GB/T 46741-2025Diagnostic connector of motorcycles and mopeds (English PDF)

5.1 Dimensions of diagnostic connector

The dimensions of the external diagnostic equipment connector are shown in Appendix

A.

The vehicle connector shall be compatible with the external diagnostic equipment connector, and the electrical, mechanical, and climatic performance of the connection shall meet the requirements.

5.2 Number of contacts

Both the vehicle diagnostic connector and the external diagnostic equipment connector shall be able to accommodate 6 contacts.

5.3 Connection requirements

The vehicle diagnostic connector shall be equipped with a female contact that can be paired with external diagnostic equipment equipped with a male contact.

5.4 Connector color/features

The vehicle diagnostic connector shall be red.

The vehicle diagnostic connector and the external diagnostic equipment connector shall have a locking function to ensure that the external diagnostic equipment connector remains mated when correctly connected. The locking function shall be designed so that the operator can clearly feel it when the external diagnostic equipment connector is fully in place.

The locking function of the vehicle diagnostic connector shall be able to unlock when the connector is disconnected.

5.5 Temperature classes

The lowest temperature class of the selected material shall be the T1(G) grade ambient temperature range specified in Table 1 of ISO 8092-2.2023, i.e., -40 °C ~ 85 °C.

5.6 Mating durability of diagnostic connector

External test equipment manufacturers shall specify the minimum number of mating and unmating cycles that the external test equipment connectors can perform while meeting the requirements.

5.7 Contact and connector parameters and performance requirements

5.7.1 Preprocessing

Each time the tests given in 5.7.5 and the requirements given in 5.7.3 and 5.7.4 are performed, a brand-new sample shall be used, and 200 mating and unmating cycles shall be performed before starting the tests in 5.7.5.

5.7.2 Functional requirements of contacts

The functional requirements of contacts are as follows.

a) The pin dimensions of the external diagnostic equipment connector shall conform to the requirements of Appendix A;

b) When performing full-circuit and single-circuit tests at 20 °C, the maximum permissible current at the contacts shall not exceed 3.5 A (DC, full circuit) and

7.5A (DC, single circuit);

c) The temperature range shall be -40 °C ~ 85 °C;

d) The voltage range shall comply with the requirements of GB/T 28046.2;

e) The connector contact system shall use wires with a cross-sectional area not exceeding 0.50 mm2.

5.7.3 Performance requirements of contacts

After each completion of the accelerated environmental aging test in 5.7.5, the contact system (paired contacts) shall meet the requirements of a). The connection resistance test shall comply with the requirements of 6.1.2.1 in ISO 8092-2.2023.

a) Cable-to-cable contact resistance for each pair of contacts. According to

6.1.2.3 of ISO 8092-2.2023, the initial connection resistance is 30 mohm when tested with a 1A constant current source.

b) Recommended contact resistance at low current. According to 6.1.2.2 of ISO

8092-2.2023, the initial contact resistance is 100 mohm when tested with a 100

µA constant current source.

5.7.4 Performance requirements of contact system

Measurements shall be performed at 23 °C ± 5 °C. After each completion of the accelerated environmental aging test in 5.7.5, the contact system (paired terminals) shall meet the requirements of a) ~ e).

a) According to 6.4 of ISO 8092-2.2023, the insulation resistance between adjacent contacts shall not be less than 100 mohm.

b) Perform a contact retention force test using appropriate testing equipment. The contactor shall have all effective locking devices. Apply a constant force to the front and/or rear of the contactor in the axial direction and hold for 10 s ~ 12 s. The contact retention force within the housing shall not be less than 60 N2).

c) Connect and disconnect the connector at a constant speed of 25 mm/min ~ 100 mm/min, as specified by the connector manufacturer. Perform 10 connection and disconnection cycles on the connector. Measure the force required for the first connection, first disconnection, and tenth disconnection. With all 6 pairs of contacts fully equipped, the force required for connection and disconnection shall not exceed 75 N3).

d) The polarity design shall be able to prevent reverse connection under a 150 N connection force.

e) Immediately after preprocessing, immerse the test sample (mated sealed connector) in deionized water with 5% NaCl and 0.1 g/L wetting agent. The liquid temperature shall be (23±5) °C. Dye should be added to the water so that the liquid ingress into the test sample can be visually inspected after electrical testing. As shown in Figure 1, immerse the test sample in the liquid for 1 hour.

Measure the leakage current of the test sample immersed in the liquid, measuring the current between each contact and the electrode. Using different test samples, take measurements between every two adjacent contacts, as shown in Figure 2.The leakage current measured at 48 V shall not exceed 50

µA. Immediately after preprocessing, perform the IPX4 waterproof test as specified in ISO 20653 on the test sample (waterproof connector). Use the minimum pipe arc. Other equipment can be used, provided the results are the same. In case of disputes between the user and the supplier, a clear conclusion shall be reached based on the IPX4 test as specified in ISO 20653 4).

2) ISO 8092-2.2005 has been abolished; 5.7.4b) is prepared in accordance with 4.7 of ISO 8092-2.2005.

3) ISO 8092-2.2005 has been abolished; 5.7.4c) is prepared in accordance with 4.3.1 of ISO 8092-2.2005.

4) ISO 8092-2.2005 has been abolished; 5.7.4e) is prepared in accordance with 4.9.1.1.2 and 4.9.1.1.3 of ISO 8092-

2.2005.

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