HYBRID & ELECTRIC VEHICLE
CONNECTION SYSTEM
Off-the-shelf Portfolio
2
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At Aptiv, we are
born to move
Aptiv is a global technology
company that develops safer,
greener and more connected
solutions enabling the future
of mobility.
Headquartered in Dublin,
Aptiv has approximately
150,000 employees and operates
14 technical centers, as well as
manufacturing sites and customer
support centers in 45 countries.
Aptiv is ready when and where you need us
VISIT APTIV.COM
TATABANYA
HUNGARY
WARREN
UNITED STATES
ANTING
CHINA
WUPPERTAL
GERMANY
EPERNON
FRANCE
SALTILLO
MEXICO
Design center
Manufacturing site APTIV’S MAJOR HV DESIGN CENTERS & MANUFACTURING SITES
KRAKOW
POLAND
3
The world of transportation
Aptiv has been a
trusted automotive
supplier for decades,
introducing practical
innovations in the
areas of safety,
effi ciency, and
connectivity.
The transportation
market has been
advancing in these
areas and Aptiv
can offer product
solutions designed
for the tougher
operational and
environmental
requirements.
Did you
KNOW?
Hybrid and electric vehicles
are creating a host of
challenges, including the
demand for a new generation
of high performance, high
power connectors and
charging solutions. Many
additional power electronics
devices are added to the
vehicle architecture including
lithium-ion (Li-ion) batteries,
inverters and DC (Direct
Current) converters. Their
impact on connector design
results in handling operation
voltages that range from 400V
up to 1000 V and carrying
currents as high as 250A.
Commercial and recreation vehicles are often exposed to higher
levels of environmental forces, including vibration, dust, water,
debris, and temperature. To protect the integrity of the electrical
system, high performance connection systems are required.
To deliver superior performance, a number of complex factors
in the electrical system must be addressed in the component
design, including sealing, locking features, and materials.
Image Source : PSA
4
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Why is
vehicle electrifi cation
now a reality?
ENVIRONMENTAL
CONCERNS
GOVERNMENT
REGULATIONS AND
INCENTIVES
RISING
FUEL COSTS
Driven by rising fuel costs,
environmental concerns and
a combination of government
regulations and incentives, the
market for EVs (Electric Vehicles)
and HEVs (Hybrid Electric Vehicles)
is now becoming a reality.
Aptiv is currently driving the
innovations required for future
multi-voltage architectures. Our
research and development teams
have leveraged the lessons learned
from the collaboration with OEM’s to
focus on technological excellence
and to provide real-life electrifi cation
performance.
With a unique expertise in architecture optimization and systems integration, Aptiv has created
one of the most comprehensive portfolios of the high power connection systems.
5
All of our mated connection
systems feature at least
external IP67 sealing
performance.
To ensure optimum sealing
performance, our connectors
are designed for the
harshest conditions due to a
back sealing feature.
EV and HEV electrical and
electronic systems generate
unwanted electromagnetic
interference (EMI)
which radiate from the
interconnecting cables.
The connection systems are
designed by minimizing the
paths along which these
signals can escape. Our
connectors and cabling
designs provide high levels
of shielding effectiveness
to ensure EMI free
performance of the complete
system.
Our connectors provide
fi nger-proof, 2-step
disconnection technologies
to guarantee optimum
safety during all handling
operations. They continue
to meet with changing
requirements of the
OEM’s in regard to HVIL
on a vehicle system and
connection system level.
Additionally, our ErgoMate™
axial mating system helps
achieve a lower profi le
solution while reducing
mating forces. Our solutions
offer position assurances in
multiple options including:
CPA (Connector Position
Assurance), TPA (Terminal
Position Assurance) and SPA
(Screw Position Assurance).
Superior
Sealing
Performances
Superior
Shielding
Performances
Superior
Safety
Performances
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6
A comprehensive
product portfolio
21
High Voltage
Auxiliary Modules
High Voltage
Power Conversion
High Voltage connection systems designed
specifi cally for the voltage and current needs
of auxiliary modules, such as PTC heater,
DC / DC converter, on-board charger (OBC),
electric pack and HV power distribution unit
(PDU).
See page 10-31
PTC heater, DC / DC converter,
On-Board Charger (OBC), Electric AC,
Battery pack, HV PDU
APPLICATION:
HV battery, E-motor,
AC / DC inverter, Power electric box,
Distribution Unit (HV PDU),
DC / DC converter
High Voltage connection systems designed
specifi cally for the voltage and current
needs up to 250A. Power conversion modules
consist of inverters, drive motors/generators,
and high current/high voltage battery outputs.
See page 32-57
7
43
High Voltage
12, 24, 48 Volt Solutions
Charging
Solutions
48V electrical centers, Power distribution
boxes, Start-stop systems, E-turbo, Battery,
Active surspension, BSG units, High current
harness and devices, Sealed pass-through
panel mount systems
On-vehicle charging inlets,
Grid-to-vehicle charging,
Charging infrastructure-to-vehicle
Growing requirements and a quickly
increasing market for 48 Volt applications
drive our technology for innovative solutions.
Two key characteristics defi ne these solutions:
High current carrying capabilities and high
sealing protection.
See page 58-63
With Aptiv products plug-in, hybrid and electric
vehicles can be powered safely and effi ciently
at home or away. Aptiv offers a complete line
of all global charging standards: SAE J1772
(North America and Japan), IEC62196 Type II
(Europe) and GB/T 20234 (China). In addition,
SAE has established a common footprint for
DC (Direct Current) fast charging in North
America and Europe, better known as Combo 1
and Combo 2.
See page 64-79
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8
TEMPERATURE
VOLTAGE AMPERAGE
VIBRATION
Class Ambient Temperature Range
T1 -40˚C to +85˚C
T2 -40˚C to +100˚C
T3 -40˚C to +125˚C
T4 -40˚C to +150˚C
Range: 12V - 1000V Range: 10A - 250A
Class Common Name Typical Application
V1 Chassis Profi le Components on sprung portions of vehicle
not coupled to Engine
V2 Engine Profi le Components coupled to Engine
with severe vibration possible
V3 Severe On-Engine Components subject
to severe vibration
V4 Extreme Vibration Used as needed to correlate
to extreme vibration areas
Performance key &
Aptiv design indicators key
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
aptiv.com | © 2019 Aptiv. All rights reserved
Auxiliary Modules
Solutions
SELECTOR GUIDE
* Please refer to this product for project with space constraints.
** Also compatible for individual cable shielding.
APPLICATIONS:
• PTC heater
• DC / DC converter
• On-Board Charger (OBC)
• Electric AC
• Battery pack
• HV PDU
Application
Battery pack,
DC / DC converter,
On-Board Charger (OBC)
Splicing
accessory loads
Product name
SHIELD-PACK™
HV280
2 WAY
SHIELD-PACK™
HV280
3 BAY HEADER*
SHIELD-PACK™
HV280
4 WAY
SHIELD-PACK™
HV280/630
SPLICE
Amperage at 85°C 40 A 40 A 40 A 40 A
Voltage 1000 V 1000 V 1000 V 1000 V
Orientation 90°
180° 180° 180° 180°
# of ways (power) 2244
HVIL ✓✓✓✓
Shielding Individual Individual Individual Individual
Vibration Class V2 V2 V1 V1
Temperature Class T3 T3 T3 T3
Sections power 2 - 5 mm² 2 - 5 mm² 3 - 5 mm² 3 - 5 mm²
Sections HVIL 0.5 mm² 0.5 mm² 0.5 - 0.75 mm² 0.5 - 0.75 mm²
See Page 12-13 14-15 16-17 18-19
Battery pack, DC / DC converter, Electric AC,
PTC heater, HV PDU,
On-Board Charger (OBC)
On-Board Charger (OBC)
SHIELD-PACK™
HV630
APEX®
HV280
APEX®
HV280
DIRECT MATE
SHIELD-PACK™
AK CLASS 1
16 & 32A
ONBOARD
CHARGERS
APEX® 950
ONBOARD
CHARGER
CONNECTOR
50 A 40 A 40 A 32 A 32 A 125 A
1000 V 1000 V 850 V 1000 V 600 V 750 V
180° 180° 180° 180° 180° 180°
2 2 2 2 & 3 4 4 + 1
×✓✓✓✓✓
Individual Bundle Bundle** Multicore No No
V2 V1 V2 V2 V1 V3
T3 T3 T3 T4 T3 T3
2 - 6 mm² 2.5 - 6 mm² 2.5 - 6 mm² 2.5 - 4.0 mm² 3 - 6 mm² 10 - 16 mm²
- 0.5 - 0.75 mm² 0.5 - 0.75 mm² 0.5 mm² 0.75 - 1.0 mm² 0.5 mm²
20-21 22-23 24-25 26-27 28-29 30-31
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12
2 Way 180° Connection System
without Pluggable Inner Connector
2 W 180° C ti S t
BENEFITS
• Inner connector with TPA can be plugged
into header during device assembly
(on wire-to-device)
• Industry-leading vibration performance
• Field proven design used across
electrifi cation market
FEATURES
• Tool-less unmating system
• Finger proof/touch safe
• Aluminum compression bushings
• ISO cable compatible
Connector Type Wire-to-device, wire-to-wire
Cable Exit Orientation 90°, 180°
Cable Range (mm2)2 - 5 (power)
0.5 (HVIL)
Terminal Type CTS 2.8, Metri-pack 2.8
# of Power Terminals 2
Shielding Type Individual
HVIL Shunt on female
Assembly Assurance CPA/TPA
Number of Indexes 3 (180°), 1 (90°)
SHIELDPACK™ HV280 2 WAY
Battery pack
DC / DC converter
On-board charger (OBC)
APPLICATIONS
AVAILABLE CONFIGURATIONS
m
e
cto
r
2 Way 180° Connection System
with Pluggable Inner Connector
2 Way 90° Connection System
PERFOMANCE
IP67
IP6K9K
TEMP
RANGE
ELECTRICAL PROTECTION
SEALING
CLASS
IP2XB
40 A V2
VIBRATION
LEVEL
1000 V
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
+125°C
-40°C
13
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
ASSOCIATED PARTS
Part number Decsription BOM
Header
13753470 Metri-pack 2.8 male terminal 1 - 2 mm²
213753471 Metri-pack 2.8 male terminal 3 mm²
13790534 Metri-pack 2.8 male terminal 4 - 5 mm²
15432235 CTS HVIL female terminal 0.5 mm² 2
15526390 TPA 1
Inline Male
13753470 Metri-pack 2.8 male terminal 1 - 2 mm²
213753471 Metri-pack 2.8 male terminal 3 mm²
13790534 Metri-pack 2.8 male terminal 4 - 5 mm²
13737699 Inner ferrule 3 mm² 2
33292550 Inner ferrule 5 mm²
13737702 Outer ferrule 3 mm² 2
33292551 Outer ferrule 5 mm²
15513453 Cable seal 3 mm² 1
15513451 Cable seal 5 mm² 1
13824779 TPA / strain relief 3 mm² 1
13888072 TPA / strain relief 5 mm² 1
Mating connector
13882331 CTS 2.8 female terminal 3 - 5 mm² 2
13737699 Inner ferrule 3 mm² 2
33292550 Inner ferrule 5 mm²
13737702 Outer ferrule 3 mm² 2
33292551 Outer ferrule 5 mm²
15513453 Cable seal 3 mm² 1
15513451 Cable seal 5 mm² 1
13824779 TPA / strain relief 3 mm² 1
13888072 TPA / strain relief 5 mm² 1
Index Header with pluggable inner connector Header Male inline
connector
Mating
connector BOM
Outer Header Inner connector
2 Way 180° Connection System
101 35201196 15526394 33240508 33358013 33339283
1102 35201197 15526395 33240509 33358014 33353455
103 35201198 15526396 33240510 33358015 33353456
2 Way 90° Connection System
101 33341078 33341079 33339283 1
35201196
33339283
33358013
33341078
DIMENSION MEASUREMENT SAMPLE
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14
SHIELDPACK™ HV280
3 BAY HEADER
BENEFITS
• Answering to space constraints by having
the 3 headers bolted together
• Inner connector with TPA can be plugged
into header during device assembly
(on wire-to-device)
• Industry-leading vibration performance
• Field proven design used across
electrifi cation market
FEATURES
• Tool-less unmating system
• Finger proof/touch safe
• Aluminum compression bushings
• ISO cable compatible
Connector Type Wire-to-device
Cable Exit Orientation 180°
Cable Range (mm2)2 - 5 (power)
0.5 (HVIL)
Terminal Type CTS 1.2, Metri-pack 2.8
# of Power Terminals 2
Shielding Type Individual
HVIL Shunt on female
Assembly Assurance CPA/TPA
Number of Indexes 3
Battery pack
DC / DC converter
On-board charger (OBC)
APPLICATIONS AVAILABLE CONFIGURATIONS
PERFOMANCE
IP67
IP6K9K
TEMP
RANGE
ELECTRICAL PROTECTION
SEALING
CLASS
IP2XB
40 A V2
VIBRATION
LEVEL
1000 V
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
+125°C
-40°C
15
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
Index Header outer Header inner connector Mating connector BOM
103
33223976
15526396 33353456
1104 15526397 33353457
105 33137225 33353458
33223976 33353456
ASSOCIATED PARTS
Part number Decsription BOM
Header
13753470 Metri-pack 2.8 male terminal 1 - 2 mm²
213753471 Metri-pack 2.8 male terminal 3 mm²
13790534 Metri-pack 2.8 male terminal 4 - 5 mm²
15432235 CTS HVIL female terminal 0.5 mm² 2
15526390 TPA 1
Mating connector
13882331 CTS 2.8 female terminal 3 - 5 mm² 2
13737699 Inner ferrule 3 mm² 2
33292550 Inner ferrule 5 mm²
13737702 Outer ferrule 3 mm² 2
33292551 Outer ferrule 5 mm²
15513453 Cable seal 3 mm² 1
15513451 Cable seal 5 mm² 1
13824779 TPA / strain relief 3 mm² 1
13888072 TPA / strain relief 5 mm² 1
DIMENSION MEASUREMENT SAMPLE
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16
SHIELDPACK™ HV280 4 WAY
BENEFITS
• No mechanical assist needed for mating
• Compact system design with integrated
HVIL
• Robust error-proof assembly and system
mating
FEATURES
• Tool-less unmating system
• Finger proof/touch safe
• 4 power circuits
• Panel mount to device with face seal
(on wire-to-device)
• Aluminum compression bushings
• Internal HVIL (shunted in harness
connector)
• ISO cable compatible
Connector Type Wire-to-device
Cable Exit Orientation 180°
Cable Range (mm2)3 - 5 (power)
O.5 - 0.75 mm (HVIL)
Terminal Type CTS 2.8
# of Power Terminals 4
Shielding Individual
HVIL Shunt on female
Assembly Assurance CPA
Number of Indexes 2
AVAILABLE CONFIGURATIONSAPPLICATIONS
Battery pack
DC / DC converter
On-board charger (OBC)
PERFOMANCE
IP67
IP6K9K
TEMP
RANGE
ELECTRICAL PROTECTION
SEALING
CLASS
IP2XB
40 A V1
VIBRATION
LEVEL
1000 V
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
+125°C
-40°C
17
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
33314147
Index Header outer Header inner connector Mating connector BOM
101 35099959 35099976 33314147 1
102 35161787 35149737 33314148
35099959
Part number Decsription BOM
Header
13597855 MTS 0.64 HVIL female terminal 0.5 - 0.75 mm 2
13753471 CTS 2.8 male terminal 3 - 5 mm² 4
13790534 CTS 2.8 male terminal 4 - 5 mm²
33314145 TPA (Terminal Position Assurance) 2
Mating Connector
13882331 CTS 2.8 female terminal 3 - 5 mm² 4
13737699 Inner ferrule 3 mm² ISO cable 4
33292550 Inner ferrule 5 mm² ISO cable
13737702 Outer ferrule 3 mm² ISO cable 4
33292551 Outer ferrule 5 mm² ISO cable
35072736 3 mm² ISO cable seal 1
35072735 5 mm² ISO cable seal
35072739 3 mm² ISO cable seal cover 1
35072738 5 mm² ISO cable seal cover
ASSOCIATED PARTS
DIMENSION MEASUREMENT SAMPLE
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18
SHIELDPACK™ HV280/630
SPLICE
BENEFITS
• Removes splices from the wiring harness
and integrates splicing capabilities into
connector
• No mechanical assist needed for mating
FEATURES
• Tool-less unmating system
• Finger proof/touch safe
• Panel mount to device with face seal
• Aluminum compression bushings
• Internal HVIL (shunted in harness
connector)
• ISO cable compatible
Connector Type Wire-to-device
Cable Exit Orientation 180°
Cable Range (mm2)3 - 5 (power)
0.5 - 0.75 (HVIL)
Terminal type CTS 2.8(2) / 6.3(2)
# of Power Terminals 4
Shielding Individual
HVIL Shunt on female
Assembly Assurance CPA
Number of Indexes 2
AVAILABLE CONFIGURATIONSAPPLICATIONS
Splicing accessory loads
PERFOMANCE
IP67
IP6K9K
TEMP
RANGE
ELECTRICAL PROTECTION
SEALING
CLASS
IP2XB
40 A V1
VIBRATION
LEVEL
1000 V
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
+125°C
-40°C
19
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
3330063433300632
Index Header outer Header inner connector Mating connector BOM
101 33300632 33311166 33300634 1
102 33300633 33311167 33300635
Part number Decsription BOM
Header
13597855 MTS 0.64 HVIL female terminal 0.5 - 0.75 mm 2
33299800 630/280 male terminal 3 - 5 mm² 2
33299799 TPA (Terminal Position Assurance) 2
Mating Connector
13882331 CTS 2.8 female terminal 3 - 5 mm² 2
13984302 CTS 6.3 female terminal 2.5 - 4 mm² 2
13984307 CTS 6.3 female terminal 4 - 6 mm²
13737699 Inner ferrule 3 mm² ISO cable 4
33292550 Inner ferrule 5 mm² ISO cable
13737702 Outer ferrule 3 mm² ISO cable 4
33292551 Outer ferrule 5 mm² ISO cable
35072736 3 mm² ISO cable seal 1
35072735 5 mm² ISO cable seal
35072739 3 mm² ISO cable seal cover 1
35072738 5 mm² ISO cable seal cover
ASSOCIATED PARTS
Power circuits shown,
two sets of 2 in x 1 out
Terminal crimp
wings are shown
un-crimped.
Application Guide for Aptiv 4W CTS 630/280 Shielded Connection
Typical Application – * Load Current Guidance
Device #1
4W CTS 280/630
HV DC
power
supply
+-
-+
2W CTS 280
Device #2 * Typical steady state currents
with 5 mm2 cable on all circuits
Input from DC power supply: 40 - 45 A
Current to Device #1: ≤ 40 A
Current to Device #2: ≤ 30 A
* Connector current ratings in vehicle
applications will be affected by multiple
factors including device heating, harness
coverings, and device duty cycles.
Please review application details with
Aptiv Product Engineering for verifi cation of
current carrying capability.
APPLICATION GUIDE
DIMENSION MEASUREMENT SAMPLE
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20
SHIELDPACK™ HV630
BENEFITS
• Inner connector with TPA can be plugged
into header during device assembly
(on wire-to-device)
• Industry’s most compact 630 2 way system
• Industry leading vibration performance
• External header housing is the same for the
HV280 and HV630
FEATURES
• Tool-less unmating system
• Finger proof/touch safe
• Panel mount to device with face seal
(on wire-to-device)
• Aluminum compression bushings
• ISO cable compatible
• Secondary terminal locking
Connector Type Wire-to-device, wire-to-wire
Cable Exit Orientation 180°
Cable Range (mm2) 3 - 6 (power)
Terminal Type CTS 6.3
# of Power Terminals 2
Shielding Type Individual
HVIL None
Assembly Assurance TPA (wire-to-device)
CPA (wire-to-wire)
Number of Indexes 3 (wire-to-device)
3 (wire-to-wire)
AVAILABLE CONFIGURATIONSAPPLICATIONS
Battery pack
DC / DC converter
On-board charger (OBC)
HV630 Header and
Mating connector*
* Mating connector is most commonly available
with the natural beige color
PERFOMANCE
IP67
IP6K9K
TEMP
RANGE
ELECTRICAL PROTECTION
SEALING
CLASS
IP2XB
50 A V2
VIBRATION
LEVEL
1000 V
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
+125°C
-40°C
21
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
35028839 35201196
Index Header outer Header inner connector Inline connector Mating connector BOM
101 35201196 35028833 35201706 35028839
1102 35201197 35028834 35201707 35028840
103 35201198 35028835 35201708 35028841
Part number Decsription BOM
Header
33375907 2.4 - 3.4 cable OD 3 - 6 mm² 2
35028830 TPA (Terminal Position Assurance) 1
Inline connector
35063063 4.8 male terminal 2
Mating connector
13737699 Inner ferrule 3 mm² cable
213737700 Inner ferrule 4 mm² cable
33292550 Inner ferrule 5 mm² & 6 mm² cable
13737702 Outer ferrule 3 mm² & 4 mm² cable 2
33292551 Outer ferrule 5 mm² & 6 mm² cable
13824779 Seal retainers 3 mm² & 4 mm² cable 1
13888072 Seal retainers 5 mm² & 6 mm² cable
15513453 Cable seal 3 mm² cable
115513452 Cable seal 4 mm² cable
15513451 Cable seal 5 mm² & 6 mm² cable
ASSOCIATED PARTS
DIMENSION MEASUREMENT SAMPLE
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22
APEX® HV280
AVAILABLE CONFIGURATIONS
Connector Type Wire-to-device
Cable Exit Orientation 180°
Cable Range (mm2)2.5 - 6 (power)
0.5 - 0.75 (HVIL)
Terminal Type Apex® 2.8
# of Power Terminals 2
Shielding Bundle
HVIL Shunt on female
Assembly Assurance CPA
Number of Indexes 2
APPLICATIONS
Battery pack
DC / DC converter
On-board charger (OBC)
BENEFITS
• Two-stage disconnect for safe unmating
• Compact package with unique integrated
electric interlock
• Header is sealed in both mated and
unmated position
FEATURES
• Bundle shielding with external braid
• HVIL shunted in harness connector
PERFOMANCE
IP67
IP6K9K
TEMP
RANGE
ELECTRICAL PROTECTION
SEALING
CLASS
IP2XB
40 A V1
VIBRATION
LEVEL
1000 V
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
+125°C
-40°C
23
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
33511766 33517428
46.4
53
56
15.8
43.9
35.4
57.3
ASSOCIATED PARTS
Part number Description BOM
Header
15509074 APEX® 2.8 male terminal 2.5 mm² 2
15516298 APEX® 2.8 male terminal 4 - 6 mm²
33511802 DCS2 1.5 male terminal gold-plated 0.22 - 0.35 mm² 2
10779703 DCS2 1.5 male terminal gold-plated 0.5 - 1.0 mm²
Mating connector
13627267 APEX® 2.5 mm² 2
10810733 APEX® 4 - 6 mm²
Seals
33512180 Header and mating: APEX® 2.8 female & male single wire seal 2.5 mm²
233512175 Header and mating: APEX® 2.8 female & male single wire seal red 4 mm²
35289308 Header and mating: APEX® 2.8 female & male single wire seal 6 mm²
15441379 Header: DCS/DSQ 1.5 red single wire seal 0.22 - 0.5 mm² 2
15441380 Header: DCS/DSQ 1.5 grey single wire seal 0.75 - 1.0 mm²
Index Header connector Mating connector BOM
101 33511766 33517428 1
102 33511767 33511765
DIMENSION MEASUREMENT SAMPLE
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24
APEX® HV280 DIRECT MATE
BENEFITS
• Same connector for both bundle and
individual cable shielding
• Cost effective solution thanks to the direct
connection between the female connector
and the male terminals within the device case
• High EMC & RFI shielding performance with
direct connection to metal device case
FEATURES
• Two HV power circuits
(APEX® 2.8 mm terminal)
• Bundle shielding with external braid
in serial production
• Individual cable shielding version available
by request
• Integrated HVIL (HV interlock line)
AVAILABLE CONFIGURATIONS
Connector Type Wire-to-device
Cable Exit Orientation 180°
Cable Range (mm2)2.5 - 6 (power)
0.5 - 0.75 (HVIL)
Terminal Type APEX® 2.8
# of Power Terminals 2
Shielding Bundle (also compatible
for individual cable shielding)
HVIL Pass-through or shunt on header
Assembly Assurance None (screwed)
Number of Indexes 1
APPLICATIONS
Battery pack
DC / DC converter
On-board charger (OBC)
PERFOMANCE
+150°C
-40°C
IP67
IP6K9K
TEMP
RANGE
ELECTRICAL PROTECTION
SEALING
CLASS
IP2XB
40 A V2
VIBRATION
LEVEL
850 V
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
25
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
Part number Description BOM
Mating connector
15509074 APEX® 2.8 female terminal 2.5 mm² 2
15516298 APEX® 2.8 female terminal 4 - 6 mm²
13834764 Single wire seal 3.4 - 4.4 mm 2
35206690 Cable strain relief 2
15549847 DSQ 1.5 female terminal silver-plated 0.35 - 0.5 mm² 2
15549848 DSQ 1.5 female terminal silver-plated 0.75 - 1.0 mm²
15441379 DCS 1.5 red single wire seal 0.35 - 0.5 mm² 2
15441380 DCS 1.5 grey single wire seal 0.75 - 1 mm²
35208936
ASSOCIATED PARTS
Header connector Mating connector BOM
Not needed (mates directly to device) 35208936 1
DIMENSION MEASUREMENT SAMPLE
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26
BENEFITS
• Standard AK interface
• High vibrations and operating temperatures
• Multiple layouts & HVIL options in the same
interface
FEATURES
• Designed according to AK interface
specification and LV215 latest revision
• Finger proof/touch safe
• Multicore shielded cable for wiring
simplification
• Fully interchangeable with other AK
supplier sources
Connector Type Wire-to-device
Cable Exit Orientation 180°
Cable Range (mm²) 2.5 - 4.0 (power)
0.5 - 0.75 (HVIL)
Terminal Type (mm) 2.8
# of Power Terminals 2
Shielding Multicore
HVIL Shunt on female or inline
Assembly Assurance CPA/TPA
Number of Indexes 5
SHIELDPACK™ AK CLASS 1 AK
APPLICATIONS
Battery pack
DC / DC converter
Electric AC
PTC heater
HV PDU
On-board charger (OBC)
AVAILABLE CONFIGURATIONS
PERFOMANCE
+140°C
-40°C
IP67
IP6K9K
TEMP
RANGE
ELECTRICAL PROTECTION
SEALING
CLASS
IP2XB, IPXXD
32 A V2
VIBRATION
LEVEL
1000 V
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
27
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
33367712 35149836
Code Header 2 way Header 3 way Mating outer housing BOM
A 35149836 35149842 33372017
1
B 35149837 35149843 33372014
C 35149838 35149844 33372016
D 35149839 35149845 33372015
E 35149840 35149846 35061103
Part number Description (shunted version)
33367712 2 x 4 mm² cable code A
35122240 2 x 4 mm² cable code B
35122241 2 x 4 mm² cable code C
33367710 2 x 4 mm² cable code D
35086590 2 x 4 mm² cable code E
Part number Description (pass-through version)
35122237 2 x 4 mm² + 2 x 0.5 mm² cable code A
35122238 2 x 4 mm² + 2 x 0.5 mm² cable code B
33367711 2 x 4 mm² + 2 x 0.5 mm² cable code C
35122239 2 x 4 mm² + 2 x 0.5 mm² cable code D
35086591 2 x 4 mm² + 2 x 0.5 mm² cable code E
Component Kits**
** Available confi gurations with associated BOM (Bill Of Materials).
* Both DCK terminals and CTS terminals are compatible.
Part number Decsription
BOM
2 way,
HVIL pass-through
2 way,
HVIL shunt 3 way
Header
35194900 DCS-2 2.8 male terminal 2.5-4 mm² Ag 2 2 3
35149868 HVIL terminal 0.5 - 0.75 2 2 -
35149869 TPA (Terminal Position Assurance) 1 1 -
15540356 TPA (Terminal Position Assurance) - - 1
Mating Connector
33514302
33522728
13799603
13882331
DCK 2.8 female terminal 2.5 mm² Ag
DCK 2.8 female terminal 4 mm² Ag
or*
CTS 2.8 female terminal 2.5 mm² Ag
CTS 2.8 female terminal 4 mm² Ag
223
33504709 Male duo twin 0.64 0.5 mm² 2 2 -
35174268 Spacer 1 1 1
35174446 Shielding 2 2 2
35174249 Cable strain relief 3 x 2.5 mm² - - 1
35174250 Cable seal 3 x 2.5 mm² - - 1
35174511 Inner housing 2 way 1 - -
35174507 Cable strain relief 2 x 4.0 mm² - 1 -
35174508 Cable seal 2 x 4.0 mm² 1 1 -
35174280 Inner ferrule 1 1 1
35174278 Outer ferrule 1 1 1
35174509 Inner housing sub-assembly - 1 -
35174448 Inner housing 3 way - - 1
35174513 TPA (Terminal Position Assurance) 1 - -
35174510 Cable strain relief 2 x 4.0 + 2 x 0.5 mm² 1 - -
ASSOCIATED PARTS
DIMENSION MEASUREMENT SAMPLE
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28
16 & 32A ONBOARD CHARGERS
BENEFITS
• Field proven technology widely used across
electrifi cation market
• Confi gurable for both 1-phase and 3-phase
applications
• Compact packaging
FEATURES
• Finger proof/touch safe
• Capability for 4 power circuits and
2 signal circuits
• Unshielded system with terminal spacing
for HV applications
• One-stage locking system with CPA
• Aluminum compression bushings
Connector Type Wire-to-device, wire-to-wire
Cable Exit Orientation 180°
Cable Range (mm2)3 - 5 (power)
0.75 - 1.0 (HVIL)
Terminal Type HES 1.0 (signal)
HES 2.4 (power)
# of Power Terminals 4 (2 signal terminals)
Shielding Type Unshielded
HVIL None
Assembly Assurance CPA
Number of Indexes 2
AVAILABLE CONFIGURATIONSAPPLICATIONS
On-board charger (OBC)
PERFOMANCE
IP67
IP6K9K
TEMP
RANGE
ELECTRICAL PROTECTION
SEALING
CLASS
IP2XB
32 A V1
VIBRATION
LEVEL
600 V
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
+125°C
-40°C
29
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
Header connector Mating connector BOM
16A 32A
33229378
13879051 (2+2) 13879048 (2+2)
1
15525754 (3+0) 15525753 (3+0)
13879050 (3+2) 13879047 (3+2)
13879049 (4+2) 13879046 (4+2)
Male inline
16A
Male inline
32A
Mating connector
16A 32A
13990593 (2+2) 13990590 (2+2) 13879051 (2+2) 13879048 (2+2)
13990591 (4+2) 13990588 (4+2) 13879049 (4+2) 13879046 (4+2)
6 Way Inline Connection System
6 Way Device Connection System
ASSOCIATED PARTS
Part number Description BOM
Header / Male inline
13663724 1.0 HES gold-plated 0.75 - 1.0 mm² 2 or 4
13783283 2.4 HES gold-plated 2 - 3 mm² 2, 3, or 4
13783284 2.4 HES gold-plated 4 - 5 mm²
Mating connector
13663728 1.0 HES gold-plated 0.75 - 1.0 mm² 2 or 4
13783300 2.4 HES gold-plated 2 - 3 mm² 2, 3, or 4
13783301 2.4 HES gold-plated 4 - 5 mm²
* Female connector is compatible with both device & inline male connectors.
33229378 13879048*13990590
DIMENSION MEASUREMENT SAMPLE
aptiv.com | © 2019 Aptiv. All rights reserved
30
APEX®950 ONBOARD
CHARGER CONNECTOR
BENEFITS
• Header is sealed in mated or unmated
position
• Unshielded 4 + 1 way to connector
designed for on-board chargers up to 125A
3-phase
• Panel mount to device with face seal to
module
FEATURES
• Unique integrated electric interlock
• HVIL shunted in harness connector
• ErgoMateTM slider for easy handling and
reduced mating force
Connector Type Wire-to-device
Cable Exit Orientation 180°
Cable Range (mm2)10 - 16 (power)
0.5 (HVIL)
Terminal Type 9.5
# of Terminals 4 (9.5) + 1 (2.8)
Shielding Type Unshielded
HVIL Shunt on female
Assembly Assurance CPA
Number of Indexes 1
AVAILABLE CONFIGURATIONSAPPLICATIONS
On-board charger (OBC)
PERFOMANCE
IP67
IP6K9K
TEMP
RANGE
ELECTRICAL PROTECTION
SEALING
CLASS
IP2XB
125 A V1
VIBRATION
LEVEL
750 V
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
+125°C
-40°C
31
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
33402137 33402139
Part number Description BOM
Header
33514386 APEX® 950 10 - 16 mm² 4
15516298 APEX® 2.8 4 mm² 1
10779703 DCS2 1.5 male terminal gold-plated 0.5 - 1.0 mm² 2
Mating connector
33514387 APEX® 950 10 - 16 mm² 4
10810733 APEX® 2.8 4 mm² 1
Seals
33503295 Header and mating: APEX® 950 yellow single wire seal 16 mm² 4
33503294 Header and mating: APEX® 950 blue single wire seal 10 mm²
33512175 Header and mating: APEX® 2.8 red single wire seal 4 mm² 1
15441379 Header and mating: APEX® DCS 1.5 red single wire seal 0.22 - 0.5 mm² 2
ASSOCIATED PARTS
Header connector Mating connector BOM
33402137 33402139 1
DIMENSION MEASUREMENT SAMPLE
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Power Conversion
SELECTOR GUIDE
APPLICATIONS:
• HV battery
• E-motor
• AC / DC inverter
• Power electric box
• Distribution Unit (HV PDU)
• DC / DC converter
* For classifi cation V2 please consult an Aptiv representative.
** For solution with HVIL please contact your local Aptiv representativ.
Application
AC / DC inverter,
DC / DC converter,
HV battery,
Power electric box,
HV PDU
E-motor,
AC / DC inverter,
Power electric
box,
HV PDU
Description SHIELD-PACK™
AK CLASS 4
HV RCS 890 SW
SERIES
HV RCS 800
SERIES
HV RCS 890
SERIES
HV RCS 890 RV
2 WAY SERIES
Amperage at 85°C 245 A 210 A 210 A 200 A 200 A
Voltage 1000 V 600 V 1000 V 1000 V 1000 V
Orientation 90°
180° 90° 180° 90° 90°
# of ways (power) 22222
HVIL ✓✓✓✓✓
Shielding Individual Individual Bundle Bundle Bundle
Vibration Class V2 V1* V1 V1 V1
Temperature Class T4 T3 T3 T3 T3
Sections power 25 - 50 mm² 35 - 70 mm² 35 - 50 mm² 35 - 50 mm² 16 - 70 mm²
Sections HVIL 0.5 mm² 0.35 - 1.0 mm² 0.5 - 0.75 mm² 0.5 - 0.75 mm² 0.5 - 0.75 mm²
See Page 34-35 36-37 38-39 40-41 42-43
AC / DC inverter,
DC / DC converter,
HV battery,
Power electric box,
HV PDU
AC / DC inverter,
HV battery,
HV PDU,
Power electric box,
E-motor
HV RCS 890 RV
3 WAY SERIES
HV RCS 800
DIRECT MATE
1 WAY
HV RCS 800
DIRECT MATE
2 WAY
HV RCS 890
DIRECT MATE
2 WAY
SHIELD-PACK™
HV2000
HV AK
PASS-THROUGH
HV METAL
PASS-THROUGH
200 A 210 A 210 A 200 A 250 A N/A N/A
1000 V 850 V 850 V 850 V 1000 V 600 V (AC)
1000 V (DC)
600 V (AC)
1000 V (DC)
90° 180° 180° 90° 90° 180° 180°
3 1 2 2 2 1, 2 & 3 1
✓××
** ✓✓××
Bundle Unshielded Individual Individual Individual Individual Individual
V1 V1* V1* V1* V3 V4 V3
T3 T3 T3 T3 T3 T4 T3
16 - 70 mm² 35 - 50 mm² 35 - 50 mm² 35 - 50 mm² 35 - 50 mm² 16 - 50 mm² 25 - 50 mm²
0.5 - 0.75 mm² – – 0.35 - 1.0 mm² 0.5 mm² – –
44-45 46-47 48-49 50-51 52-53 54-55 56-57
aptiv.com | © 2019 Aptiv. All rights reserved
34
BENEFITS
• Standard AK interface
• High robustness against vibrations
• Higher operating temperatures
FEATURES
• Header compatible with both straight &
right angle female connector
• Connector and header design according to
AK interface specification and LV215 latest
revision
• Individual shielded cables
• Fully compatible with other AK supplier
sources
Connector Type Wire-to-device
Cable Exit Orientation 90°, 180°
Cable Range (mm²) 25 - 50 (power)
0.5 (HVIL)
Terminal Type 8 mm round contact system
# of Power Terminals 2
Shielding Individual
HVIL Shunt on female
Assembly Assurance CPA/TPA
Number of Indexes 4
AC / DC inverter
HV battery
HV PDU
E-motor
Power electric box
SHIELDPACK™ AK CLASS 4 AK
AVAILABLE CONFIGURATIONSAPPLICATIONS
PERFOMANCE
+140°C
-40°C
IP67
IP6K9K
TEMP
RANGE
ELECTRICAL PROTECTION
SEALING
CLASS
IP2XB
180 A V2
VIBRATION
LEVEL
1000 V
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
35
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
35166503 33355781
Code Header UL HB Header UL VO 2 way mating outer housing BOM
A 35166503 33351454 33355781
1
B 35166504 33351455 33355782
C 35166505 - 33355783
D 35166506 - 33355784
Description Cable size BOM*
25 mm² 35 mm² 50 mm²
Outer insulation 35172730 2
Active female terminal 35172744 2
Crimp female terminal 35172741 35172742 2
Inner ferrule 35172724 35172725 35172726 2
Outer ferrule - Ni plated 35172727 35172728 35172729 2
Cable strain relief 35172735 35172736 35172737 2
Cable seal 35172732 35172733 35172734 2
HVIL 1.2 male terminal MCON* 0.5 mm² 13954415 3
HVIL 1.2 male terminal MCON* 0.75 mm² 13952636 3
Part number Code
Assembly for 25 mm² cable
35039798 A
35039799 B
35039800 C
35039801 D
Part number Code
Assembly for 35 mm² cable
35039802 A
35039804 B
35039805 C
35039806 D
Part number Code
Assembly for 50 mm² cable
35039808 A
35039809 B
35039810 C
35039811 D
Component Kits**
** Available confi gurations with associated BOM (Bill Of Materials).
* Reference refers to external supplier.
ASSOCIATED PARTS
DIMENSION MEASUREMENT SAMPLE
aptiv.com | © 2019 Aptiv. All rights reserved
36
BENEFITS
• Specifi cally designed for compact
environments
• High-water protections resulting from
sealed unmated header
• Easy assembly thanks to slider feature on
female connector
FEATURES
• Header has fl at and simple device interface
• Connectors dismounting in 2 steps for time
delay between interlock opening and power
disconnection
• Slider solution offers the maximum
pressure surface in limited space
conditions
Connector Type Wire-to-device
Cable Exit Orientation 90°
Cable Range (mm²) 35 - 70
Terminal Type 8 mm round contact system
# of Power Terminals 2
Shielding Individual
HVIL Shunt on female
Assembly Assurance CPA
Number of Indexes 1
HV RCS 890 SW SERIES
AVAILABLE CONFIGURATIONS
PERFOMANCE
IP67
IP6K9K
TEMP
RANGE
ELECTRICAL PROTECTION
SEALING
CLASS
IP2XB
210 A V1*
VIBRATION
LEVEL
600 V
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
+125°C
-40°C
* For classifi cation V2
please consult an Aptiv
representative.
AC / DC inverter
DC / DC converter
HV battery
Power electric box
HV PDU
APPLICATIONS
37
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
35254402 35254366
DIMENSION MEASUREMENT SAMPLE
Part number Description BOM
Header
15549847 DSQ 1.5 female terminal silver-plated 0.35 - 0.50 mm² 2
15549848 DSQ 1.5 female terminal silver-plated 0.75 - 1.00 mm²
15441379 DCS/DSQ 1.5 male red single wire seal 0.22 - 0.5 mm² 2
15441380 DCS/DSQ 1.5 male grey single wire seal 0.75 - 1.0 mm²
Mating Connector
33502217 RCS890 female terminal silver-plated 35 - 50 mm² 2
35166051 RCS890 female terminal silver-plated 70 mm²
35082415 Outer ferrule 35 mm² 2
35234890 Outer ferrule 50 - 70 mm²
35084603 Recovery shield assembly 35 mm² 2
35236787 Recovery shield assembly 50 - 70 mm²
35084610 Single wire seal & retainer 35 mm²
235084586 Single wire seal & retainer 50 mm²
35236755 Single wire seal & retainer 70 mm²
Header connector Mating connector BOM
35254402 35254366 1
ASSOCIATED PARTS
aptiv.com | © 2019 Aptiv. All rights reserved
38
HV RCS 800 SERIES
BENEFITS
• Easy to assemble with integrated
ErgoMate™ Axial Mating Assist System on
harness connector
• Compact package with unique integrated
electric interlock
• Header is sealed in both mated and
unmated positions
FEATURES
• Bundle shielding with external braid
• Panel mount to device with face seal to
module
• Two-stage disconnect for safe unmating
Connector Type Wire-to-device
Cable Exit Orientation 180°
Cable Range (mm²) 35 - 50 (power)
0.5 - 0.75 (HVIL)
Terminal Type 8 mm round contact system
# of Power Terminals 2
Shielding Bundle
HVIL Shunt on female
Assembly Assurance CPA
Number of Indexes 2
AC / DC inverter
DC / DC converter
HV battery
Power electric box
HV PDU
AVAILABLE CONFIGURATIONSAPPLICATIONS
PERFOMANCE
IP67
IP6K9K
TEMP
RANGE
ELECTRICAL PROTECTION
SEALING
CLASS
IP2XB
210 A V1
VIBRATION
LEVEL
1000 V
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
+125°C
-40°C
39
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
1397446933511764
83
53
68.5
13.5
69
48.8
74.3
Part number Description BOM
Header
33512193 RCS 800/890 male pin terminal silver version standard length
233511746 RCS 800/890 male pin terminal silver version V1 length
33511747 RCS 800/890 male pin terminal silver version V2 length
10779703 DCS2 1.5 male terminal gold-plated 0.5 - 1.0 mm² 2
15441379 DCS/DSQ 1.5 red single wire seal 0.22 - 0.5 mm² 2
15441380 DCS/DSQ 1.5 grey single wire seal 0.75 - 1.0 mm²
Mating Connector
13893887 RCS 800 female terminal silver version 35 - 50 mm² 2
13893889 RCS 800 female retainer (plug) 2
13893888 RCS 800 female 35 - 40 mm² (plug) 2
13923559 RCS 800 female 50 mm² (plug)
Index Header connector Mating connector BOM
1 33511764 13974469 1
2 33511762 33511761
ASSOCIATED PARTS
DIMENSION MEASUREMENT SAMPLE
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40
HV RCS 890 SERIES
BENEFITS
• Easy to assemble with integrated
ErgoMate™ Axial Mating Assist System on
harness connector
• Compact package with unique integrated
electric interlock
• Header is sealed in both mated and
unmated position
FEATURES
• Bundle shielding with external braid
• Panel mount to device with face seal to
module
• Two-stage disconnect for safe unmating
Connector Type Wire-to-device
Cable Exit Orientation 90°
Cable Range (mm²) 35 - 50 (power)
0.5 - 0.75 (HVIL)
Terminal Type 8 mm round contact system
# of Power Terminals 2
Shielding Bundle
HVIL Shunt on female
Assembly Assurance CPA
Number of Indexes 1
AC / DC inverter
DC / DC converter
HV battery
Power electric box
HV PDU
AVAILABLE CONFIGURATIONSAPPLICATIONS
FOR NEW DESIGN, CONSIDER THE NEW HV 890 RV SERIES
PERFOMANCE
IP67
IP6K9K
TEMP
RANGE
ELECTRICAL PROTECTION
SEALING
CLASS
IP2XB
200 A V1
VIBRATION
LEVEL
1000 V
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
+125°C
-40°C
41
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
85
55.9
54.5
13.1
71.4 49.1
89
3351175033503821
Part number Description BOM
Header
33512193 RCS 800/890 male pin terminal silver version standard length
233511746 RCS 800/890 male pin terminal silver version V1 length
33511747 RCS 800/890 male pin terminal silver version V2 length
10811962 DCS2 1.5 female terminal gold-plated 0.5 - 1.0 mm² 2
15441379 DCS/DSQ 1.5 red single wire seal 0.22 - 0.5 mm² 2
15441380 DCS/DSQ 1.5 grey single wire seal 0.75 - 1.0 mm²
Mating Connector
33511752 RCS 890 female terminal silver version 16 - 25 mm²
233502217 RCS 890 female terminal silver version 35 - 50 mm²
35166051 RCS 890 female terminal silver version 70 mm²
33521619 RCS 890 single wire seal & retainer 16-25 mm²
2
33511753 RCS 890 single wire seal & retainer 35 - 40 mm²
33511754 RCS 890 single wire seal & retainer 50 mm²
35199856 RCS 890 single wire seal & retainer 70 mm²
33504038 RCS 890 2-way half clamp 2
ASSOCIATED PARTS
Header connector Mating connector BOM
33503821 33511750 1
DIMENSION MEASUREMENT SAMPLE
aptiv.com | © 2019 Aptiv. All rights reserved
42
HV RCS 890 RV 2 WAY SERIES
BENEFITS
• Ultra compact design for applications with
space constraints
• Panel mount to device with face seal to
module
• Header is sealed in both mated and
unmated position
FEATURES
• Two-stage disconnect for safe unmating
• Easier mating with Slider Mating Assist
System on harness connector
• Bundle shielding with external braid
• HVIL shunted in harness connector
Connector Type Wire-to-device
Cable Exit Orientation 90°
Cable Range (mm²) 16 - 70 (power)
0.35 - 1.0 (HVIL)
Terminal Type 8 mm round contact system
# of Power Terminals 2
Shielding Bundle
HVIL Shunt on female
Assembly Assurance CPA
Number of Indexes 2
AC / DC inverter
DC / DC converter
HV battery
Power electric box
HV PDU
AVAILABLE CONFIGURATIONSAPPLICATIONS
USE FOR NEW DESIGN
PERFOMANCE
IP67
IP6K9K
TEMP
RANGE
ELECTRICAL PROTECTION
SEALING
CLASS
IP2XB
200 A V1
VIBRATION
LEVEL
1000 V
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
+125°C
-40°C
43
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
35326611 35092244
Part number Description BOM
Header
10811962 DCS2 1.5 female terminal gold-plated 0.5 - 1.0 mm² 2
15441379 DCS/DSQ 1.5 red single wire seal 0.35 - 0.5 mm² 2
15441380 DCS/DSQ 1.5 grey single wire seal 0.75 - 1.0 mm²
33273083 RCS 800 male bus bar terminal silver version polarized pin 2
Mating Connector
33511752 RCS 890 female terminal silver version 16 - 25 mm²
233502217 RCS 890 female terminal silver version 35 - 50 mm²
35166051 RCS 890 female terminal silver version 70 mm²
33521619 RCS 890 single wire seal & retainer (plug) 16 - 25 mm²
2
33511753 RCS 890 2-way female single wire seal & retainer (plug) 35 - 40 mm²
33511754 RCS 890 2-way female single wire seal & retainer (plug) 50 mm²
35199856 RCS 890 2-way female single wire seal & retainer (plug) 70 mm²
35091447 RCS 890 2-way half clamp 2
Index Header connector Mating connector BOM
1 35326611 35092244 1
2 35326613 35092239
ASSOCIATED PARTS
DIMENSION MEASUREMENT SAMPLE
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44
HV RCS 890 RV 3 WAY SERIES
BENEFITS
• Ultra compact design for applications with
space constraints
• Panel mount to device with face seal to
module
• Header is sealed in both mated and
unmated position
FEATURES
• Two-stage disconnect for safe unmating
• Easier mating with Slider Mating Assist
System on harness connector
• Bundle shielding with external braid
• HVIL shunted in harness connector
Connector Type Wire-to-device
Cable Exit Orientation 90°
Cable Range (mm²) 16 - 70 (power)
0.5 - 0.75 (HVIL)
Terminal Type 8 mm round contact system
# of Power Terminals 3
Shielding Bundle
HVIL Shunt on female
Assembly Assurance CPA
Number of Indexes 2
AC / DC inverter
DC / DC converter
HV battery
Power electric box
HV PDU
AVAILABLE CONFIGURATIONSAPPLICATIONS
PERFOMANCE
IP67
IP6K9K
TEMP
RANGE
ELECTRICAL PROTECTION
SEALING
CLASS
IP2XB
200 A V1
VIBRATION
LEVEL
1000 V
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
+125°C
-40°C
45
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
35310180 33272670
Part number Description BOM
Header
33273083 RCS 800 male bus bar terminal silver version polarized pin 3
10811962 DCS2 1.5 female terminal gold-plated 0.5 - 1.0 mm² 2
15441379 DCS/DSQ 1.5 red single wire seal 0.35 - 0.5 mm² 2
15441380 DCS/DSQ 1.5 grey single wire seal 0.75 - 1.0 mm²
Mating Connector
33511752 RCS 890 female terminal silver version 16 - 25 mm²
333502217 RCS 890 female terminal silver version 35 - 50 mm²
35166051 RCS 890 female terminal silver version 70 mm²
33521619 RCS 890 single wire seal & retainer 16 - 25 mm²
3
33511753 RCS 890 single wire seal & retainer 35 - 40 mm²
33511754 RCS 890 single wire seal & retainer 50 mm²
35199856 RCS 890 single wire seal & retainer 70 mm²
33272561 RCS 890 3-way half clamp 2
Index Header connector Mating connector BOM
1 35310180 33272670 1
2 35310181 33282936
ASSOCIATED PARTS
DIMENSION MEASUREMENT SAMPLE
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46
HV RCS 800
DIRECT MATE 1 WAY
BENEFITS
• Cost effective thanks to the direct
connection between the female connector
and the male terminals within the device
case
• Unique and safe mating screwing with
innovative Screw Position Assurance (SPA)
• Versatile solution covering multiple
applications: high voltage power conversion
and 48 volt
FEATURES
• Robust bolt driven mate assist
• Fingersafe via plastic tips on male pins
• Unshielded connector system
Connector Type Wire-to-device
Cable Exit Orientation 180°
Cable Range (mm2) 35 - 50 (power)
Terminal Type 8 mm round contact system
# of Power Terminals 1
Shielding None
HVIL None
Assembly Assurance SPA
Number of Indexes 1
AC / DC inverter
DC / DC converter
HV battery
Power electric box
HV PDU
AVAILABLE CONFIGURATIONSAPPLICATIONS
* For classifi cation V2
please consult an Aptiv
representative.
PERFOMANCE
IP67
IP6K9K
TEMP
RANGE
ELECTRICAL PROTECTION
SEALING
CLASS
IP2XB
210 A V1*
VIBRATION
LEVEL
850 V
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
+125°C
-40°C
47
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
Header connector* Mating connector BOM
35098440 35098437 1
Part number Description BOM
Mating Connector
13893887 RCS 800 female terminal 35 - 50 mm² 1
13893888 Female black single wire seal 35 mm² 1
13923559 Female grey single wire seal 50 mm²
13893889 Retainer 1
3509843735098440
* Header connector is a fully assembled part and therefore has no associated parts.
ASSOCIATED PARTS
DIMENSION MEASUREMENT SAMPLE
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48
HV RCS 800
DIRECT MATE 2 WAY
BENEFITS
• Cost effective solution with unshielded
terminal holder within device replacing
traditional shielded headers
• Unique and safe mating screwing with
innovative Screw Position Assurance (SPA)
• Header is sealed in both mated and
unmated position
FEATURES
• Robust bolt driven mate assist
• Fingersafe via plastic tips on male pins
• Cable range: ~ 50 mm² and smaller
Connector Type Wire-to-device
Cable Exit Orientation 180°
Cable Range (mm2)35 - 50 (power)
0.35 - 1.0 (HVIL)
Terminal Type 8 mm round contact system
# of Power Terminals 2
Shielding Individual
HVIL Shunt on female
Assembly Assurance SPA
Number of Indexes 1
AC / DC inverter
DC / DC converter
HV battery
Power electric box
HV PDU
AVAILABLE CONFIGURATIONSAPPLICATIONS
* For classifi cation V2
please consult an Aptiv
representative.
PERFOMANCE
IP67
IP6K9K
TEMP
RANGE
ELECTRICAL PROTECTION
SEALING
CLASS
IP2XB
210 A V1*
VIBRATION
LEVEL
850 V
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
+125°C
-40°C
49
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
3509845335099885
Header* Header with HVIL** Mating connector BOM
35099885 35099880 35098453 1
Part number Description BOM
Mating connector
13893887 RCS 800 female terminal silver-plated 35 - 50 mm² 2
35082410 Inner ferrule 35 and 50 mm² 2
35082415 Outer ferrule 35 and 50 mm² 2
35099247 Single wire seal & retainer 35 mm² 2
35099248*** Single wire seal & retainer 50 mm²
35092416 RCS800 tube 35 - 50 mm² 2
* Header connector is a fully assembled part and therefore has no associated parts.
** Please contact your local Aptiv representative for serial production information.
*** Available only by prototype, please contact your local Aptiv representative for more information on serial production.
ASSOCIATED PARTS
DIMENSION MEASUREMENT SAMPLE
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50
HV RCS 890
DIRECT MATE 2 WAY
BENEFITS
• Cost effective solution with unshielded
terminal holder within device replacing
traditional shielded headers
• Unique and safe mating screwing with
innovative Screw Position Assurance (SPA)
• Header is sealed in both mated and
unmated position
FEATURES
• Robust bolt driven mate assist
• Fingersafe via plastic tips on male pins
• Cable range: ~ 50 mm² and smaller
Connector Type Wire-to-device
Cable Exit Orientation 90°
Cable Range (mm2)35 - 50 (power)
0.35 - 1.0 (HVIL)
Terminal Type 8 mm round contact system
# of Power Terminals 2
Shielding Individual
HVIL Shunt on female
Assembly Assurance SPA (Screwed Position
Assurance)
Number of Indexes 1
AC / DC inverter
DC / DC converter
HV battery
Power electric box
HV PDU
AVAILABLE CONFIGURATIONSAPPLICATIONS
* For classifi cation V2
please consult an Aptiv
representative.
PERFOMANCE
IP67
IP6K9K
TEMP
RANGE
ELECTRICAL PROTECTION
SEALING
CLASS
IP2XB
200 A V1*
VIBRATION
LEVEL
850 V
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
+125°C
-40°C
51
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
35084594 35084575
Header Mating connector BOM
35084594 35084575 1
Part number Description BOM
Header
15549847 DSQ 1.5 female terminal silver-plated 0.35 - 0.50 mm² 2
15549848 DSQ 1.5 female terminal silver-plated 0.75 - 1.00 mm²
15441379 DCS/DSQ 1.5 red single wire seal 0.22 - 0.5 mm²
2
15441380 DCS/DSQ 1.5 grey single wire seal 0.75 - 1.0 mm²
Mating connector
33502217 RCS 890 female terminal silver-plated 35 - 50 mm² 2
35082415 Outer ferrule 35 mm² 2
35234890 Outer ferrule 50 mm²
35084603 Recovery shield assembly 35 mm² 2
35236787 Recovery shield assembly 50 mm²
35084610 Single wire seal & retainer 35 mm² 2
35084586 Single wire seal & retainer 50 mm²
ASSOCIATED PARTS
DIMENSION MEASUREMENT SAMPLE
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52
SHIELDPACK™ HV2000
BENEFITS
• Header interface is integrated into device
case
• Cost-effective full plastic header assembled
from inside out
• Bolt driven mate assist
• Ultrasonic welding used for power terminal
FEATURES
• Internal HVIL shunted in harness connector
• Finger proof and non-fi nger proof options
available
• Provides fi nger proof terminal towers and
HVIL
• Header accepts busbars provided by
module
AC / DC inverter
DC / DC converter
HV battery
Power electric box
HV PDU
AVAILABLE CONFIGURATIONSAPPLICATIONS
Connector Type Wire-to-device
Cable Exit Orientation 90°
Cable Range (mm2)35 - 50 (power)
0.5 (HVIL)
Terminal Type Power Pack 2000 17.7
# of Terminals 2
Shielding Type Individual
HVIL Shunt on female
Assembly Assurance CPA/TPA
Number of Indexes 1
PERFOMANCE
IP67
IP6K9K
TEMP
RANGE
ELECTRICAL PROTECTION
SEALING
CLASS
IP2XB
250 A V1
VIBRATION
LEVEL
1000 V
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
+125°C
-40°C
53
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
33346375 33352038
Header connector Mating connector BOM
33346375 33352038 1
Part number Decsription BOM
Header
15432237 CTS female terminal silver-plated HVIL 0.35 mm² 2
33346276 HVIL TPA 1
Mating Connector
13801592 Power Pack 2000 female sonic weld terminal 2
33352058 Inner ferrule 35 mm² 2
33352059 Inner ferrule 50 mm² 2
33352056 Outer ferrule 35 mm² & 50 mm² 2
33352048 Cable seal 35 mm² 2
33352049 Cable seal 50 mm² 2
33352051 Strain relief 35 mm² 2
33352052 Strain relief 50 mm² 2
33352055 TPA 1
13849267 Fastener M5 1
ASSOCIATED PARTS
DIMENSION MEASUREMENT SAMPLE
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54
HV AK PASS-THROUGH AK
BENEFITS
• Very compact dimensions
• High robustness against vibrations
• Higher operating temperatures
FEATURES
• Ring terminal is bolted to device
• Cables are 360° individually shielded
• High voltage panel mount system
• Fully interchangeable with other AK
supplier sources
AVAILABLE CONFIGURATIONSAPPLICATIONS
Connector Type Pass-through
Cable Exit Orientation 180°
Cable Range (mm²) 16 - 50 (power)
Terminal Type O-ring
Shielding Individual
HVIL None
AC / DC inverter
HV battery
HV PDU
Power electric box
E-motor
+140°C
-40°C
PERFOMANCE
IP67
IP6K9K
TEMP
RANGE
ELECTRICAL PROTECTION
SEALING
CLASS
IP2XB
275 A V3
VIBRATION
LEVEL
600 V
(AC)
1000 V
(DC)
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
55
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
33340524 33340525 33340526
Code Cable size BOM
16 mm225 mm2 35 mm2 50 mm2
1 Way
A 33350177 33350176 33350175 33349598 1
B - - - 35083309 1
2 Way
A 33350180 33350179 3335178 33349600 2
3 Way
A 33350183 33350182 33350181 33350072 3
Code Number of ways BOM
123
A 33340524 33340525 33340526 1
B 35066699 - -
Description Cable size BOM*
16 mm225 mm2 35 mm2 50 mm2
Peripheral seal 35116341 1, 2 or 3
Inner ferrule 35172747 1, 2 or 3
Outer ferrule 33340554 35172745 35172743 33340551 1, 2 or 3
Single wire seal 33340537 35172739 35172738 33340534 1, 2 or 3
Cable strain relief 33340542 33340541 33340540 33340539 1, 2 or 3
** Available confi gurations with associated BOM (Bill Of Materials).
* Depending on if the component is for 1, 2 or 3 Way pass-through.
Component Kits**
Main Housing Body Components
ASSOCIATED PARTS
DIMENSION MEASUREMENT SAMPLE
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56
HV METAL PASSTHROUGH
BENEFITS
• Robust design for harsh environments
• Very compact dimensions
• Wide variety of indexes depending on wire
sections
FEATURES
• High voltage panel mount system
• 1 Way sealed and shielded solution
• Ring terminal bolted to device
Connector Type Pass-through
Cable Exit Orientation 180°
Cable Range (mm²) 25 - 50 (power)
Terminal Type Ring
# of Power Terminals 1
Shielding Individual
HVIL None
Number of Indexes 6-8, depending on wire section
AVAILABLE CONFIGURATIONSAPPLICATIONS
AC / DC inverter
HV battery
HV PDU
Power electric box
E-motor
PERFOMANCE
IP67
IP6K9K
TEMP
RANGE
ELECTRICAL PROTECTION
SEALING
CLASS
IP2XB
275 A V4
VIBRATION
LEVEL
600 V
(AC)
1000 V
(DC)
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
+125°C
-40°C
57
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
13888001
Index 25 mm² wire section 35 mm² wire section 50 mm² wire section BOM
102 13888001 13894189 33112598
1
103 13888002 13894190 33112599
104 13888003 13894191 33112600
105 13888004 13894192 33112601
106 - - 33112602
107 - - 33112608
108 33253253 33253255 33112609
109 33253254 33253256 33112610
Part number Description
25 mm²
13888023 25 mm² seal retainer
13888030 25 mm² seal
13888025 O-ring seal
33295901 25 mm² ferrule
Part number Description
35 mm²
13894241 35 mm² seal retainer
33288396 35 mm² seal
13888025 O-ring seal
33295902 35 mm² ferrule
Part number Description
50 mm²
33112613 50 mm² seal retainer
33112616 50 mm² seal
13888025 O-ring seal
33295903 50 mm² ferrule
ASSOCIATED PARTS
Main Housing Body Components
DIMENSION MEASUREMENT SAMPLE
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12, 24 & 48 Volt
Solutions
SELECTOR GUIDE
APPLICATIONS:
• 48V electrical centers
• Power distribution boxes
• Start-stop systems
• E-turbo
• Battery
• Active surspension
• BSG units
• High current harness and devices
• Sealed pass-through panel mount systems
Application
48V electrical centers,
Power distribution boxes,
Start-stop systems, E-turbo, Battery,
Active suspension, BSG units
Description SEALED RING CONNECTOR
Amperage at 85°C 250 A
Voltage 12 - 48 V
Orientation 90°
# of Ways 1
Shielding No
Vibration Class V3
Temperature Class T4
Sections 35 mm²
50 mm²
See Page 60-61
aptiv.com | © 2019 Aptiv. All rights reserved
60
48V SEALED RING CONNECTOR
BENEFITS
• Fast and easy assembly process
• High robustness against vibrations
• High current carrying capabilities
FEATURES
• Ideal solution for 12 to 48V requiring sealed
ring connections
• Can be screwed from the top
• Header interface available for system
supplier integration on the box
• M8 ring terminal bolted to device
Connector Type Wire-to-device
Cable Exit Orientation 90°
Cable Range (mm2) 35, 50
Terminal Type M8 ring terminal
# of Power Terminals 1
Shielding Type Unshielded
HVIL None
Assembly Assurance None
Number of Indexes 1
AVAILABLE CONFIGURATIONSAPPLICATIONS
48V electrical centers
Power distribution boxes
Start-stop systems
E-turbo
Battery
Active suspension
BSG units
PERFOMANCE
+140°C
-40°C
IP67
IP6K9K
TEMP
RANGE
SEALING
CLASS
250 A V3
VIBRATION
LEVEL
48 V
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
61
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
33376962
Mating connector Header connector BOM
33376962 Please contact you Aptiv representative for more information 1
Part number Type Applicable wire size (mm2) Cable type BOM
33376821 Single wire seal retainer 35 - 50 - 1
33329995 M8 O-ring terminal 35 - 50 - 1
35093138 Single wire seal 35 Unshielded 1
ASSOCIATED PARTS
DIMENSION MEASUREMENT SAMPLE
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62
POWER PACK 1000
BENEFITS
• High current carrying capacity
• Proven terminal system
• Compact system design
• Field proven in both automotive and
heavy duty applications
FEATURES
• Silver-plated multi-contact terminal system
• Sealed panel mount pre-stages prior to
fastening
• Panel mount secured in place with self-
tapping screws
• Pass-through connection accepts both
straight and right angle connectors
Connector Type Wire-to-device, wire-to-wire,
pass-through
Cable Exit Orientation 180°, 90°
Cable Range (mm2) 8 - 25
Terminal Type Power Pack 1000
# of Power Terminals 1 or 2
Shielding Type Unshielded
HVIL None
Assembly Assurance None
Number of Indexes 2
AVAILABLE CONFIGURATIONS
APPLICATIONS
High current harnesses and devices
Sealed pass-through panel mount systems
1 Way Inline
Connectors
2 Way Inline
Connectors
2 Way Device and
Pass-Through Connectors
PERFOMANCE
IP67
IP6K9K
TEMP
RANGE
SEALING
CLASS
145 A V1
VIBRATION
LEVEL
48 V
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
+125°C
-40°C
63
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
13959824
13882980
13849756
13952702
13849758
Index Header connector Mating connector BOM
103 13849747 13849756 1
104 13849748 13849757
Header connector Mating connector BOM
13882980 13952702 1
Index Header connector Mating connector BOM
180° 90°
103 13959824 13849756 13849758 1
2 Way Inline Connectors
2 Way Device and Pass-Through Connectors
1 Way Inline Connectors
Part number Description BOM
Header / Male inline
13675577 PP1000 silver-plated 8 - 10 mm² 1
13675579 PP1000 silver-plated 19 - 25 mm²
Mating connector
13675583 PP1000 silver-plated 8 - 10 mm² 1
13675585 PP1000 silver-plated 19 - 25 mm²
Seals and Retainers*
13675510 Cable seal PP1000 4.54 - 5.79 dia cable (grey) 8 - 10 mm² 1
13675513 Cable seal PP1000 1.01 - 9.19 dia cable (blue) 19 - 25 mm²
13849785 Cable seal retainer PP1000 8 - 10 mm² 1
13849788 Cable seal retainer PP1000 19 - 25 mm²
ASSOCIATED PARTS
* For both header, male inline + mating connector
DIMENSION MEASUREMENT SAMPLE
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Charging Solutions
SELECTOR GUIDE APPLICATIONS:
• On-vehicle charging inlets
• Grid-to-vehicle charging
• Charging infrastructure-to-vehicle
Application
Cable assemblies
for integration into
charging stations
Charging between vehicle
and charge station Grid to vehicle charging
Description CHARGE
PIGTAILS
CHARGE MODE 3
JUMPER CABLE
CHARGE MODE 2
CABLE
Mating cycles 10 000 10 000 / 14 000 10 000
# of phases 1 or 3 1 & 3 1
Amperage 16 - 40 A (AC) 20 - 32 A (AC) 6 - 14 A (AC)
Voltage 120 - 480 V (AC) 240 - 400 V (AC) 240 V (AC)
Wire selections –––
Cable length 5 - 7.6 m 4 - 7 m 5 m
See Page 66-67 68-69 70-71
Plug-in hybrid and
electric vehicle
AC charge inlet
Plug-in hybrid and
electric vehicle
AC charge inlet
Charging interface
for slow AC and
fast DC charging
Charging interface
for slow AC and
fast DC charging
CHARGE INLET
TYPE I
CHARGE INLET
TYPE II COMBO 1 COMBO 2
10 000 10 000 10 000 10 000
1 1 or 3 1 1 or 3
15 - 32 A (AC) 16 - 63 A (AC) 32 A (AC)
125 A (DC)
20 A (AC)
125 A (DC)
120 V (AC Level 1)
240 V (AC Level 2 ) 400 V (AC) 250 V (AC)
600 V (DC)
480 V (AC)
600 V (DC)
2 - 5 mm² 2.5 - 16 mm² 6 mm² (AC)
35 mm² (DC)
4 mm² (AC)
35 mm² (DC)
––––
72-73 74-75 76-77 78-79
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66
CHARGE PIGTAILS
BENEFITS
• Superior durability and proven in
automotive mass production
• Vehicle to charging station connection
• UL, CE, CQC marking/certifi cation
FEATURES
• SAE J1772/IEC62196 Type I,
IEC62196 Type II, and
GB/T 20234 standards
• Wiring crimps sealed from environment
• Different design options
AVAILABLE CONFIGURATIONSAPPLICATIONS
Grid-to-vehicle
Infrastructure to electric vehicle charging
Design Plastic handle or rubber over mold
Outlet Standard UL, CE, CQC
TECHNICAL CHARACTERISTICS
Mating Cycles 10 000
PERFOMANCE
Individual
wiring crimps
+50°C
-40°C
IP67
TEMP
RANGE
SEALING
CLASS
16 A -
40 A V1
VIBRATION
LEVEL
120 V -
480 V
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
67
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
COMPATIBLE WITH
For more specifi c information, please contact your Aptiv representative.
Part
number
Type
(veh/wall) Design Current # Phase Cable
Length Cable Section Certifi cation
33248422 Type I/SAE J1772 Plastic Handle 18A 1-phase 7.0 / 23 3G AWG14 + 0.8 UL
33248425 Type I/SAE J1772 Plastic Handle 25A 1-phase 7.6 / 25 3G AWG12 + 0.8 UL
35078184 Type I/SAE J1772 Plastic Handle 40A 1-phase 7.6 / 25 3G AWG10 + 0.8 UL
33155748 Type I Rubber Over Mold 20A 1-phase 5.0 / 16.40 3G2.5 + 0.5 CE
33155747 Type II Rubber Over Mold 20A 1-phase 5.0 / 16.40 3G2.5 + 0.5 CE
33155746 Type II Rubber Over Mold 20A 3-phase 5.0 / 16.40 5G6 + 0.5 CE
33155745 Type II Rubber Over Mold 32A 3-phase 5.0 / 16.40 5G6 + 0.5 CE
33502596 Type II Plastic Handle 16A 1-phase 6.5 / 21.32 3G2.5 + 0.75 CE
33366532 GBT Plastic Handle 16A 1-phase 7.5 / 24.6 3G2.5 + 0.5 CQC
33366674 GBT Plastic Handle 32A 1-phase 7.5 / 24.6 3G2.5 + 0.75 CQC
Type I/SAE J1772 Inlet IEC62196 Type II Inlet
71.2
200
63.0
55.6
219.5
67.5
52
265
228
58
60
248
Type I
Rubber Over Mold
Type II
Rubber Over Mold
Type I/SAE J1772
Plastic Handle
GBT
Plastic Handle
GBT Inlet*
*For more information, please contact your Aptiv representative
DIMENSION MEASUREMENT SAMPLE
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68
CHARGE MODE 3
JUMPERS CABLE
BENEFITS
• Superior durability and proven in
automotive mass production
• Wiring crimps sealed from environment
• CE and CQC marking/certifi cation
FEATURES
• Vehicle connector according to
IEC62196-2-1/IEC62196-2-2 and
GB/T 20234
• Superior durability: 14,000 cycles
(while IEC standard only requires
10,000 cycles)
• Low mating/unmating forces:
Initial < 40N, Mating forces < 80N
guaranteed until 14,000 cycles
AVAILABLE CONFIGURATIONSAPPLICATIONS
Cable assemblies for plugging
from charging stations to vehicle
TECHNICAL CHARACTERISTICS
Mating Cycles 14 000 (CE Products),
10 000 (CQC Products)
Design Plastic handle
Outlet Standard CE, CQC
Confi gurations T2-T2, T1-T2, T1-T3, GBT-GBT
PERFOMANCE
Individual
wiring crimps
+50°C
-40°C
IP67
TEMP
RANGE
SEALING
CLASS
20 A -
32 A V1
VIBRATION
LEVEL
240 V -
400 V
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
69
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
33358146
Ø70
Ø57
236
242
Part number Type (veh/wall) Current # Phase Cable length Cable section Certifi cation
33358146 Jumper T2 - T2 20A 3-phase 6.5 / 21.32 5G4 + 0.75 CE
35137656 Jumper T2 - T2 32A 3-phase 4.0 / 13.12 5G6 + 0.75 CE
35141693 Jumper T2 - T2 32A 3-phase 6.5 / 21.32 5G6 + 0.75 CE
35341995 Jumper T2 - T2 32A 1-phase 5.0 / 16.40 3G6 + 0.75 CE
33401184 Jumper T1 - T2 20A 1-phase 6.0 / 19.68 3G2.5 + 0.75 CE
33403378 Jumper T1 - T2 32A 1-phase 6.0 / 19.68 3G6 + 0.75 CE
33295948 Jumper GBT - GBT 16A 1-phase 5.0 / 16.40 3G2.5 + 0.5 CQC
33295463 Jumper GBT - GBT 32A 1-phase 7.0 / 22.96 3G6 + 0.5 CQC
COMPATIBLE WITH
Type I/SAE J1772 Inlet IEC62196 Type II Inlet GBT Inlet*
*For more information, please contact your Aptiv representative
DIMENSION MEASUREMENT SAMPLE
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70
CHARGE MODE 2 CABLE
BENEFITS
• Superior durability and proven in
automotive mass production
• Dual-thermo sensors in the grid plug
provide superior overheating protection
• Grid cord as required by country of use
FEATURES
• EVSE provides restart in the event of power
grid fault
• Product according to the new IEC62752
standard including Type B RCD and
residential DC current detection
• Superior control box water sealing
protection: IP67 (higher than the standard)
AVAILABLE CONFIGURATIONSAPPLICATIONS
Portable Electric Vehicle Supply
Equipment (EVSE) for grid-to-vehicle
charging
TECHNICAL CHARACTERISTICS
Mating Cycles 10 000
Design Rubber overmold
Inlet Standard IEC62196 Type II
PERFOMANCE
EVSE Box
+50°C
-40°C
IP67
TEMP
RANGE
SEALING
CLASS
6 A -
14 A V1
VIBRATION
LEVEL
240 V
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
71
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
* Other countries outside Europe also available.
Part number Type
(veh/wall) Current # Phase Cable length Countries* Certifi cation
35054780 Type 2 10A 1-phase 5.0 / 16.40 Europe (Germany, France...) CE
35086913 Type 2 8A 1-phase 5.0 / 16.41 Finland CE
35054781 Type 2 10A 1-phase 5.0 / 16.42 UK, Ireland, Cyprus, Malta CE
35058252 Type 2 6A 1-phase 5.0 / 16.43 Denmark CE
35054782 Type 2 8A 1-phase 5.0 / 16.44 Switzerland CE
35054784 Type 2 10A 1-phase 5.0 / 16.45 Norway CE
35054788 Type 2 8A 1-phase 5.0 / 16.46 Italy CE
35268956 Type 2 14A 1-phase 5.0 / 16.47 Europe - Grid plug CEE 16/3 CE
COMPATIBLE WITH
IEC62196 Type II Inlet
71.2
200
63.0
Type II
Rubber Over Mold
DIMENSION MEASUREMENT SAMPLE
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72
CHARGE INLET TYPE I
BENEFITS
• Interface complies with SAE J1772 and
IEC62196 Type I standard
• Panel mounts to vehicle
• Protective grommet/wire dress mounts to
inlet
FEATURES
• Supports multiple levels of AC currents:
Level 1 (15A, 120V) and Level 2 (32A, 240V)
• Validation: UL recognized
AVAILABLE CONFIGURATIONSAPPLICATIONS
Plug-in hybrid and electric on-vehicle
charge inlet (1-phase AC charging)
Connector Type Vehicle inlet
Cable Exit Orientation 180°
Cable Range (mm2) 2 - 5 (AC)
Terminal Type Round terminals
# of Terminals AC: 3
Signal: 2
Shielding Type Unshielded
TECHNICAL CHARACTERISTICS
Validation UL recognized
Mating Cycles 10 000
PERFOMANCE
+85°C
-40°C
AC Level 1 (120V)
AC Level 2 (240V)
with cover
when mated
IP55
IP44
TEMP
RANGE
SEALING
CLASS
15 A
32 A V1
VIBRATION
LEVEL
240 V
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
73
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
Part Number Description Wire size range
(AWG)
Wire section
(mm²) BOM
Terminals
13884348 1.5 mm pin 18 0.75 2
13884350 2.8 mm pin 14 2.5 1
13884351 2.8 mm pin 10 5
13884352 3.6 mm pin 14 2.5 2
13884353 3.6 mm pin 10 5
13826395
Part number Description BOM
13826395 Cover opens left 1
ASSOCIATED PARTS
Part number Description BOM
Grommet
13826280 Grommet wire protection 1
Part number Description BOM
TPA
13826277 TPA 1
DIMENSION MEASUREMENT SAMPLE
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74
CHARGE INLET TYPE II
BENEFITS
• Interface complies with IEC62196
• Panel mounts to vehicle
• Integrated thermal circuit breaker to
prevent abnormal temperature increase
FEATURES
• Cover provides dust protection
• Inlet designed to drain fl uids when
opened
• Lock actuator positioned on the top
• Available with cover opening right or left
AVAILABLE CONFIGURATIONSAPPLICATIONS
Plug-in hybrid and electric
on-vehicle charge inlet
(1-phase or 3-phase AC charging)
Connector Type Vehicle inlet
Cable Exit Orientation 90° (left or right)
Cable Range (mm2) 2.5 - 16 (AC)
Terminal Type Round terminals
# of Terminals AC: 5
Signal: 2
Shielding Type Unshielded
TECHNICAL CHARACTERISTICS
Mating Cycles 10 000
PERFOMANCE
1-phase or
3-phase
with cover
when mated
IP55
IP44
TEMP
RANGE
SEALING
CLASS
16 A
63 A V1
VIBRATION
LEVEL
400 V
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
+50°C
-40°C
75
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
33402098
Part number Description BOM
33402098
33400030
Inlet sub-assy - Inlet Type II right open cover, left wire exit
Rear cover, left wire exit 1
OR
33402097
33400076
Inlet sub-assy - Inlet Type II left open cover, right wire exit
Rear cover, right wire exit 1
Part Number Description Wire section
(mm²)
BOM
(1-phase)
BOM
(3-phase)
Terminals for 16A version (1-phase)
33267394 Male terminal Ø 6 mm with cap Ag (N, L1) 2.5 2 -
33513981 Male terminal Ø 6 mm without cap Ni (PE) 2.5 1 -
33502256 Male terminal Ø 3 mm, length 13 mm (CP) 0.5 1 -
33502238 Male terminal Ø 3 mm, length 25 mm (PP) 0.5 1 -
Terminals for 32A version (1-phase or 3-phase)*
33403032 Male terminal Ø 6 mm with cap Ag (N, L1, L2, L3) 6 2 4
33403033 Male terminal Ø 6 mm without cap Ag (PE) 6 1 1
33502256 Male terminal Ø 3 mm, length 13 mm (CP) 0.5 1 1
33502238 Male terminal Ø 3 mm, length 25 mm (PP) 0.5 1 1
Terminals for 63A version (1-phase or 3-phase)*
33267396 Male terminal Ø 6 mm with cap Ag (L1, L2, L3, N) 16 2 3 or 4
33267394 Male terminal Ø 6 mm with cap Ag (N) 4 - 1 or 0
33267382 Male terminal Ø 6 mm without cap Ag (PE) 16 1 1
33502256 Male terminal Ø 3 mm, length 13 mm (CP) 0.5 1 1
33502238 Male terminal Ø 3 mm, length 25 mm (PP) 0.5 1 1
* Compulsory usage of thermo sensor set
ASSOCIATED PARTS
Part number Description BOM
Grommet
33401379 Grommet 1
Screw
33514388 Screw 3
Part number Description BOM
TPA
33508692 TPA 1
Thermo Sensor
33514398 Thermo sensor set 1
DIMENSION MEASUREMENT SAMPLE
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76
COMBO 1 INLET
BENEFITS
• Interface complies with IEC62196
• Combined charging system for electrical
vehicle
• AC/DC: slow (1-phase 32A) / fast charge
(600V, 125A)
FEATURES
• Actuator located from a top position point
enabling locking connector to inlet during
charging
• Wire Cross Section:
Contact Pin/Present Pin (0.5 mm²),
PE (16 mm²), L1/N (6.0 mm²),
DC +/- (35 mm²)
Connector Type Vehicle Inlet
Cable Exit Orientation 180°
Cable Range (mm2)6 (AC)
35 (DC)
Terminal Type Round Terminals
# of Terminals
AC: 3
Signal: 2
DC: 2
Shielding Type Unshielded
AVAILABLE CONFIGURATIONSAPPLICATIONS
TECHNICAL CHARACTERISTICS
Plug-in hybrid and electric on-vehicle
charge inlet (combined 1-phase AC and
DC charging)
Connection/Inlet mating
and unmating force < 100 N
Mating Cycles 10 000
PERFOMANCE
+80°C
-40°C
1-phase AC
DC
AC
DC
with cover
when mated
IP55
IP44
TEMP
RANGE
SEALING
CLASS
32 A
125 A V1
VIBRATION
LEVEL
250 V
600 V
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
77
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
33133127
119.5
98
15.5
74.1
141.3
Part number Description BOM
33133127 Main Housing 1
Part number Description BOM
Terminals
15522876 Ø 3.6 mm / 6 mm2 cable cross section (AC power N, L1, L2 with protection cap) 2
15522875 Ø 2.8 mm / 16 mm2 cable cross section (Ground) 1
13884348 Ø 1.5 mm (Pilot) 2
15522877 Ø 8.0 mm / 35 mm2 (DC power) 2
Components and Accesories
33133129 AC back cover 1
33133126 AC block seal cable (6 mm2 cable) 1
33133116 AC block seal terminal 1
33133128 DC back cover 1
33133115 DC block seal cable 1
33133108 DC retainer 1
33103899 DC O-ring 2
33133132 AC retainer 1
15532546 Screw 7
Dust Caps
33133134 Dust caps 1
Actuator and Seals
33235151 Actuator Combo 1 1
33133105 Block seal for actuator 1
ASSOCIATED PARTS
DIMENSION MEASUREMENT SAMPLE
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78
COMBO 2 INLET
BENEFITS
• Interface complies with IEC62196
• Combined charging system for electrical
vehicle
• AC/DC: slow (3-phase, 20A) / fast charge
(600V, 125A)
FEATURES
• Actuator located from a top position point
enabling locking connector to inlet during
charging
• Wire cross section:
Contact Pin/Present Pin (0.5 mm²),
PE (16 mm²), L1/N (4.0 mm²),
DC +/- (35 mm²)
Connector Type Vehicle Inlet
Cable Exit Orientation 180°
Cable Range (mm2)4 (AC)
35 (DC)
Terminal Type Round Terminals
# of Terminals
AC: 5
Signal: 2
DC: 2
Shielding Type Unshielded
AVAILABLE CONFIGURATIONSAPPLICATIONS
TECHNICAL CHARACTERISTICS
Plug-in hybrid and electric on-vehicle
charge inlet (combined 3-phase AC and
DC charging)
Connection/Inlet mating
and unmating force < 100 N
Mating Cycles 10 000
PERFOMANCE
+80°C
-40°C
3-phase AC
DC
AC
DC
with cover
when mated
IP55
IP44
TEMP
RANGE
SEALING
CLASS
20 A
125 A V1
VIBRATION
LEVEL
480 V
600 V
MAX DC
VOLTAGE
MAX CURRENT
AT 85°C
79
Part numbers, specifi cations, dimensions and performance data in this document
are for general references only and are subject to change without notice.
To verify product information, please contact an Aptiv representative.
141.9
119.5
98
7
76.4
33265593
Part number Description BOM
33265593 Main Housing 1
Part number Description BOM
Terminals
33133795 Ø 6 mm / 4 mm2 cable cross section (AC power with protection cap) 2 or 4
15522870 Ø 6 mm / 16 mm2 cable cross section (PE/Ground) 1
33133789 Ø 3 mm (PP/Pilot) 1
33133739 Ø 3 mm (CP/Pilot) 2
Components and Accesories
33265597 AC back cover 1
33265958 AC block seal cable (4 mm2 cable) 1
33265598 AC retainer 1
33265965 AC block seal terminal 1
33133855 DC backcover 1
33133931 DC block seal cable 1
33133859 DC retainer 1
33103899 DC O-ring 2
15532546 Screw 7
Dust Caps
33134019 Dust caps 1
Actuator and Seals
10808197 Actuator Combo 2 1
33133105 Block seal for actuator 1
ASSOCIATED PARTS
DIMENSION MEASUREMENT SAMPLE
Asia Pacifi c
Regional Operations
200 Yuanguo Road
Anting, Jiading District
Shanghai, 201814 China
Tel: (86) 21.5956.2200
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CS-SP125-HV-En0919
Europe
Customer Center
ZI des longs Réages,
28230 Épernon
France
Tel: (33) 237.187.600
Germany
Tel: (49) 202.291.0
North America
Customer Center
5725 Innovation Drive
Troy, Michigan 48098-2815
USA
Tel: (1) 248.813.2000
South America
Regional Operations
APTIV Automotive Systems
do Brasil Ltda.
Rod. dos Tamoios, Km 21,8
Jambeiro, Sao Paulo
12270-000 Brazil
Tel: (55) 12.3978.2098
For more information:
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