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ES-BU5T-14A121-AA
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 REVISION DR CK PREPARED BY:
12-13-2016 AELE-E-12982958-314
03-30-2017 H1 9 REViSED SECTOR 2.4 RR RR
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.
Attachments
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.
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.
Wiring suppliers may determine their own crimp tooling as long as validation is per EL-
0038 or EL-0176. Terminal suppliers must provide crimp validation data, crimp tool
Global Manufacturing Quality FRAME 4 OF 33
GIS1 Item Number: 27.6
GIS2 Classification: Confidential Date Issued: 1998/01/27
FAF03-150-1 (previously form: 3947-A1) 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.
Each applicator system must be capable of meeting the finished crimp quality
inspection including the following characteristics and others determined by FMEA's:
2.3.2 Material
Assure that the proper terminal, seal, and cable is being used for each new setup
or terminal/cable change.
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.
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.
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.
2.3.11 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).
2.3.12 Bellmouth (Flare) The conductor grip (d.) must have a bellmouth
(flare) or a raised (two stage) crimp on the side of
Bellmouth (flare) is the grip nearest the insulation grip.
required here The conductor grip may also have a bellmouth
(flare) on the front edge of the conductor grip,
nearest the terminal body.
d
.
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.
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.
3.2 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 solder-
dipped terminal should have its + tolerance increased 0.10 mm to allow for the
thickness of the added solder. (FOR FINISHED HARNESS AUDITS ONLY)
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.
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.
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.
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 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
CSA
(mm2)
Peel 10 14 23 28 35 41 44 53 62 73 88 124 159
Force
(N)
4.4 Insulation
When wires are joined in a wiring assembly by splicing, the splice shall be insulated
as specified on the drawing.
WSS-M99D56-A4.
Products other than these may be used if reviewed and approved by Ford
EDS Core.
4.5 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.
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 when specified on the assembly print.
The assembly print shall take precedence over the values in the table above.
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.
• 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
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-C0AF-
14A121-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).
6.3 Removed
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. 110
Use of retaining clip, strap, etc. is optional.
Over vinyl tubing or vinyl jacketed cable. 110
Over braid. 65
Over non-metallic conduit 65
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.
Cumulative
Over Including Tolerances Limits*
(mm) (mm) (mm) (mm)
10 50 +/- 6 +/- 10
*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.
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.
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.
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.
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.
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.
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.
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:
Gauge: 0.042 mm
This tape is to be identified on harness prints with the suffix ‘(FT)’ – thus, ES-BU5T-
14A121-AA (FT).
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.
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.
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.
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.).
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.
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.
13.0 Identification
Multiple wire assemblies shall be identified with a label per either ES-2U5A-1289-AA, ES-
HU5T-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.
Print Carrier
• Material
Extruded film, white, gloss, non-PVC
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.”
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
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 Prefix
Position 6 – 11 Family No. (Base-No.)
Position 12 – 14 Suffix
3 mm
5 mm
X S 7 1 -1 4 4 0 1 Part No. (Bold)
AAA
3 mm
11 mm Suffix (Bold)
3 mm
2 mm EE00-E-10473585-000 Release No.
3 mm
2 mm A10744765 Potential Alert 2 Potential Alert No.
3 mm
2 mm Potential Alert 3 Potential Alert 4 Potential Alert No.
3 mm
max. 100 mm
7 mm
3 mm
Ford Min. 7 Depentent On No. Of
Alert (Bold&Italic)
Central Line (bold)
3 mm 15 mm
Country & Supplier Code (thin lines)
3 mm S-SK For Plant Disposal
3 mm
Dash lines (thin)
Free Field For Supplier Internal
11 mm For Supplier Disposal
Information (Barcode etc.)
Dash lines (thin)
AAA
3 mm
11 mm Suffix (Bold)
3 mm
3 mm
All fonts shall be Arial or similar and font size as close as possible to the one shown
in the specification.
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.
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 FRAME 25 OF 33
GIS1 Item Number: 27.6
GIS2 Classification: Confidential Date Issued: 1998/01/27
FAF03-150-1 (previously form: 3947-A1) 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
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
TABLE 1: TESTS THAT QUALIFY AS PV AND IP
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
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
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.
4. APPROVAL OF MATERIALS