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Standard

ELECTRICAL CONNECTOR ASSEMBLY ERGONOMIC DESIGN CRITERIA

2003-05-03

HISTORICAL

USCAR25

This document describes the design and assembly force guidelines for conventional and mechanical assist (lever and slide-lock) electrical connectors and CPA’s. All possible designs and applications cannot be anticipated in creating these guidelines. Where there are questions of adherence to this document, such as use of an “off-the-shelf” design, always consult the responsible Ergonomics department. Refer to SAE/USCAR-12 Wiring Component Design Guidelines for additional guidelines.

Standard

ELECTRICAL CONNECTOR ASSEMBLY ERGONOMIC DESIGN CRITERIA

2008-09-26

HISTORICAL

USCAR25-1

This document describes the design, assembly force, and packaging guidelines for conventional hand-plug, mechanical assist and twist lock electrical connectors, as well as Connector Position Assurances (CPAs). All possible designs and applications could not be anticipated in creating these guidelines. Where there are questions of adherence to this document, such as use of an “off-the-shelf” design, always consult the responsible Ergonomics Department. Refer to SAE/USCAR-12 Wiring Component Design Guidelines for additional guidelines.

Standard

Ergonomics Specification for Electrical Connections

2016-02-15

HISTORICAL

USCAR25-2

This document describes the design relative to assembly force, and hand clearance guidelines for conventional hand-plug, mechanical assist and twist lock electrical connectors, as well as Connector Position Assurances (CPAs). The minimum values associated with this design guide need to be evaluated against other critical characteristics that impact quality, efficiency and other traits of assembly feasibility. All possible designs and applications could not be anticipated in creating these guidelines. Where there are questions of adherence to this document, such as use of an “off-the-shelf” design, always consult the responsible Ergonomics Department.

Standard

Ergonomics Specification for Electrical Connections

2016-03-10

CURRENT

USCAR25-3

This document describes the design relative to assembly force, and hand clearance guidelines for conventional hand-plug, mechanical assist and twist lock electrical connectors, as well as Connector Position Assurances (CPAs). The minimum values associated with this design guide need to be evaluated against other critical characteristics that impact quality, efficiency and other traits of assembly feasibility. All possible designs and applications could not be anticipated in creating these guidelines. Where there are questions of adherence to this document, such as use of an “off-the-shelf” design, always consult the responsible Ergonomics Department.

Standard

NEW FINISH DEVELOPMENT DOCUMENT

2020-11-19

CURRENT

USCAR32-1

This standard lists variables that shall be investigated and reported as an initial investigation into new or revised surface finishes intended for use on fasteners. This standard provides instruction for producing a final report that will be used to determine if further investigation of a surface finish is justified. Further investigation may include tests and evaluations specific to an individual OEM prior to introduction/approval of the surface finish. The final report shall include the results, observations, and conclusions for all of the variables. The final report may be made up of several individual reports covering each variable. In all cases the laboratory performing the test, the test date and the report approver shall be included in the final report.

Standard

NEW FINISH DEVELOPMENT DOCUMENT

2007-03-13

HISTORICAL

USCAR32

This standard lists variables that shall be investigated and reported as an initial investigation into new or revised surface finishes intended for use on fasteners. This standard provides instruction for producing a final report that will be used to determine if further investigation of a surface finish is justified. Further investigation may include tests and evaluations specific to an individual OEM prior to introduction/approval of the surface finish. The final report shall include the results, observations, and conclusions for all of the variables. The final report may be made up of several individual reports covering each variable. In all cases the laboratory performing the test, the test date and the report approver shall be included in the final report.

Standard

PERFORMANCE SPECIFICATION FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS

2004-05-25

HISTORICAL

USCAR2-4

Procedures included within this specification are intended to cover performance testing at all phases of development, production, and field analysis of electrical terminals, connectors, and components that constitute the electrical connection systems in low voltage (0 - 20 VDC) road vehicle applications. These procedures are only applicable to terminals used for In-Line, Header, and Device Connector systems with and without Shorting Bars. They are not applicable to Edge Board connector systems, > 20 VAC or DC, or to eyelet type terminals.

Standard

PERFORMANCE SPECIFICATION FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS

2007-10-08

HISTORICAL

USCAR2-5

Procedures included within this specification are intended to cover performance testing at all phases of development, production, and field analysis of electrical terminals, connectors, and components that constitute the electrical connection systems in low voltage (0 - 20 VDC) road vehicle applications. These procedures are only applicable to terminals used for In-Line, Header, and Device Connector systems with and without Shorting Bars. They are not applicable to Edge Board connector systems, twist lock connector systems, > 20 VAC or DC, or to eyelet type terminals.

Standard

PERFORMANCE SPECIFICATION FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS

2022-06-30

CURRENT

USCAR2-8

This specification covers performance testing at all phases of development, production, and field analysis of electrical terminals, connectors, and components that constitute the electrical connection systems in road vehicle applications that are: low voltage (0 to 20 VDC) or Coaxial. Incomplete (mechanical) specifications for jacketed twisted pair connectors are also provided. These procedures are only applicable to terminals used for In-Line, Header, and Device Connector systems. They are not applicable to Edge Board connector systems, twist-lock connector systems, >20 VAC or DC, or to eyelet terminals. No electrical connector, terminal, or related component may be represented as having met USCAR specifications unless conformance to all applicable requirements of this specification have been verified and documented. All required verification and documentation must be done by the supplier of the part or parts.

Standard

PERFORMANCE SPECIFICATION FOR AUTOMOTIVE WIRE HARNESS RETAINER CLIPS

2017-05-10

HISTORICAL

USCAR44

This specification describes a method and acceptance criteria for testing automotive wire harness retainer clips. Retainer clips are plastic parts that hold a wire harness or electrical connector in a specific position. Typical plastic retainers work by having a set of “branches” that can be inserted into a hole sized to be easy to install but provide acceptable retention. This specification tests retainer clips for mechanical retention when exposed to the mechanical and environmental stresses typically found in automotive applications over a 15-year service life. This specification has several test options to allow the test to match to the expected service conditions. The variability of applications typically arises a) from different ambient temperatures near the clip, different proximity to automotive fluids, different exposure to standing water or water spray and different thicknesses of the holes that the clip is inserted into.

Standard

PERFORMANCE SPECIFICATION FOR AUTOMOTIVE WIRE HARNESS RETAINER CLIPS

2021-01-20

HISTORICAL

USCAR44-1

This specification describes a method and acceptance criteria for testing automotive wire harness retainer clips. Retainer clips are plastic parts that hold a wire harness or electrical connector in a specific position. Typical plastic retainers work by having a set of “branches” that can be inserted into a hole sized to be easy to install but provide acceptable retention. This specification tests retainer clips for mechanical retention when exposed to the mechanical and environmental stresses typically found in automotive applications over a 15-year service life. This specification has several test options to allow the test to match to the expected service conditions. The variability of applications typically arises from different ambient temperatures near the clip, different proximity to automotive fluids, different exposure to standing water or water spray, and different thicknesses of the holes that the clip is inserted into.

Standard

PERFORMANCE SPECIFICATION FOR AUTOMOTIVE WIRE HARNESS RETAINER CLIPS

2023-03-23

CURRENT

USCAR44-2

This specification describes a method and acceptance criteria for testing automotive wire harness retainer clips. Retainer clips are plastic parts that hold a wire harness or electrical connector in a specific position. Typical plastic retainers work by having a set of “branches” that can be inserted into a hole sized to be easy to install but provide acceptable retention. This specification tests retainer clips for mechanical retention when exposed to the mechanical and environmental stresses typically found in automotive applications over a 15-year service life. This specification has several test options to allow the test to match to the expected service conditions. The variability of applications typically arises from different ambient temperatures near the clip, different proximity to automotive fluids, different exposure to standing water or water spray, and different thicknesses of the holes that the clip is inserted into.

Standard

PERFORMANCE STANDARD FOR AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEMS

2001-04-01

HISTORICAL

USCAR2

Procedures included within this specification are intended to cover performance testing at all phases of development, production, and field analysis of electrical terminals, connectors, and components that constitute the electrical connection systems in low voltage (0 - 20 VDC) road vehicle applications. These procedures are only applicable to terminals used for In-Line, Header, and Device connector systems. They are not applicable to Edge Board connector systems, > 20 VAC or DC, or to eyelet type terminals. Note that this specification does not cover the mechanical assist portions of connectors that include such devices. The Authorized Person must provide details of any additional testing desired to validate these mechanisms as part of the test request/order.

Standard

Performance Specification for Automotive Electrical Connector Systems

2013-02-01

HISTORICAL

USCAR2-6

Procedures included within this specification are intended to cover performance testing at all phases of development, production, and field analysis of electrical terminals, connectors, and components that constitute the electrical connection systems in low voltage (0 – 20 VDC) road vehicle applications. These procedures are only applicable to terminals used for In-Line, Header, and Device Connector systems. They are not applicable to Edge Board connector systems, twist lock connector systems, > 20 VAC or DC, or to eyelet-type terminals. No electrical connector, terminal, or related component may be represented as having met USCAR/EWCAP specifications unless conformance to all applicable requirements of this specification have been verified and documented. All required verification and documentation must be done by the supplier of the part or parts.

Standard

ROAD VEHICLES – 60 V AND 600 V SINGLE CORE (ISO/METRIC) CABLES – DIMENSIONS, TEST METHODS AND REQUIREMENTS

2017-07-13

CURRENT

USCAR23-1

This International Standard specifies the dimensions, test methods, and requirements for single core 60 V cables intended for use in road vehicle applications where the nominal system voltage is ≤ (60 V DC or 25 V AC). It also specifies additional test methods and/or requirements for 600 V cables intended for use in road vehicle applications where the nominal system voltage is > (60 V DC or 25 V AC) to ≤ (600 V DC or 600 V AC). It also applies to individual cores in multi-core cables. See ISO 6722 for “Temperature Class Ratings”.

Standard

ROAD VEHICLES – 60 V AND 600 V SINGLE CORE (ISO/METRIC) CABLES – DIMENSIONS, TEST METHODS AND REQUIREMENTS

2002-09-09

HISTORICAL

USCAR23

This International Standard specifies the dimensions, test methods, and requirements for single core 60 V cables intended for use in road vehicle applications where the nominal system voltage is ≤ (60 V DC or 25 V AC). It also specifies additional test methods and/or requirements for 600 V cables intended for use in road vehicle applications where the nominal system voltage is > (60 V DC or 25 V AC) to ≤ (600 V DC or 600 V AC). It also applies to individual cores in multi-core cables. See ISO 6722 for “Temperature Class Ratings”.

Standard

SPECIFICATION FOR TESTING AUTOMOTIVE HALOGEN LIGHT SOURCES

2022-03-15

CURRENT

USCAR14-3

The procedures contained in this specification cover the laboratory testing of replaceable halogen incandescent bulbs for use in automotive road illumination. The following tests are intended to be run under the following conditions. New bulb design Design or process change made to an existing bulb, which could affect the outcome of the test The completion of one calendar year, accept as noted in the following Test Schedule Table. Test Title Yearly Physical Dimensions X Mean Spherical Candela (MSCD) X External Visual Examination X Color X Leak/Sealability Through Terminals and Seals X Deflection X Fluid Compatibility Terminal Retention X Resonant Frequencies Aged Resonant Frequency Salt Spray Outgassing Temperatures Requirement Laboratory Life at 14.0 VDC X Luminous Intensity Maintenance X Vibration Durability Shock Aged Vibration Durability Terminal Requirements DRL (SAE J2087)

Standard

SPECIFICATION FOR TESTING AUTOMOTIVE HALOGEN LIGHT SOURCES

2002-04-15

HISTORICAL

USCAR14-1

The procedures contained in this specification cover the laboratory testing of replaceable halogen incandescent bulbs for use in automotive road illumination. The following tests are intended to be run under the following conditions. New bulb design Design or process change made to an existing bulb, which could affect the outcome of the test The completion of one calendar year, accept as noted in the following Test Schedule Table. Test Title Yearly Physical Dimensions X Mean Spherical Candela (MSCD) X External Visual Examination X Color X Leak /Sealability Through Terminals and Seals X Deflection X Fluid Compatibility Terminal Retention X Resonant Frequencies Aged Resonant Frequency Salt Spray Outgassing Temperatures Requirement Laboratory Life at 14.0 VDC X Luminous Intensity Maintenance Vibration Durability Shock Aged Vibration Durability Terminal Requirements DRL (SAE J2087)

Standard

SPECIFICATION FOR TESTING AUTOMOTIVE LAMP ASSEMBLIES

2022-03-15

CURRENT

USCAR34

The procedures contained in this specification cover the laboratory testing of Exterior Lamps for use in automotive road illumination. The following tests are intended to be run under the following conditions. This document shall be applied to systems that meet the requirements for design, performance and validation established by government standards. If other manufacture’s components are intended to be approved for use in the lamp assembly, then those possible combinations of components shall be considered a new lamp assembly and shall also be tested.

Standard

SPECIFICATION FOR TESTING AUTOMOTIVE MINIATURE BULBS

2022-03-15

CURRENT

USCAR3-4

The procedures contained in this specification cover the laboratory testing of miniature incandescent bulbs for use in automotive illumination and signaling applications. The following tests shall be run whenever the following occurs: New bulb design Design or process change made to an existing bulb, which could affect the outcome of the test. The completion of one calendar year as noted in the following Test Schedule Table. Process control data is acceptable.