CHANGE NOTICE PROCESS AND COMPONENT INFORMATION

Transcription

1 CHANGE NOTICE Change Request No. Date: Supplier name Supplier manufacturing location Supplier change contact Phone number adress OEM initiated change (yes/no) Affected OEM Resp. Component Engineer: Customer receiving locations Initiator: Further information PROCESS AND COMPONENT INFORMATION Delphi (old) part number Part change level number (old REV) Delphi Delphi (new) part number Delphi Plant Hungary Part change level number (new REV) Customer part number Drawing number Delphi / Daimler DWG change level number (REV) Drawing date Daimler Part name Oliver Hackel Change Description Affected Carline Daimler ZGS 002 Unchanged in process in process in process Receptacle Housing 14w Design change various CHANGE DESCRIPTION Reason for change Detailed description of change Picture of current model Improvment of intermateability process Reduction of the hole dimension at the surrounding housing; Please check and report back if there is any impact on any of your process parameters / holders, etc.; no change on Daimler -and supplier number Picture of new model Affects: Production Process Manufacturing Location Point of Purchase Tool (Capa, Replacement) Material Sub- supplier Packaging Drawing / Dimensions Supply Condition Function Design Other X Detailed desription of impact of the change according to the indicated affects (please see attached transfer plan) Change compatible with previous revision level of mating parts? Tooling: Disposition Stock: Additional IMPLEMENTATION PLANNING INFORMATION Immediate Change Implementation date earliest --- OEM approval date 2 weeks after implementation date Sample date PPAP date latest with 1st delivery First shipment date use scrap Revised Running Change Yes No Date Signature O. Hackel Customer Feedback Comments: Signature & Date Name Phone Purchasing Supplier Quality Development Customer Service Center Operations NOTE: Revision 01 DPGP-4.5-PE-WCS. 01 F06 DPGW-4.5-PE-WCS-01 F06

2 PROCESS AND COMPONENT CHANGE INFORMATION Receptacle Housing 14 way ZGS A FEB2016 Delphi Confidential

3 PROCESS AND COMPONENT CHANGE INFORMATION Current design with initial openings New request Delphi Confidential Affected Housings: A A A A A A divider wall added

4 PROCESS AND COMPONENT CHANGE INFORMATION Affects Reduction of hole size required new help tools and handling to close the TPA (Terminal secondary lock) Please check and review the following process parameters: 1. Close the TPA by tool DPN instead of DPN Oben the TPA by tool DPN Affect on test modules 4. Others Delphi Confidential

5 PROCESS AND COMPONENT CHANGE INFORMATION Comparison Initial openings first changes new request Delphi Confidential

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7 Female Connector 14/10/9/6-way for Xenon Lights Preliminary Assembly L REV 02 - Mar 2017

8 Female Connector 14-way for Xenon Lights - preliminary assembly TABLE OF CONTENTS Components (exploded view) List of components Versions PRELIMINARY ASSEMBLY: step 1: inserting Housing Seal... 6 step 2: inserting Cavity Module... 7 step 3: inserting CPA... 8 Delivery Status / Descriptions Revisions The information contained in these assembly instructions is subject to alteration without prior notice and does not represent any obligation on the part of DELPHI. All information is correct at the time of releasing. Reprinting or translation is not permitted without written permission from DELPHI. Copyright 2017 DELPHI. All rights reserved CUS75-S01 2/10

9 Female Connector 14-way for Xenon Lights - preliminary assembly EXPLODED VIEW CPA PART-NO Receptacle Housing Frame PART-NO Module Seal PART-NO Cavity Module 14-way PART-NO CUS75-S01 3/10

10 Female Connector 14-way for Xenon Lights - preliminary assembly LIST OF COMPONENTS Component (single parts): Delphi PART-NO. amount Cavity Module 14-way (black - RAL 9011) (black - RAL 9011) (transparent) Cavity Module 10-way (curry-yellow - RAL 1027) Cavity Module 9-way (curry-yellow - RAL 1027) Cavity Module 6-way (curry-yellow - RAL 1027) 1 Module Seal (transparent) 1 Receptacle Housing Frame (gray - RAL 7037) 1 CPA (gray RAL 7037) CUS75-S01 4/10

11 Female Connector 14-way for Xenon Lights - preliminary assembly VERSIONS CUS75-S01 5/10

12 Female Connector 14-way for Xenon Lights - preliminary assembly INSERTING HOUSING SEAL PRELIMINARY ASSEMBLY CONNECTOR 14/10/9/6-WAY ATTENTION! Sealing surfaces must be free of defects, parting lines, mold mismatch and knit lines for sealing Step 1: Insert Module Seal onto the Cavity Module. correctly inserted Housing Seal Step 1 completed. P R E - A S S E M B L Y CUS75-S01 6/10

13 Female Connector 14-way for Xenon Lights - preliminary assembly CONNECTOR 14/10/9/6-WAY INSERTING CAVITY MODULE Step 2: Insert Cavity Module into the Receptacle Housing Frame until four locking hooks are correctly engaged. correctly engaged locking hook (one of four) Step 2 completed. P R E - A S S E M B L Y CUS75-S01 7/10

14 Female Connector 14-way for Xenon Lights - preliminary assembly CONNECTOR 14/10/9/6-WAY INSERTING CPA Step 3: Insert CPA into the Receptacle Housing Frame until it is locked in preassembled position. Step 3 completed. CPA is locked in pre-position P R E - A S S E M B L Y CUS75-S01 8/10

15 Female Connector 14-way for Xenon Lights - preliminary assembly HARNESS PLANT DELIVERY STATUS DELIVERY STAT. / DECRIPTIONS CPA is locked in pre-position in the Receptacle Housing Frame secondary locks are open DESCRIPTIONS CUS75-S01 9/10

16 Female Connector 14-way for Xenon Lights - preliminary assembly REVISIONS Revision Change description Date REV 01 Initial Edition Jun 27, 2007 REV 02 Design changed Mar 13, CUS75-S01 10/10

17 Female Connector 14/10/9/6-way for Xenon Lights Assembly at harness plant L REV 02 - Mar 2017

18 Female Connector 14-way for Xenon Lights - assembly at harness plant TABLE OF CONTENTS Components (exploded view) List of components Delivery Status / Descriptions... 5 Versions... 6 ASSEMBLY SEQUENCE: step 1: inserting Terminals SLK step 2: inserting Terminals MLK 1.2 / MCP step 3: locking secondary locks... 9 step 4: electrical test DISASSEMBLY SEQUENCE: step D-1: unlocking secondary locks step D-2: removing Terminals MLK 1.2 / MCP step D-3: removing Terminals SLK Table of tools Revisions The information contained in these assembly instructions is subject to alteration without prior notice and does not represent any obligation on the part of DELPHI. All information is correct at the time of releasing. Reprinting or translation is not permitted without written permission from DELPHI. Copyright 2017 DELPHI. All rights reserved. delphi.com/connectors REV 02 Mar 13, CUS76-S01 2/16

19 Female Connector 14-way for Xenon Lights - assembly at harness plant EXPLODED VIEW Female Terminal SLK 2.8 Female Terminal MLK 1.2 Connector 14-way (Assy) PART-NO !!! Pictures used in this Assembly Manual and original parts may differ in some details, This difference has no influence on the assembly process!!! delphi.com/connectors REV 02 Mar 13, CUS76-S01 3/16

20 Female Connector 14-way for Xenon Lights - assembly at harness plant LIST OF COMPONENTS Component DELPHI PART- NO. CUSTOMER PART- NO. AMOUNT Connector 14-way (Assy) var A kz 1 var A kz var A kz Connector 10-way (Assy) var A kz Connector 9-way (Assy) var A kz Connector 6-way (Assy) var A kz Female Terminals MLK 1.2 / MCP 1.2 A / A max. 8 Female Terminals SLK 2.8 A max. 6 Dummy Plug for MLK / MCP1,2 Cavity A kz Dummy Plug for SLK2,8 Cavity A kz delphi.com/connectors REV 02 Mar 13, CUS76-S01 4/16

21 Female Connector 14-way for Xenon Lights - assembly at harness plant HARNESS PLANT DELIVERY STATUS DELIVERY STAT. / DECRIPTIONS CPA is locked in pre-position in the Receptacle Housing Frame secondary locks are open DESCRIPTIONS delphi.com/connectors REV 02 Mar 13, CUS76-S01 5/16

22 Female Connector 14-way for Xenon Lights - assembly at harness plant VERSIONS delphi.com/connectors REV 02 Mar 13, CUS76-S01 6/16

23 Female Connector 14-way for Xenon Lights - assembly at harness plant INSERTING SLK 2.8 ASSEMBLY CONNECTOR 14/10/9/6-WAY Step 1: Insert Female Terminals SLK 2.8 into the Cavity Module. For BLIND PLUGS Assembly see recommendations: PN _CUS72 Cavity No A S S E M B L Y Step 1 completed. correctly locked Terminal tangs delphi.com/connectors REV 02 Mar 13, CUS76-S01 7/16

24 Female Connector 14-way for Xenon Lights - assembly at harness plant CONNECTOR 14/10/9/6-WAY INSERTING MLK 1.2 Step 2: Insert Female Terminals MLK 1.2 / MCP 1.2 into the Cavity Module. For BLIND PLUGS Assembly see recommendations: PN _CUS72 Cavity No correctly locked Terminal tang Step 2 completed A S S E M B L Y delphi.com/connectors REV 02 Mar 13, CUS76-S01 8/16

25 Female Connector 14-way for Xenon Lights - assembly at harness plant CONNECTOR 14/10/9/6-WAY LOCKING SECONDARY LOCKS Step 3: Using tool DPN to lock four secondary locks (locking arms). correctly locked secondary lock (shown two of four) A S S E M B L Y Step 3 completed. delphi.com/connectors REV 02 Mar 13, CUS76-S01 9/16

26 Female Connector 14-way for Xenon Lights - assembly at harness plant CONNECTOR 14/10/9/6-WAY ELECTRICAL TEST Step 4: Perform electrical test. Following checks have to be done after the harness was made and no deviations were permitted: - Check of any kind of damaging at the Receptacle Housing - Dimension accuracy according harness drawing - Completeness of the Receptacle Housing regarding subscriptions, specifications and harness drawing. During the complete assembly process and also during the checks it is not allowed to break into the inside of the Terminal contact zone with test pins or similar objects. For testing Information for MLK 1.2 Terminals see Kostal specification: DOC rev.09 May For testing Information for SLK 2.8 Terminals see Kostal specification: DOC rev.04 May A S S E M B L Y delphi.com/connectors REV 02 Mar 13, CUS76-S01 10/16

27 Female Connector 14-way for Xenon Lights - assembly at harness plant delphi.com/connectors REV 02 Mar 13, CUS76-S01 11/16

28 Female Connector 14-way for Xenon Lights - assembly at harness plant CONNECTOR 14/10/9/6-WAY UNLOCKING SECONDARY LOCKS Step D-1: Using tool DPN unlock four secondary locks. D I S A S S E M B L Y Step D-1 completed. delphi.com/connectors REV 02 Mar 13, CUS76-S01 12/16

29 Female Connector 14-way for Xenon Lights - assembly at harness plant CONNECTOR 14/10/9/6-WAY REMOVING MLK 1.2 Step D-2: Locate Terminal tangs at the front of the cavity. Insert (arrow 1) the tool DPN straight into the channel of cavity, deflect tangs to unseat the Terminal and gently pull on the cable to remove (arrow 2) MLK 1.2 / MCP 1.2 Female Terminal from the Connector 14/10/9/6-way. D I S A S S E M B L Y Step D-2 completed. delphi.com/connectors REV 02 Mar 13, CUS76-S01 13/16

30 Female Connector 14-way for Xenon Lights - assembly at harness plant CONNECTOR 14/10/9/6-WAY REMOVING SLK 2.8 Step D-3: Locate Terminal tangs at the front of the cavity. Insert (arrow 1) the tool DPN straight into the channel of cavity, deflect tangs to unseat the Terminal and gently pull on the cable to remove (arrow 2) SLK 2.8 Female Terminal from the Connector 14/10/9/6-way. D I S A S S E M B L Y Step D-3 completed. delphi.com/connectors REV 02 Mar 13, CUS76-S01 14/16

31 Assembly Manuals Female Connector 14-way - assembly at harness plant TABLE OF TOOLS Adjustment by stop limit Item Function Tool PN. 1 Removal tool for MLK 1.2 Female Terminals Removal tool for SLK 2.8 Female Terminals Locking tool for Secondary locks Unlocking tool for Secondary locks Those tools are available at: Sales & Service phone: fax: CUS78-S01 14/15

32 Female Connector 14-way for Xenon Lights - assembly at harness plant REVISIONS Revision Change description Date REV 01 Initial Edition Jun 27, 2007 REV 01AA Reference to Blind Plug Seal Assy added (p 6, 7) Jan 17, 2014 REV 01AB Reference to Blind Plug Seal Assy added PN (p 6, 7) Feb 07, 2014 REV 02 Design changed Mar 13, 2017 delphi.com/connectors REV 02 Mar 13, CUS76-S01 16/16

33 Female Connector 14/10/9/6-way for Xenon Lights Assembly at the car L REV 02 - Mar 2017

34 Female Connector 14-way for Xenon Lights assembly at the car TABLE OF CONTENTS Page Components (exploded view) List of components Versions ASSEMBLY SEQUENCE: step 1: assemble Connector 14/10/9/6 way... 6 step 2: locking CPA... 7 DISASSEMBLY SEQUENCE: step D-1: unlocking CPA step D-2: disassemble Connector 14/10/9/6 way Delivery Status / Descriptions Revisions The information contained in these assembly instructions is subject to alteration without prior notice and does not represent any obligation on the part of DELPHI. All information is correct at the time of releasing. Reprinting or translation is not permitted without written permission from DELPHI. Copyright 2017 DELPHI. All rights reserved CUS77-S01 2/11

35 Female Connector 14-way for Xenon Lights assembly at the car EXPLODED VIEW Connector 14-way (Assy) PART-NO Header CUS77-S01 3/11

36 Female Connector 14-way for Xenon Lights assembly at the car LIST OF COMPONENTS Component DELPHI PART- NO. CUSTOMER PART- NO. AMOUNT Connector 14-way (Assy) var A kz 1 var A kz var A kz Connector 10-way (Assy) var A kz Connector 9-way (Assy) var A kz Connector 6-way (Assy) var A kz Header CUS77-S01 4/11

37 Female Connector 14-way for Xenon Lights assembly at the car VERSIONS CUS77-S01 5/11

38 Female Connector 14-way for Xenon Lights assembly at the car CONNECTOR 14/10/9/6-WAY INSERTING CONNECTOR Step 1: Insert Connector 14/10/9/6 way into Header.! Check whether the CPA remains in preliminary position! C O N N E C T I N G Step 1 completed CUS77-S01 6/11

39 Female Connector 14-way for Xenon Lights assembly at the car CONNECTOR 14/10/9/6-WAY CONNECTING CPA in pre-position Step 2: Push CPA until it is locked in end-position. CPA locked in end-position C O N N E C T I N G Step 2 completed CUS77-S01 7/11

40 Female Connector 14-way for Xenon Lights assembly at the car CUS77-S01 8/11

41 Female Connector 14-way for Xenon Lights assembly at the car UNLOCKING CPA CONNECTOR 14/10/9/6-WAY CPA locked in end-position Step D-1: Pull CPA until it is locked in pre-position. CPA in pre-position Step D-1 completed. D I S C O N N E C T I N G CUS77-S01 9/11

42 Female Connector 14-way for Xenon Lights assembly at the car CONNECTOR 14/10/9/6-WAY DISCONNECTING Step D-2: Push unlock (arrow 1) CPA, and disconnect (arrow 2) Connector way and Header. Step D-2 completed. D I S C O N N E C T I N G CUS77-S01 10/11

43 Female Connector 14-way for Xenon Lights assembly at the car REVISIONS Revision Change description Date REV 01 Initial Edition Jun 27, 2007 REV 02 Design changed Mar 13, CUS77-S01 11/11

44 Female Connector 14-way Assembly at harness plant L REV 02 - Mar 2017

45 Assembly Manuals Female Connector 14-way - assembly at harness plant TABLE OF CONTENTS Components (exploded view) List of components Delivery Status / Descriptions... 5 ASSEMBLY SEQUENCE: step 1: inserting Terminals SLK step 2: inserting Terminals MLK 1.2 / MCP step 3: locking secondary locks... 8 step 4: electrical test... 9 DISASSEMBLY SEQUENCE: step D-1: unlocking secondary locks step D-2: removing Terminals MLK 1.2 / MCP step D-3: removing Terminals SLK Table of tools Revisions The information contained in these assembly instructions is subject to alteration without prior notice and does not represent any obligation on the part of DELPHI. All information is correct at the time of releasing. Reprinting or translation is not permitted without written permission from DELPHI. Copyright 2017 DELPHI. All rights reserved CUS78-S01 2/15

46 Assembly Manuals Female Connector 14-way - assembly at harness plant EXPLODED VIEW Female Terminal SLK 2.8 Female Terminal MLK 1.2 Connector 14-way (Assy) PART-NO !!! Pictures used in this Assembly Manual and original parts may differ in some details, This difference has no influence on the assembly process!!! CUS78-S01 3/15

47 Assembly Manuals Female Connector 14-way - assembly at harness plant LIST OF COMPONENTS Component Delphi PART-NO. SUPPLIER Drawing No. amount Connector 14-way (Assy) Female Terminals Kostal MLK 1.2 max. 8 Female Terminals Kostal DOC SLK 2.8 max. 6 Dummy Plug for MLK 1,2 Cavity Dummy Plug for SLK 2,8 Cavity CUS78-S01 4/15

48 Assembly Manuals Female Connector 14-way - assembly at harness plant HARNESS PLANT DELIVERY STATUS DELIVERY STAT. / DECRIPTIONS CPA is in intentionally end position and this connector can be mated with the male connector properly. secondary locks are open DESCRIPTIONS CUS78-S01 5/15

49 Assembly Manuals Female Connector 14-way - assembly at harness plant INSERTING SLK 2.8 ASSEMBLY CONNECTOR 14-WAY Step 1: Insert Female Terminals SLK 2.8 into the Cavity Module. For BLIND PLUGS Assembly see recommendations: PN _CUS72 Cavity No Step 1 completed. correctly locked Terminal tangs 5 6 A S S E M B L Y CUS78-S01 6/15

50 Assembly Manuals Female Connector 14-way - assembly at harness plant CONNECTOR 14-WAY INSERTING MLK 1.2 Step 2: Insert Female Terminals MLK 1.2 into the Cavity Module. For BLIND PLUGS Assembly see recommendations: PN _CUS72 Cavity No correctly locked Terminal tang Step 2 completed A S S E M B L Y CUS78-S01 7/15

51 Assembly Manuals Female Connector 14-way - assembly at harness plant CONNECTOR 14-WAY LOCKING SECONDARY LOCKS Step 3: Using tool DPN to lock four secondary locks (locking arms). correctly locked secondary lock (shown two of four) A S S E M B L Y Step 3 completed CUS78-S01 8/15

52 Assembly Manuals Female Connector 14-way - assembly at harness plant CONNECTOR 14-WAY ELECTRICAL TEST Step 4: Perform electrical test. Following checks have to be done after the harness was made and no deviations were permitted: - Check of any kind of damaging at the Receptacle Housing - Dimension accuracy according harness drawing - Completeness of the Receptacle Housing regarding subscriptions, specifications and harness drawing. During the complete assembly process and also during the checks it is not allowed to break into the inside of the Terminal contact zone with test pins or similar objects. For testing Information for MLK 1.2 Terminals see Kostal specification: DOC rev.09 May For testing Information for SLK 2.8 Terminals see Kostal specification: DOC rev.04 May A S S E M B L Y CUS78-S01 9/15

53 Assembly Manuals Female Connector 14-way - assembly at harness plant CUS78-S01 10/15

54 Assembly Manuals Female Connector 14-way - assembly at harness plant CONNECTOR 14-WAY UNLOCKING SECONDARY LOCKS Step D-1: Using tool DPN unlock four secondary locks. D I S A S S E M B L Y Step D-1 completed CUS78-S01 11/15

55 Assembly Manuals Female Connector 14-way - assembly at harness plant CONNECTOR 14-WAY REMOVING MLK 1.2 Step D-2: Locate Terminal tangs at the front of the cavity. Insert (arrow 1) the tool DPN straight into the channel of cavity, deflect tangs to unseat the Terminal and gently pull on the cable to remove (arrow 2) MLK 1.2 Female Terminal from the Connector 14-way. D I S A S S E M B L Y Step D-2 completed CUS78-S01 12/15

56 Assembly Manuals Female Connector 14-way - assembly at harness plant CONNECTOR 14-WAY REMOVING SLK 2.8 Step D-3: Locate Terminal tangs at the front of the cavity. Insert (arrow 1) the tool DPN straight into the channel of cavity, deflect tangs to unseat the Terminal and gently pull on the cable to remove (arrow 2) SLK 2.8 Female Terminal from the Connector 14-way. D I S A S S E M B L Y Step D-3 completed CUS78-S01 13/15

57 Assembly Manuals Female Connector 14-way - assembly at harness plant TABLE OF TOOLS Adjustment by stop limit Item Function Tool PN. 1 Removal tool for MLK 1.2 Female Terminals Removal tool for SLK 2.8 Female Terminals Locking tool for Secondary locks Unlocking tool for Secondary locks Those tools are available at: Sales & Service phone: fax: CUS78-S01 14/15

58 Daimler Chrysler Assembly Manuals Female Connector 14-way for Xenon Lights - assembly at harness plant REVISIONS Revision Change description Date REV 01 Initial Edition Nov 21, 2013 REV 01AA Reference to Blind Plug Seal Assy added (p 6, 7) Jan 17, 2014 REV 01AB Reference to Blind Plug Seal Assy added PN (p 6, 7) Feb 07, 2014 REV 02 Design changed Mar 13, CUS78-S01 15/15