not pass the electrical resistance specification of EL-0038. Soldering is expensive and is expected only as a temporary alternative. For splice clips, see section 4. Ford Connector group must approve all deviations in writing.

2.2

Application of Terminals Automatic application of terminals to both single and double terminations is preferred over bench presses. Use of hand-held crimping tools is forbidden. Wiring suppliers may determine their own crimp tooling as long as validation is per EL0038 or EL-0176. Terminal suppliers must provide crimp validation data, crimp tool

Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

FRAME 4 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA dimensions and/or crimp tooling used for terminal validation upon request by the Wiring Supplier to insure Crimp Electrical and Mechanical Capability. 2.3

Termination Quality Wire harness suppliers must have an approved control plan for their overall crimp process. This plan must contain “visual crimp standards, measurement methods, test methods, and frequency of testing” to be used for in-process evaluation. Each applicator system must be capable of meeting the finished crimp quality inspection including the following characteristics and others determined by FMEA's: 2.3.1 Tooling Certification Certify that the proper authorized tooling is being used in each new setup or tooling change to assure that the correct crimp geometry is achieved and to comply to crimp validations. 2.3.2 Material Assure that the proper terminal, seal, and cable is being used for each new setup or terminal/cable change. 2.3.3 Conductor crimp width C.C.W. Measure crimp widths at initial setup and after making tooling changes and compare to requirements from approved wiring supplier or terminal supplier crimp development table. 2.3.4 Conductor crimp height C.C.H. Measure crimp height at initial setup, tooling change, material change, and once each hour. This frequency may be less if capability is demonstrated. C.C.H. must meet requirements from approved crimp development table. Control of the C.C.H and tooling is actual method of control for the conductor wire crimping process. Process capability (including the capability of the measurement method) must be demonstrated. 2.3.5 Strip end of insulation The end of the insulation must be visible in the window between the wire crimp wings and the insulation crimp such that the conductor is visible and should be centralized as much as possible. In no case may insulation be crimped in the conductor crimp. 2.3.6 Wire strand ends The end of the conductor must extend beyond the front edge of the conductor crimp. The projecting end of the conductor must not affect the insertion, locking functions of the terminal, or mat seals. Conductor length is not to extend past the conductor crimp by more than 0.5 mm if not otherwise specified by the terminal manufacturer. Tighter conductor lengths shall be followed when specified on the wire harness print.

Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

FRAME 5 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA Exception: For eyelets and battery cable terminals, conductor lengths extending past the conductor crimps more than 0.5 mm are permissible as long as sealing, fastener installation, clamp load, tool access and electrical function are not affected. 2.3.7 Insulation crimp width I.C.W. Measure crimp widths at initial setup and after making tooling changes and compare to requirements of approved crimp development table. 2.3.8 Insulation crimp height I.C.H. Measure crimp height at initial setup and after making tooling change, compare to requirements of approved crimp development table. 2.3.9 Terminal Bend Controls on terminal bend angle are required to assure product performance. Terminal bend angles are supplied by the terminal manufacturer. In cases when the terminal bend angle is not specified, the wire harness suppliers must follow the direction as outlined. For male crimp terminals, the bottom of terminal box should be fixed flat without constraining the conductor crimp. Crimp tooling should be designed to avoid contact with the male blade in order to prevent damage.

Male Terminal For female crimp terminals, the bottom of the terminal box should be fixed flat without constraining the conductor crimp.

Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

FRAME 6 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA

Female Terminal If the wire harness supplier does not have the ability to measure as indicated by the terminal manufacturer or as above, a checking aid is required to align the box of the terminal and check the angles as required. 2.3.10 Conductor Crimp Roll Controls on terminal roll angle are required to assure product performance. Terminal bend angles are supplied by the terminal manufacturer. In cases when the terminal roll angle is not specified the wire harness suppliers must follow the direction as outlined. 2.3.11 Fractures No fractures are permissible. (Special attention should be provided to the transition area of the terminal between the conductor wing and body or conductor wing and insulation grip). The conductor grip (d.) must have a bellmouth (flare) or a raised (two stage) crimp on the side of the grip nearest the insulation grip. The conductor grip may also have a bellmouth (flare) on the front edge of the conductor grip, nearest the terminal body.

2.3.12 Bellmouth (Flare) Bellmouth (flare) is required here

Bellmouth (flare) on the insulation grips (e.) should not exceed the insulation crimp tolerances.

d .

Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

FRAME 7 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA 2.3.13 Cut-off Tab The cut-off length shall not exceed 0.5 mm, unless otherwise specified on the component print, or protrude from the connector cavity. The burr on the cut-off must not exceed 0.3 mm, unless otherwise specified on the component print. The cut-off and burr must not affect the insertion function of the terminal into the connector. 2.3.14 Missing or Broken strands No broken or missing strands are allowed on 7-strand or fewer strand construction. One broken or missing strand is allowed on 19-strand cable. All terminations, containing missing or broken strands, must be validated per paragraph 2.1 of this specification. Supplier Product Engineering must approve missing strand count cable. 2.3.15 Individual Wire Seal and Mat Seals (Terminal pushed through seal) The individual wire seal must be firmly secured by the insulation crimp. The individual wire seal must show no signs of damage. The individual wire seal shall be visible between the insulation and conductor crimp wings. The cable insulation must be visible beyond the end of the individual cable seal. Terminals that are pushed through Mat Seals must not cut or damage seals such that USCAR Submergible Sealing Test will not meet acceptance criteria. One of the ways this may be assured is to have crimp tooling such that the front of crimp wire strands are pushed or held down during the crimping process and controlled wire handling to prevent high strands that will cut seals. Periodic microscopic inspection and visual inspection standards should be done to make sure the process is in control. Requirements EL-0038 and EL-0176 call out retention force requirements for individual wire seals. These forces must be met but direct measurement as an in-process control is not required; meeting insulation crimp dimensions is sufficient evidence that the seal retention in-process matches the retention forces measured in the lab. These factors must be managed to avoid damaging mat seals: Wire brush, anvil flash, conductor crimp bend angle, insulation crimp bend angle, CCH/CCW, grip offset, cut off. 2.3.16 Pull Testing Since CCH is the primary control for proving crimping process capability pull testing should not be used for this purpose. If pull force testing is done, it shall be performed per applicable sections of USCAR-21. 2.3.17 Cut or pierced insulation The crimping and/or wire cutting process must not damage the cable insulation. Periodic inspection should be done to make sure the process is in control. Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

FRAME 8 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA 2.3.18 Termination Sensors Equipment that will monitor the crimping process during termination of the circuits (termination sensors) is preferred. 2.4

Eyelet Crimp Sealing or Insulating Per design rule 1801_ED-22, any eyelet that has a shrouded, covered, or insulated crimp must have that shroud/cover/insulation cover the entire crimp and extend a minimum of 3 mm beyond the terminal/crimp interface onto the wire insulation (NOTE TO DESIGN ENGINEERS: this applies to powered-at-all-times eyelets). Methods used to seal or insulate eyelet crimps must not interfere with terminal fit and function – e.g., the heat-shrink adhesive must not flow onto the interface (flat) surfaces of the eyelet, the tubing must not extend onto the interface surfaces, etc. Eyelet crimps that are sealed must meet the requirements of ES-F0EB-1A263-AA, section 2.

3.0

Soldering Requirements 3.1

Every wire harness supplier must have an approved control plan for all types of soldering processes. Only lead-free solders may be used. This is required for compliance with the Ford Restricted Substance Management Standard (RSMS WSS-M99P9999-A1).

3.2

Dip soldering the terminal and conductor crimp is normally used on ring (eyelet) terminals, bulb contact terminals, or where specified on wire assembly drawings. Crimps validated per EL-0038 or EL-0176 do not require soldering unless specified on the wire harness print for additional corrosion or water protection.

3.3

Re-flow (point) soldering of the conductor crimp is typically used where dip soldering would interfere with terminal fit or function (such as a female terminal with a spring member).

3.4

When certifying crimp dimensions, the conductor crimp height dimension on a solderdipped terminal should have its + tolerance increased 0.10 mm to allow for the thickness of the added solder. (FOR FINISHED HARNESS AUDITS ONLY)

3.5

Dip Soldering Dip soldering is defined as the process of dipping the terminal into molten solder so that the solder flows into the crimp. Forms a bond between the conductor and the terminal and subsequently evenly coats the entire terminal with a layer of solder. This soldering method must assure that excess solder does not adhere to the terminal such that it interferes with function or fit. Parts to be soldered must be clean.

Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

FRAME 9 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA 3.6

Re-flow Soldering Re-flow soldering shall be defined as the process of heating a conductor crimp, where a pre-stripped and solder- dipped conductor has been crimped to a pre-tinned terminal, so that the solder melts and re-flows into the conductor crimp to form a solder bond between the conductor and the terminal.

3.7

Spot Soldering Spot soldering shall be defined as the process of heating a conductor crimp and applying solder. The solder must not flow into the insulation or interfere with terminal function.

4.0 Splicing Splices shall be made using methods (e.g. resistance welding, ultrasonic welding, crimping and soldering, etc.) appropriate to the application where process capability has been demonstrated and documented. Splice clips are allowed as long as EL-0038 (RQT-180107-008676) section 7 requirements are met, including the requirement that the current rating for the clip be equal to or greater than the current being handled by the splice. Spot soldering, per section 3.7, is not allowed as a method for using splice clips that do not pass the electrical resistance specification of EL-0038. 4.1

Requirements Any method that is used to hold the strands of wire together into a splice must capture all strands of the affected wires. These splices must be free of any broken strands or strand ends outside of the bond that could pierce or extend outside molds, tape, heat shrink tubing or other splice covering. Center strip splices must meet the same requirements as end strip splices. By definition, center stripped splices have the insulation removed from a length of the cable rather than the end, such that another center stripped wire or end stripped wire can be spliced to it. Splices that are to be sealed are to be constructed such that the distance between the nugget and the wire insulation is 3.5 +/- 1.5 mm and that the amount of overlap between the farthest conductive surface and the sealing material is at least 3 mm.

4.2

Splice Pull Test Cables spliced by splice clips shall not pull out of the splice clip when the smallest size cable in the splice is subjected to a force equal to the pull out force per specification USCAR-21.

Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

FRAME 10 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA Cables spliced by welding or soldering shall not pull loose from the splice nugget when the smallest size cable in the splice is subjected to a force equal to the pull force per the following table. The pull forces for unlisted wire sizes can be defined by linear interpolation (i.e. read out from plotted values in the following table). It is preferred that welded splices be 100% monitored by a weld quality monitoring system for improved weld quality. Wire Gage (mm²) Wire Gage (AWG) Minimum Pull Force (N) 0.13 26 21 0.22 24 35 0.35 22 55 0.50 20 75 0.75 108 0.80 18 110 1.0 16 155 1.5 216 2.0 14 290 2.5 317 3.0 12 360 4.0 397 5.0 10 450 6.0 597 8.0 8 890 10.0 1283 16.0 2163 The pull test shall be applied to a minimum of three samples per hour or three per 3000 pieces, whichever comes first, using one cable on each side of the splice simultaneously. Sample size and/or frequency are permitted to be at a reduced level if the supplier has a control plan and can demonstrate process capability. Sample cables of the same construction type are permitted for splice pull testing in lieu of production circuits. 4.3

Splice Peel Test Test equipment: Test conditions:

Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

tensile testing machine tension speed: 100 mm/min tension direction: radial to the joint wire with the smallest cross section (a) should be tested. wire with the biggest cross section (b) should be used on the other side for fixing/retention. test temperature: room temperature

FRAME 11 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA

Minimal peel strength depends on the wire cross-sectional area. Note that 0.13 mm2 wire does not have a peel force value, as any splice using that wire must also have dual-wall heat shrink tubing applied. Wire CSA (mm2) Peel Force (N)

4.4

0.35

0.5

0.75

1.0

1.5

2.0

2.5

3.0

4.0

5.0

6.0

10.0

16.0

10

14

23

28

35

41

44

53

62

73

88

124

159

Insulation When wires are joined in a wiring assembly by splicing, the splice shall be insulated as specified on the drawing. 4.4.1 Dry Areas Only Option A: WSS-M99D69-A2 single wall heat shrink non-adhesive tubing. The formerly approved ESF-M3L66-A has been replaced by WSS-M99D69-A2 and is no longer active. Option B: Tape meeting ES-AC3T-1A303-AA (minimum 38 mm wide) applied so that all exposed surfaces of the splice are covered by a minimum of three thicknesses of tape. Option C: Heat shrink tubing meeting the following specifications: ES-3M5T1A263-AA (rated to 125 °C); ES-2S7T-1A263-AA (rated to 150 °C); or ES3M5T-1A263-CA (rated to 200 °C)

Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

FRAME 12 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA 4.4.2 Wet or Dry Areas Sealed splices must meet the requirements of ES-F0EB-1A263-AA using either Option D, Option E, or Option F. Option D: Heat shrink adhesive (Dual Wall) ESB-M99D56-A2 or WSS-M99D56-A4. Option E: Liquid sealant as specified in Appendix A (specify on harness prints by manufacturer’s name and product number) Option F: Heat shrink tubing meeting the following specifications: ES-3M5T1A263-BA (rated to 125 °C) or ES-2S7T-1A263-BA (rated to 150 °C) Products other than these may be used if reviewed and approved by Ford EDS Core. 4.5

5.0

Location Splice locations, as noted on detail drawings, may not be relocated without prior Product Engineering authorization. Use tolerance of +/- 13 mm unless larger tolerance is permitted on chart per 7.2 of this document. If tolerances larger than +/13 mm are being used, then Product Engineering authorization is required in order to insure that the splice location does not impact the design.

Outer Covering The outer covering for wiring assemblies shall conform to the specifications (material or performance) referred to on the face of the drawing. All unbound wires must be held under covering at takeout points where required for manufacturing feasibility. The use of spot taping, diaper wrapping, tape wrapping, etc., is acceptable for this application. Wire loops protruding from any gaps in the covering are not acceptable. 5.1

Tape Full tape wrap must be applied neatly and be free of open sections. The wings of the retainers are to be covered completely with the tape. Spaces between wraps are permissible only at fold points that may occur during handling and packaging. Spaces between wraps which are apparent only in an intermediate stage of assembly (i.e., a takeout on a PIA part is stowed for shipment), or which are invisible when the harness and all takeouts are installed in proper vehicle position, are permissible. Unsecured ends of non-adhesive coverings must be secured with an adhesive tape or other approved method. Candy striping (spiral wrapping) is permissible as a manufacturing aid when approved by the design activity and will have no effect on the function of the wiring design. On machine wrapped assemblies where percent of wrap overlay is dependent on harness diameter, spaces between wraps are permissible at points of

Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

FRAME 13 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA an abrupt diameter increase or at points where differentials in circuit lengths must be absorbed. Loops of wire protruding through the spaces between the wraps are not acceptable. The minimum number of wraps for any harness section length shall be according to the following table: Tape Width

Harness Wraps per Diameter 300mm (Min.) 19mm 3 - 8 mm 19mm 8 – 13 mm 19mm 13-19 mm 19mm 19 mm and up 25mm 8 – 10 mm 25mm 10 – 15 mm 25mm 15 – 25 mm 25mm 25 mm and up

8 14 15 16 9 10 11 12

Candy striping (spiral wrapping) is permissible when specified on the assembly print. The assembly print shall take precedence over the values in the table above. 5.2 Taping to the back of connectors Tape wrap shall stop at a distance back from the connector equal to the maximum spread between terminal cavities on that connector plus 5 mm, with a +/- 5 mm tolerance (distance D1). This distance is to be considered as fully taped all the way to the back of the connector (See figure 1 for non-dressed connectors and figure 2 for dressed connectors). If the connector is not fully populated – that is, if the wires in a connector are arranged in such a way that the maximum spread between wires is less than the maximum spread between terminal cavities, then tape wrap may be applied closer than the maximum spread between cavities, stopping at the maximum spread between wires. If the connector is populated differently in different versions/levels of the same harness, then for ease in manufacturing, the taping for all versions/levels may stop at distance D1 as defined above; it will be considered as fully taped all of the way back to the connector for all versions/levels of that harness takeout. Braid (non-metallic braided or knitted hoses) Due to the disturbances that unbalance the equal tensions required on all braided threads, a harness section containing an abrupt diameter change or takeout point may have loose braid. This area should not exceed 125mm of linear length before balance is re-established. In other sections of harness, where the diameter is consistent and there are no takeouts, the braid shall be applied in a neat, uniform manner. The braid shall be securely taped to the wire at both ends, and the pigtail shall not exceed 40mm-in length.

Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

FRAME 14 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA 5.3 Avoiding wire damage from coverings Harnesses must be constructed so that any harness outer covering (tape, tubing, shields, etc.) must not be able to damage the wires during and after installation in the vehicle (ref. SDS requirement RQT-180100-009524). Here are some examples:

5.4

•

Wires must not splay out of the slits in convoluted tubing

•

Wires must not be able to contact or chafe on the edges (cut ends, slits, etc.) of convoluted tubing

•

Harness takeouts may not exit convolute through the slit; the tubing must be broken or divided at the takeout point Applying Other Coverings to the Back of Connectors

Other coverings shall stop at a distance back from the connector equal to the maximum spread between terminal cavities on that connector plus 5 mm, with a +/- 5 mm tolerance (distance D1). This distance is to be considered as fully covered all the way to the back of the connector (See figure 1 for non-dressed connectors and figure 2 for dressed connectors). If the diameter of the other covering equals or exceeds the maximum spread as defined above, then it may go all the way to the back of the connector. If the connector is not fully populated – that is, if the wires in a connector are arranged in such a way that the maximum spread between wires is less than the maximum spread between terminal cavities, then the other covering may be applied closer than the maximum spread between cavities, stopping at the maximum spread between wires, or all the way to the back if the diameter is larger than the maximum spread between wires. If the connector is populated differently in different versions/levels of the same harness, then for ease in manufacturing, the covering for all versions/levels may stop at distance D1 as defined above; it will be considered as fully covered all of the way back to the connector for all versions/levels of that harness takeout. NOTE: this section does not apply to coverings that are intended to cover the connector completely, e.g. for heat shielding.

6.0

Molding/Insulation Where mold/insulation is called out, the following criteria are required (Ref.: ES-C0AF14A121-A, Part ll). 6.1

Durometer All D-mold connectors (Ref. Spec. ESB-M4D317-A) with female terminals and all skirted connectors must use Type III compound (unless otherwise specified). All other D-mold connectors shall use Type IV or V (unless otherwise specified.)

6.2

Coloring Molding compound shall be black (unless otherwise specified on the face of the assembly drawing or the individual item detail).

Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

FRAME 15 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA 6.3

Removed

6.4

Grommet Pull Test Grommets on any assembly drawing must withstand the pull force as identified below unless otherwise specified (pull force to be applied longitudinally along harness). Pull Force Application (Newtons) Over tape, single or multiple wires. Use of retaining clip, strap, etc. is optional. Over vinyl tubing or vinyl jacketed cable. Over braid. Over non-metallic conduit

7.0

110 110 65 65

Dimensioning and Tolerancing Section: Dimensioning. All takeout dimensions are measured to the centerline of the harness bundle unless otherwise specified. All harness dimensions for connectors are measured to the back face of the connector or to the defined attachment point in the connector model as shown on the harness print unless otherwise specified. All harness dimensions for eyelet terminals are measured to the center of the eyelet hole unless otherwise specified. See Figure 3 for details. All retainer/clip dimensions are measured to the centerline of the attaching feature (e.g., retainer fins, stud channel, portable hole, etc) unless otherwise specified on the drawing. Section: Angular Tolerances. Angular tolerances, shown on views or sections, shall be +/45 degrees unless otherwise specified. 7.1

7.2

Single Wire Bundle length Tolerances for Single Wire Assemblies (unless otherwise specified): Over 15mm

Including 75mm

75mm 380mm 3050mm

380mm 3050mm Up

Tolerances +/- 8mm +/- 10mm +/- 20mm +/- 40mm

Multiple Wire Bundle length Tolerances for Multiple Wire Assemblies (unless otherwise specified):

Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

FRAME 16 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA Over (mm)

Including (mm)

Tolerances (mm)

Cumulative Limits* (mm)

10

50

+/- 6

+/- 10

50

150

+/- 10

+/- 15

150

300

+/- 20

+/- 25

300

900

+/- 25

+/- 40

900

2500

+/- 30

+/- 50

2500

Up

+/- 50

+/- 60

*The total length of any two or more adjacent bundle lengths along the “main” harness or along a takeout back to the “main” harness must be equal to the sum of their nominal dimensions within the cumulative limits specified above, while not exceeding the tolerance of the individual bundle lengths. Only nodes used to identify bundle segments, connector end points, or datums are to be included in the cumulative limit calculations. See Figure 4 for a cumulative tolerance example. Assembly drawings documenting tighter tolerances, or at different points than what are shown in Figure 4, take precedence over this specification. 7.3

Tape Ties Tolerance for locating dimensions of tape ties and locator bands on wiring assemblies shall be +/- 15 mm unless otherwise specified. If tape ties are used for locating retainers or other retention features, then the tolerance in section 7.4 is to be used.

7.4

Retainers and All Other Components Tolerance for locating dimensions of retainers and all other components (ID labels, shields, etc.) shall be +/- 10 mm unless otherwise specified on the assembly drawing. For example, this applies to any dimension involving a retainer/clip (clip-to-clip, clip to connector, clip to takeout, etc.). Unless otherwise specified on the harness print, tolerances are based on the adjacent bundle segment length to the next fixed point node (e.g., retainer/clip, takeout point, connector, etc.). Tape ties, end of coverings, and reference dimensions are not to be considered as fixed points. See Figures 5 and 6 for examples. Nodes, used to identify the position of other components (e.g., grommets, shields, brackets, etc), are tied to a fixed point on the component (e.g., grommet end/tape tab, shield tape tab, centerline of grommet sealing interface, etc) Views and sections are typically used for clarification.

Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

FRAME 17 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA 7.5

Retainer Pull Force Requirement Single plastic locator clips, or clips sub-assembled to plastic strips, are to be fastened in place on the wiring assembly so that a minimum of 110 Newtons (or other value specified on the component or harness print) is required to pull the clips off the wiring assembly. The pull force is to be applied perpendicular to the wiring assembly longitudinal axis in the direction of the locator.

7.6

Wire Harness Neatness Looped wires are not allowed inside of any harness bundle unless specified on the harness print or specifically authorized by Ford Engineering. Circuits entering connectors must have their lengths adjusted to prevent stress from being applied to any circuit or causing connector seals, especially mat seals, to be deformed. Tape, including packaging/hanking/tear tape, applied to electrical connectors must not interfere with their locking or mating features. Tie-strap retainers must have their excess strap material cut flush to the lock, with a maximum of 3 mm excess material permitted.

8.0

Materials 8.1

Wire Materials 8.1.1 0.13 mm2 Wire Materials The only allowable wire conductor materials to be used in CAN circuits are: a. CuSn (Copper-Tin) b. CuMg (Copper-Magnesium) c. Cu-Co-P (Copper-Cobalt-Phosphorus) For the latest approvals, please contact the EDS Core wire specialist.

8.2

Compatibility with Wire Insulation Any substance (e.g., grease, lubricant, cleaner, etc.) that can come into contact with the wire insulation, whether it is deliberately applied or has incidental contact, must not cause the insulation diameter to change by more than 10%, to crack, or to otherwise degrade. This is to be verified by performing the Fluid Compatibility test of SAE J1128, section 6.7 on the substance/insulation combination(s) in question. Combinations previously tested do not need to be retested.

Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

FRAME 18 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA

9.0

Shielding Composition 9.1

General Drain wire designated as circuit DXXaa (example: DE135) in ES-6L2T-1274-AA, when used in shielding application, will be tinned, uninsulated, copper wire - twisted stranding, spirally wrapped over specified circuits at a spacing of one wrap per 75100mm. For a single twisted pair application using a drain wire, a permissible alternate construction is to lay, instead of twist, the drain wire along the specified twisted circuits then wrap with foil tape as specified below. For multiple twisted pairs under a common shield, a permissible alternate construction is to use a single drain wire twisted at a spacing of one wrap per 75100mm around all pairs then wrap with foil tape as specified below. All circuits will then be spirally wrapped and lapped (50% overlap), with aluminum foil tape, over the twisted tinned stranding. Only the tinned stranding is to be terminated the aluminum foil tape is to be secured at each end with adhesive tape to prevent unraveling. The adhesive tape must be appropriately rated for the environment in which it will be used. The aluminum foil tape is to have the following construction and characteristics: Laminate dimensions: Aluminum foil 0.008 mm Polypropylene film 0.025 mm Aluminum foil 0.008 mm Breaking strength: 10.875 KG per 25 mm width Tensile strength: 86,034 KPa Elongation at Break: 35% Gauge: 0.042 mm Width: (To Be Determined by Wire Harness Supplier – typically 20-25 mm) Color: Natural (silver/reflective) This tape is to be identified on harness prints with the suffix ‘(FT)’ – thus, ES-BU5T14A121-AA (FT).

Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

FRAME 19 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA ALTERNATE CONSTRUCTION: use foil tape meeting performance specification ESBU5T-1A303-AA. Alternate constructions employing single sided foil per ES-BU5T1A303-AA must be reviewed and approved by the Ford subsystem owner and Ford EMC groups. Where specified, shielded wire groups must be insulated from each other or unwanted grounds. If two or more foil-wrapped circuit groupings share a harness bundle, then each grouping, except for one, is to be spirally wrapped and lapped (50% overlap) with a non-conductive tape meeting ES-AC3T-1A303-AA or its successor spec. 9.2

Shielded Drain Wire The non-terminated end of the drain wire must be protected such that the ends cannot penetrate adjacent wires to cause a shorting condition. Suggested shielding methods include heat shrink, hot melt, or Tape.

10.0 Sealed Connectors A check must be conducted to ensure unused cavities are plugged (e.g.: leak (vacuum or pressure) testing, presence check, etc). The wire insulation should not be damaged or deformed beneath the sealing area; processing equipment should not handle the wire in this location. 10.1

Mat Seals No seal material shall be dislodged (i.e. torn away) during the plugging or servicing (i.e. removal and re-plugging) of the terminal through the seal. Crimp tooling shall depress the wire strands and control the cut-off tabs as described in SAE/USCAR-21 to prevent such damage. Fluoroplastic or fluoropolymer insulation is not to be used in mat seal connectors without successfully passing the SAE/USCAR-2 5.9.7 Sealed Connector System Environmental Test Sequence. Manufacturing plants will either need to obtain this test data or perform the tests themselves.

10.2

Individual Wire Seals The seal must be firmly secured by the insulation crimp. The seal must show no signs of damage. The end of the seal neck must be visible in the area between the insulation crimp and the conductor crimp. The cable insulation must be visible under the seal. Note: Seal retention is assured by meeting in-process insulation crimp dimensions per EL-0038 part 3. No additional in-process testing is required.

Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

FRAME 20 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA 10.3

Cavity plugs Per SDS requirement EL-0178 (RQT-180107-008730), a tool must be used to install cavity plugs such that the plugs are installed in position 2, as shown in Figure 7. The plugs must be installed prior to any terminals being plugged. If a tool proves impractical, alternate methods for installation may be used if approved by EDS Core or Core Connectors.

11.0 Terminal Secondary Locks (a.k.a. TPA) As a manufacturing/assembly reliability feature, many connector assemblies utilize a secondary terminal lock/inspection component, such as a wedge or spacer (typically front loaded at the mating end). All wire assemblies shall have the presence and correct position of this terminal secondary lock inspected. Any tool or mechanical assist device used to install the terminal secondary lock must be approved by Ford Connector Engineering. In those instances where there is no terminal secondary lock, then inspection equipment must verify that all terminal plastic lock fingers in the connector are seated. If these deflected plastic terminal lock fingers cannot be detected, then terminal push-out testing per Section 11.1 is required. All of these inspections must be performed prior to final electrical continuity testing. 11.1

Terminal Push-out Testing Push test must be done using a push test fixture constructed such that properly seated circuits remain in design position during a 13 to 22 Newton applied force and improperly seated terminals "pushout" and are detected. If any circuits fail the push test, all circuitry in that connector must be electrically re-tested after repairs are made.

12.0 Electrical Requirements After the harness is completed through the total manufacturing process, all wiring assemblies must be electrically tested. The electrical test must check for crossed circuits, continuity, opens, and shorts; the electrical test shall be conducted sequentially, testing each circuit and each branch of each circuit (including diodes and relays). Relays are to be functioned once to verify basic operation; apply a voltage of range 9 to 13 V to the coil to energize it and verify continuity through the contacts. Harness makers will electrically test shorting bar circuits for continuity when unmated and for lack of continuity when the shorting bar is deflected to simulate being mated to the appropriate connector. The presence and continuity of busing circuits or components (bus bars), excluding fuses, used to short harness circuits must be tested. Re-testing of all positions will be required for any connector which fails to have every position successfully tested. Additionally, the presence of the correct components is to be checked (locators, molds, clips, connectors, TPA's, seal plugs, fuses, circuit breakers, etc.).

Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

FRAME 21 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA The wiring assembly supplier is responsible for the design of fixtures which contact or probe terminals, for the purpose of electrical inspection. These fixtures must be designed such that they are harmless and compatible with the component. At the completion of a successful test, the test system must provide the operator with a "success signal" (or release a locking mechanism on a wire assembly as a result of the successful test) which is significantly different from the various in-process test signal(s) emitted during other states of harness testing. For example, if numbers are displayed during other stages of testing, the "success signal" may not be a number. 12.1

Fixtures Which Contact Terminals Any design fixture may become damaged or degrade over time causing the forces they apply to the harness terminals to increase above fixture design intent. Regardless of component capability, fixtures which contact or probe terminals (e.g., continuity fixtures) shall meet SDS requirement EL-0052 (RQT-180107-008690. When female barrel terminals of different inside diameters, but having construction similar enough to allow them to fit into the same terminal cavity of a connector, are used on the same circuit, any check must assure that the correct terminal has been used. This applies to single circuits and to circuits that are joined by means of a splice. When the condition occurs within a splice, if the lengths of the circuits could not physically be mixed, the difference in length can serve as the means to assure that they will not be used incorrectly.

12.2

Electrical Control/Maintenance Plans Wire harness suppliers must have control plans or preventive maintenance plans for their fixtures which contact or probe terminals. These plans must define the frequency of fixture inspections to verify compliance to paragraph 12.1 and reaction plans to ensure customer protection when non-compliances are found. EL-0052 is the requirement for test fixture development. In addition, some terminal and connector drawings call out probe design and location of contact. When available these guidelines must be followed as well. Wire harness suppliers must have control plans and maintenance/replacement plans for reusable harness assembly aids. Grease applicators, when used, must not come into contact with the terminals and must be documented in the control plan.

12.3

Diodes When diodes are present in the circuit being tested, specific diode polarity and function must be tested after covering, but may be in sub-assembly. Testing to verify diode polarity and function is accomplished by retesting with the polarity reversed from the initial test set-up.

Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

FRAME 22 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA 12.4

Similar Terminals in the Same Connector When similar terminals, but with different part numbers, are used in the same connector, a check must be conducted to assure that the correct terminal has been used in each connector cavity location. This check may be visual, but the minimum frequency of inspection must be once per shift. The frequency of inspection may be reduced once the process has been proven capable, however. The inspection data and process capability must be maintained by the wiring supplier and made available to any customer representative upon request.

13.0 Identification Multiple wire assemblies shall be identified with a label per either ES-2U5A-1289-AA, ESHU5T-1289-AA or as shown below unless otherwise noted. The label shall be located per drawing note. The program’s Engineering Sgtatement of Work (ESOW) will specify which label spec to use.

13.1

Label Characteristics The label material is to be water-resistant and UV-light-resistant. Print Carrier •

Material Extruded film, white, gloss, non-PVC

•

Tear strength longitudinal (DIN 53455)

18 +/- 4 N/mm2

Adhesive Must conform to the following: “Any change in materials or source of used parts will result in testing to determine materials’ compatibility with associated wiring components. Compatibility testing is to be conducted at the appropriate temperature range for that application.” 13.2

Printing Method Reference: Thermal transfer printing is one of the most widely used technologies in the industrial world to print labels and tags on site and on demand. The printed image is produced using an inked thermal transfer ribbon. Heat is applied by the printhead which melts the ink and transfers the image onto the printing medium. TTP printing using the „ in line“ technique enables direct printing on materials like labels or tags. The printed image obtained using thermal ribbons will be resistant to

Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

FRAME 23 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA UV-light, have good edge definition and bar codes will be scannable provided the correct head and speed settings have been used. Ford bar code has to contain the part number in alphanumeric form, code number to be used is 128B. A translation of the bar code, as commercially used underneath in small fonts, is allowed but not required. Note: Alternative printing methods like laser etc. having comparable printing performance and durability are accepted as well. Position 1 – 5 Position 6 – 11 Position 12 – 14 13.3

Prefix Family No. (Base-No.) Suffix

Design and Proportions max.66 mm

3 mm 5 mm 3 mm

X S 7 1 -1 4 4 0 1

AAA

11 mm

3 mm

EE00-E-10473585-000

2 mm 3 mm 2 mm

3 mm

max. 100 mm

3 mm 3 mm

15 mm

3 mm

S-SK

Potential Alert No.

Potential Alert 3

Potential Alert 4

Potential Alert No.

For Plant Disposal

3 mm

11 mm

3 mm

10 mm

Min. 7 Depentent On No. Of Alert (Bold&Italic) Central Line (bold) Country & Supplier Code (thin lines) Dash lines (thin)

3 mm

11 mm

Release No.

Potential Alert 2

Ford

7 mm

Suffix (Bold)

A10744765

3 mm 2 mm

Part No. (Bold)

For Supplier Disposal

AAA

Free Field For Supplier Internal Information (Barcode etc.) Dash lines (thin) Suffix (Bold)

Barcode Ford (Typ 128B)

3 mm

All fonts shall be Arial or similar and font size as close as possible to the one shown in the specification. 13.4

Single Wire and Rip Cord Single wire and ripcord assemblies may be marked by printing directly on the conductor insulation. Double (2) wire assemblies, which are not covered (with tape or other jacket), may be marked by printing directly on the conductor insulation of one or both wires. This printing is an acceptable alternative to the applied printed tape or tag, even when a tag is specified on the part drawing. Printing shall be black, except on dark range base wire colors where printing shall be white.

Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

FRAME 24 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA

14.0 Shipping Requirements Connectors on harnesses are to be shipped in a ready-to-be-installed configuration. Other than the removal of protective coverings, shipping caps or harness hanking tape, the connectors must be ready to be mated or installed with no additional actions required by the operator. Exceptions require approval of EDS Core and EDS Core Connectors. All approved exceptions shall be shown on the connector drawing. To prevent warpage and cracking, ensure that packaging/dunnage eliminates high forces on connectors and other plastic components. Force limits should be obtained from the component owners through discussions between the harness suppliers and component suppliers (example: tier 2 SCCAF). Terminals within connectors are to be protected from damage during packaging and shipping. Contact to terminals by any part of the harness or other harnesses within the dunnage must be prevented.

15.0 Black Box Components Components shown on supplier drawings with Ford part numbers shall be processed in compliance with all written specifications and instructions provided by the component supplier. This does not apply to terminal suppliers' crimps applications, which must be reviewed for compliance to SAE/USCAR-21. (Specification must contain an electrical verification test of crimp performance).

Attachments Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

FRAME 25 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA

X+5

Figure 1

Min. bend Radius: 2.5 * Bundle Diameter for copper conductors and 5.0 * Bundle Diameter for aluminum conductors Note 1: Circuits/Wires exiting the covering are to maintain a minimum bend radius of 2.5 * Bundle Diameter for copper conductors and 5.0 * Bundle Diameter for aluminum conductors and have sufficient and equal slack to prevent stress on the individual wires. Note 2: X is the maximum spread of terminals in the connector

Figure 2

Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

FRAME 26 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA

Figure 3

Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

FRAME 27 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA

Figure 4

Figure 5

Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

FRAME 28 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA

Figure 6

Figure 7 TABLE 1: TESTS THAT QUALIFY AS PV AND IP Tests/Procedures Splice Pull Test Splice Peel USCAR-38 Section 4.4 Peel Force ES-F0EB-1A263-AA Section 2

Section No. of Mfg. Spec 4.2 4.3 4.3

PV

IP

Sample Size

X X X

X X X

Reserved Reserved Reserved

Splices Ultrasonically Welded Eyelets

2.4, 4.4.2

X

X

Reserved

Bubble test

Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

Comments

FRAME 29 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA Grommet Pull Test Connector Seal Checks 100% Electrical Check Diode Check Proper Terminal Checks Terminal Pull-Out Force Test Torque Test USCAR-21 Tests USCAR-38 for Ultrasonically Welded Eyelets

6.4 10.1, 10.2

X X

X

Reserved Reserved

12.0

X

X

Reserved

12.3 12.4

X X

X X

Reserved Reserved

2.3.16, USCAR 21

X

Reserved

X X X

Reserved Reserved Reserved

All

X

Visual Inspections – primarily IP,some PV Section 4.4, peel and pull force - PV Section 4.7, Electrical Performance Test (PV) Tests in Appendix C, Weld Development and Geometry (PV)

Clip pull-off force 7.4 X Reserved from bundle Note: Ford EDS and Ford STA to review and approve all proposed PV and IP Testing.

Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

FRAME 30 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA APPENDIX A This appendix contains the content of Ford Material Specification WSB-M4G352-A, which had been specified as the liquid sealant to use per section 4.4.2, option F, of this specification.. M4G352 is currently (March 2017) in N status, meaning it is not to be used for new programs, and is likely to be inactivated. The intent is that the performance requirements for the sealant be met; other sections are to be regarded as reference material. 1. SCOPE The material defined by this specification is a thermpolastic blend of polymers and synthetic elastomers. 2. APPLICATION This specification was released originally for material used to seal wire splices in electrical wiring harnesses. It is applied by a process of dipping a splice in the heated molten material. After cooling, this material provides an effective flexible encapsulation. 3. REQUIREMENTS In addition to the requirements specified herein, the finished encapsulated splice shall pass applicable performance specifications specified on the engineering drawing. 3.1 STATISTICAL PROCESS Suppliers must conform to the requirements of Ford Quality System Standard Q-101. A mutually acceptable Control Plan as described therein is required for material/source approval. Appropriate statistical tools must be used to analyze process/product data so that variation in the final product is continuously reduced. 3.2 INFRARED SPECTROPHOTOMETRY AND/OR THERMAL ANALYSIS Ford Motor Company, at its option, may conduct infrared and/or thermal analysis of material/parts supplied to this specification. The IR spectra and thermograms established for initial approval shall constitute the reference standard and shall be kept on file at the designated material laboratory. All samples shall produce IR spectra and thermograms that correspond to the reference standard when tested under the same conditions. 3.3 CONDITIONING AND TEST CONDITIONS All test values indicated herein are based on material conditioned in a controlled atmosphere of 23 +/- 2 C and 50 +/- 5 % relative humidity for not less than 24 h prior to testing and tested under the same conditions unless otherwise specified. 3.4 DENSITY AT 23 C 0.76 - 0.96 kg/L (ASTM D 1475) 3.5 VISCOSITY 560 - 2790 mPa.s (ASTM D 4402, Brookfield Thermosel Model RVT, #27 spindle, 20 rpm, 177 C) Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

FRAME 31 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA 3.6 LOW TEMPERATURE FLEXIBILITY at - 30 C No cracking Test Method: Condition a 25 x 200 x 0.5 mm strip of material for 24 h at - 30 C. Then flex it five times around a conditioned 12 mm mandrel. 3.7 WATER ABSORPTION, max (ISO 62, Method 1) 24 h immersion 0.0 % 4 weeks immersion 0.0 % 3.8 COPPER CORROSION No discoloration (FLTM BU 106-01) 3.9 DIELECTRIC BREAKDOWN STRENGTH 10 kV/mm (IEC 243/ASTM D 149, short time) 3.10 OZONE RESISTANCE Rating 0 (FLTM BP 101-01) No checking or crazing visible under 7X magnification. 3.11 FLAMMABILITY (ISO 3795/SAE J369) Burn Rate, max 100 mm/minute 3.12 FOGGING (FLTM BO 116-03) Fog Number, min 75 The formation of droplets or coalescence into a clear film is cause for rejection. 3.13 HEAT AGED (ISO 188/ASTM D 573, 150 +/- 50 air changes/h, 1000 h at 80 +/- 2 C) 3.16.1 Hardness Change, max +/- 20 % 3.16.2 Tensile Strength Change, max +/- 25 % 3.16.3 Elongation Change, max +/- 25 % 3.16.4 Visual Evaluation No surface tackiness or cracks when folded flat against itself. 3.14 STORAGE STABILITY It is recommended that the material shall be stored at temperatures below 70 C away from all sources of heat and sunlight. When the material is stored at room temperatures below 23 C, it shall be conditioned at room temperature 24 h prior to application. 3.15 FUNCTIONAL APPROVAL Materials being evaluated for approval to this specification shall be subjected to a production trial. Functional trial results must be approved by the affected assembly operation and Design Engineering. Results shall be made available to Materials Engineering prior to material approval and release. Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

FRAME 32 OF 33 Date Issued: 1998/01/27 Version Date: 20150331

Engineering Specification ES-BU5T-14A121-AA 3.16 SUPPLIER'S RESPONSIBILITY All materials supplied to this specification must be equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any change in the properties, composition, construction, color, processing or labeling of the material originally approved under this specification, whether or not such changes affect the material's ability to meet the specification requirements, the Supplier shall notify Purchasing, Toxicology and the affected Materials Engineering activity of the proposed changes and obtain the written approval of the Materials Engineering activity. Test data, test samples and a new code identification are to be submitted with the request. Substance restrictions imposed by law, regulations or Ford, apply to the materials addressed by this document. The restrictions are defined in Engineering Material Specification WSS-M99P9999-A1. 4. APPROVAL OF MATERIALS Materials defined by this specification must have prior approval by the responsible Materials Engineering activity. Suppliers desiring approval of their materials shall first obtain an expression of interest from the affected Purchasing, Design and Materials Engineering activity. Upon request, the Supplier shall submit to the affected Materials Engineering activity a completed copy of their laboratory test reports, signed by a qualified and authorized representative of the test facility, demonstrating full compliance with all the requirements of this specification (test results, not nominal values), the material designation and code number, and test specimens for Ford evaluation. Ford's engineering approval of a material will be based on its performance to this specification and on an assessment of suitability for intended processes and/or applications. Upon approval, the material will be added to the Engineering Material Approved Source List.

Global Manufacturing Quality GIS1 Item Number: 27.6 GIS2 Classification: Confidential FAF03-150-1 (previously form: 3947-A1)

FRAME 33 OF 33 Date Issued: 1998/01/27 Version Date: 20150331