Design Solutions for Vehicle Wiring Applications DRC50 35 FCI 36 Bosch compact 37 Delphi Series 38 - 39 Kostal 40 Milflex ABS 41 DIN 72585 42 Circular Connectors 43 Other Interfaces

Design Solutions for Vehicle Wiring Applications

tel: +44 (0)1675 4682222

about us - OEM design cultureHarnessflex is a leading designer and manufacturer offlexible conduit systems and connector interfaces,protecting critical electrical and electronic wiring assembliesin the automotive industry, principally focussed on chassisand engine manufacturers within bus, truck, agriculturalvehicle and heavy machinery markets.

With a network of specialist distributors and the experienceof our own sales engineers, Harnessflex can respondspeedily to the most demanding of customer requirementsanywhere in the world.

With literally thousands of combinations the Harnessflexsystem offers the complete solution for routing and protectionof electrical wiring against damage by mechanical abrasion,liquid ingress and corrosive salts. The use of connectorinterfaces ensures that there are no vulnerable connectorsexposed to the elements, impact of foreign bodies and jetwashing, which could so easily cause malfunction and failure,compromising the operation of a vehicle.

Our success has come from our systematic commitment toproviding an extensive range of high-grade qualitycomponents. Combining a full range of slit and un-slitconduit, fittings and connectors, we also offer the largestrange of hinged system components and connectorinterfaces within the industry.

Based in the UK we manufacture to internationallyrecognised quality and environmental standards ensuringthat our products are safe and reliable.

global marketManufacturers of vehicle harnesses operate on a truly globalscale. Our products can be found on vehicles and enginesthroughout the world in Africa, America, Australia, Europe,the Middle East and the Far East where we have beenworking with our customers for many years.

marketsThe Harnessflex system is suitable for use on vehicles in awide variety of markets and geographical locations. We canprovide harness solutions for:

• Agricultural Vehicles.

• Construction Vehicles

• Engine Manufacturers

• Harness Manufacturers

• Truck & Bus Manufacturers

• Tanker & Trailer Manufacturers

• Specialist Vehicle Components

• Military Vehicles

Contents

Conduit 4 -14

NC 6 - 7

CTPA 8 - 9

HNC 10

CPC 11

PP 12

DSPP 13

PKC 14

Hinged fittings 15 - 26

Joiners 16

Elbows 17

Tee Pieces 18 - 19

Y Pieces 20 - 21

Shrouds 22

X Pieces 23

Manifolds 24

Split Manifolds 25

Circular Manifolds 26

Interfaces 27 - 46

Amp Superseal 28

Amp Junior 29

Ampseal 30

Amp CPC 31

Deutsch DT 32 - 33

Deutsch DT04 34

Deutsch DRC50 35

FCI 36

Bosch compact 37

Delphi Series 38 - 39

Kostal 40

Milflex ABS 41

DIN 72585 42

Circular Connectors 43

Other Interfaces 44

Accessories 45

Sealed Fittings 47 - 63

Straights 48 - 49

Elbows 50 - 51

90o degree flanges 52

Tee's 53

X Pieces 54

Manifolds 55

Circular UNEF 56

Solenoid Connectors 57

Reducers 58

Glands 59

Accessories 60 - 61

Clips 62 - 63

Technical 64 - 66

Contents

www.harnessflex.com 3

Selection table for Conduit

tel: +44 (0)1675 4682224

Catalogue Page no. 6 8 10 11 12 13 14

Static temp. (oC) Min -40 -40 -50 -45 -20 -20 -60

Max 120 120 110 135 90 90 260

UV Resistance ��

Flexibility ��

Fatigue Life ��

Halogen Free � � � � � � �

Self Extinguishing � � � � � � �

External Wear Resistance ��

Slit version available � � � � � Slit only �

Conduits

NC

(Po

lyam

ide

6)

CT

PA

(Po

lyam

ide

6)

HN

C

(Po

lyam

ide

11)

CP

C

(FR

Co

-po

lye

ste

r)

PP

(Po

lyp

rop

yle

ne)

DS

PP

(FR

Po

lyp

rop

yle

ne)

PK

C

(Po

lyeth

ere

therk

eto

ne)

Key: S = Suitable, L = Limited Suitability, U = Unsustainable, NT = Not Tested. All chemicals tested for resistance at 33oC.

Maximum Performance = ��

IRM 903 (ASTM Oil No.2) S S S S S S S

Diesel Oil S S S S S S S

Ethylene Glycol (Anti-freeze) S S S S S S S

Lubricating Oil S S S S S S S

Methyl Alcohol L L S S S S S

Parafin Oil S S S S S S S

Petrol S S S S S S S

Sodium Chloride S S S S S S S

Sodium Hydroxide (10%) S S S S S S S

Transformer Oil S S S S S S S

Urea S S S NT NT NT S

Vegetable Oil S S S S S S S

Sea (Water) S S S S S S S

Ch

em

ical

Re

sist

an

ce

Design Interaction


Ingress Protection (I.P.) ratingsHarnessflex hinged systems are rated at IP40.

Harnessflex Sealed systems are rated atIP66, 67, 68 (2 BAR for 30mins) & 69k.

product specificationsAll Harnessflex fittings are manufacturedfrom Polyamide 6,6 (PA 6,6) and are blackin colour. Other colours and materials canbe made available to achieve specificcustomer requirements.

Product datasheets and dimension chartsare available for the full Harnessflex range - please submit your request via ourwebsite or call the Harnessflex technicalsupport desk.

design dataHarnessflex parts are developed in houseusing the following CAD systems:

• PTC Pro-Engineer Wildfire 2 & 3.

• AutoDesk Inventor V10, V11 & 2008

• AutoDesk AutoCAD 2006, ‘07 & ‘08

Drawing files are available in the followingCAD formats (as well as the versitile PDF format):

DWG, DXF, DWF, IGES, STEP, STL, PRT,ASM, IPT, IAM.

pre-production samplesFrom CAD data we are able to produceaccurate representations of finalmanufactured products, using a 3D printing process.

Prototype fittings are typically produced inDuraform PA, a material that gives similarperformance in tests to PA 6,6.

Prototype extrusions can be manufacturedin a variety of materials (please contact us for details).

This process allows a product design to bevalidated before the part is tooled formanufacture.

technical supportWorldwide sales support via ourexperienced engineers.

Please contact us to discuss any of ourproducts, or the possibility of developing asolution specific to your needs.

NC conduit configurations and dimensions

B A

C

NC Standard weightPolyamide 6

General purpose conduit

tel: +44 (0)1675 4682226

DescriptionFlexible standard weight nylon (PA6)conduit is a general-purpose conduitsuitable for automotive harnessapplications. It can withstand extremes oftemperatures and resists automotive oilsand solvents. It is extremely tough and hasa high impact strength and fatigue life.

Solid NC conduits provide protectionagainst mechanical shock and ingress ofwater whilst maintaining their form throughtight bend radii.

ApplicationsNC standard weight is extensively used inharnesses on HGV, off road vehicles andmarine applications where a superiorprotection against impact and mechanicalshock is preferred. The conduit is used forboth chassis and engine applications andcan be used in a wide range oftemperatures. Polyamide 6 is highlyresistant to all hydrocarbon based oils andfluids and many types of solvents.

NC is designed for connection to allHarnessflex sealed and hinged systemfittings.

NC conduits are available in a range ofpopular sizes. The standard colour is blackwith other colours also being available onrequest.

Configuration/nominal dimensions/part numbers

Part Conduit Nominal Min Min static ReelNumber Size O/D Bore bend rad Length

(NC) (NW) A B C (m)

NC06 06 4.5 7.1 4.5 5 100

NC08 08 7.5 10.0 6.5 15 100

NC10 10 8.5 11.5 8.4 15 100

NC12 12 10 13.0 9.9 20 100

NC16 16 13 16.0 11.8 30 100

NC20 20 17 21.2 16.6 35 50

NC25 25 22 25.6 21.3 40 50

NC28 28 23 28.5 22.6 45 50

NC32 32 29 34.5 28.8 55 50

NC40 40 36 42.5 34.8 65 25

NC50 50 48 54.5 46.9 70 25

note: dimensions are in mm

NC Slit Standard weightPolyamide 6General purpose conduit


NC Slit conduit configurations and dimensions

B A

C

Hints & TipsKwikcut is the ideal cutting tool for all non-metallic conduits upto 32mm.

cutting instructionsPlace the conduit between the cuttingblade and lower support, squeeze thehandles and rotate the conduit for a clean,easy cut.

Spare blades are available

part no.sKwikcut

Kwikcut-Blade



(NC) (NW) A B C (m)

NC06-S 06 4.5 7.1 4.5 5 100

NC08-S 08 7.5 10.0 6.5 15 100

NC10-S 10 8.5 11.5 8.4 15 100

NC12-S 12 10 13.0 9.9 20 100

NC16-S 16 13 16.0 11.8 30 100

NC20-S 20 17 21.2 16.6 35 50

NC25-S 25 22 25.6 21.3 40 50

NC28-S 28 23 28.5 22.6 45 50

NC32-S 32 29 34.5 28.8 55 50

NC40-S 40 36 42.5 34.8 65 25

NC50-S 50 48 54.5 46.9 70 25


CTPA, LightweightPolyamide 6

Flexible conduit

tel: +44 (0)1675 4682228



(NC) (NW) A B C (m)

CTPA08 08 7.5 10.0 6.5 10 100

CTPA10 10 8.5 11.5 8.7 15 100

CTPA12 12 10 13.0 10.1 20 100

CTPA16 16 13 16.0 11.8 35 100

CTPA20 20 17 21.2 16.9 45 100

CTPA25 25 22 25.6 21.3 45 100

CTPA28 28 23 28.3 23.1 45 100

CTPA32 32 29 34.5 28.8 55 100

CTPA40 40 36 42.5 35.0 65 50

CTPA50 50 48 54.3 46.5 75 50


CTPA conduit configurations and dimensions

B A

C

DescriptionFlexible lightweight nylon (PA6) conduit isa general-purpose conduit suitable forautomotive harness applications. It canwithstand extremes of temperatures andresists automotive oils and solvents. It isextremely tough and has a high impactstrength and fatigue life.

CTPA conduits provide protection againstmechanical shock and ingress of waterwhilst maintaining their form through tightbend radii.

ApplicationsLightweight convoluted tube used forinterior harnesses offering limitedmechanical protection to provide abrasionresistance and enhance the aesthetics ofthe harness.

Extremely light and fexible.

Resistant to oils and solvents.

CTPA Slit, LightweightPolyamide 6Flexible conduit

CTPA conduit configurations and dimensions

B A

C



(NC) (NW) A B C (m)

CTPA08-S 08 7.5 10.0 6.5 10 100

CTPA10-S 10 8.5 11.5 8.7 15 100

CTPA12-S 12 10 13.0 10.1 20 100

CTPA16-S 16 13 16.0 11.8 35 100

CTPA20-S 20 17 21.2 16.9 45 100

CTPA25-S 25 22 25.6 21.3 45 100

CTPA28-S 28 23 28.3 23.1 45 100

CTPA32-S 32 29 34.5 28.8 55 100

CTPA40-S 40 36 42.5 35.0 65 50

CTPA50-S 50 48 54.3 46.5 75 50






part no.sKwikcut

Kwikcut-Blade

HNC, standard weightPolyamide 11, Low temperature

Extra flexible conduit

tel: +44 (0)1675 46822210

HNC conduit configurations and dimensions

B A

C

DescriptionHNC standard weight conduit is made frompolyamide 11 and is specially formulated tomeet the environmental and mechanicalrequirements for the exterior of workingvehicles.

HNC conduit also provides protectionagainst mechanical shock and ingress ofwater whilst maintaining its form throughtight bend radii. It has been specificallydesigned to cope with extremes oftemperature combined with repeatedmovement and vibration.

ApplicationsHNC conduit is particularly used inapplications requiring repeated flexingcoupled with low temperature impacttoughness.

Robotics, rapid or continuous motionapplications demanding high fatique lifeand extra flexibility are covered by HNCwhich is also used in low temperatureenvironments.

HNC Standard weight conduit is designedfor connection to all Harnessflex hinged andsealed fittings.



(NC) (NW) A B C (m)

HNC08 08 7.5 10.0 6.2 15 100

HNC12 12 10 13.0 9.9 25 100

HNC16 16 12 15.8 11.7 30 100

HNC20 20 17 21.2 16.6 35 50

HNC25 25 22 25.3 21.0 40 50

HNC28 28 23 28.5 21.7 45 50

HNC32 32 29 34.5 27.7 55 50

HNC40 40 36 42.5 35.5 60 25

HNC50 50 48 54.5 46.6 70 25


CPC, medium weight(FR Co-polyester) flame retarded conduit


DescriptionCP standard weight conduit is made fromflame retarded co-polyester, which is ahalogen free, low smoke and very lowtoxicity material. It has excellent high andlow temperature properties.

CP conduits provide protection againstmechanical shock and ingress of waterwhilst maintaining their form through tightbend radii. This material demonstratesexcellent chemical resistance to greases,hydrocarbons, fuels and oils.

ApplicationsCP is particularly used in applicationsrequiring low fire hazard performance, it islightweight and retains its flexibility atextremes of temperature. CP is designedfor use in the interior and exterior ofvehicles and marine passenger cabins.

CP is designed for connection to allHarnessflex Hinged and Sealed fittings.

CPC conduit configurations and dimensions

B A

C



(NC) (NW) A B C (m)

CPC08 08 7.5 9.8 6.2 20 50

CPC12 12 10 13.0 9.4 25 50

CPC16 16 13 16.0 11 30 50

CPC20 20 17 21.2 16.1 40 50

CPC25 25 22 25.3 21.0 45 50

CPC28 28 23 28.5 21.2 45 50

CPC32 32 29 34.5 27.2 50 50

CPC40 40 36 42.5 34.2 55 25

CPC50 50 48 54.1 46.0 65 25





part no.sKwikcut

Kwikcut-Blade



(NC) (NW) A B C (m)

PP08 08 7.5 10.0 6.4 15 100

PP12 12 10 13.0 9.6 25 50

PP16 16 13 16.2 11.2 35 50

PP20 20 17 21.2 16.9 35 50

PP25 25 22 25.6 21.5 40 50

PP28 28 23 28.5 23.2 45 50

PP32 32 29 34.5 29.1 50 50


Modified PP conduit configurations and dimensions

Modified PP, medium weightPolypropylene conduit

DescriptionPP is a flexible conduit made fromPolypropylene.

PP conduits provide very good acidresistance, they have very good flexibilityand a very high fatigue life.

ApplicationsPP is particularly used in lighter applicationswhere compression strength and LFH is notso important. The main property of thisconduit, being acid resistance.

Halogen free – not self-extinguishing

PP conduits are available in a range ofpopular sizes. The conduit comes in blackonly.

PP is designed for connection to allHarnessflex Sealed and Hinged systemfittings.

tel: +44 (0)1675 46822212

B A

C

Deep Section Modified Slit PPPolypropylene,Medium weight conduit

Description

DSPP conduit is made from a halogen free,flame retarded material and althoughmeeting the requirements of IEC61386, wouldnot be considered LFH.

DSPP slit conduits provide protection againstmechanical shock whilst maintaining its formthrough tight bend radii.

Applications

DSPP is particularly used in light weightapplications where LFH and compressionproperties are not as important.

DSPP is designed for connection to allHarnessflex Hinged and Sealed fitings.





part no.sKwikcut

Kwikcut-Blade

Deep section PP conduit configurations and dimensions

B A

C

Deep section PP conduit configurations and dimensions

B A

C



(NC) (NW) A B C (m)

DSPP08 08 7.5 10.0 6.6 10 100

DSPP12 12 10 13.0 8.5 18 100

DSPP16 16 13 16.2 11.1 32 100

DSPP20 20 17 21.2 15.0 40 100

DSPP28 28 23 28.5 21.7 50 100

DSPP32 32 29 34.5 27.7 58 50

DSPP40 40 36 42.5 34.6 80 25

DSPP50 50 48 54.5 46.5 100 25



PKC, standard weightPolyketone Super Low

Fire HazardConduit

tel: +44 (0)1675 46822214

PKC conduit configurations and dimensions

B A

C

DescriptionSuper Low Fire Hazard PK is a standardweight conduit, which offers superiormechanical strength as well as highradiation and chemical protection often inextreme temperatures. It is a uniqueproduct manufactured from a specialistpolymer, for use in the most demandingapplications

Peek is a truly high performance conduit.

ApplicationsThis conduit with its high specificationperformance is used in some of the mostdemanding applications for flexible conduit.

It is often found in Aerospace, Off-shore,Military, Heat treatment, Nuclear,Petrochemical and Marine application



(NC) (NW) A B C (m)

PKC12 12 10 13.0 6.4 20 25

PKC16 16 13 15.8 9.5 35 25

PKC20 20 17 21.2 11.2 45 25

PKC25 25 22 25.8 16.6 60 25

PKC28 28 23 28.5 21.7 65 25

PKC32 32 29 34.3 27.5 80 25


Documents

Design Solutions for Vehicle Wiring Applications DRC50 35 FCI 36 Bosch compact 37 Delphi Series 38 - 39 Kostal 40 Milflex ABS 41 DIN 72585 42 Circular Connectors 43 Other Interfaces