ISO 6856:2005

Road vehicles — Unscreened high-voltage ignition cable assemblies — Test methods and general requirements

ISO 6856:2005 specifies test methods and general requirements for unscreened high-voltage ignition cable assemblies, and is applicable to all such assemblies used in road vehicle applications.

Véhicules routiers — Assemblages de câbles d'allumage haute tension non blindés — Méthodes d'essai et exigences générales

General Information

• Status: Published
• Publication Date: 27-Feb-2005
• ICS: 43.060.50 - Electrical and electronic equipment. Control systems
• Technical Committee: ISO/TC 22/SC 32 - Electrical and electronic components and general system aspects
• Drafting Committee: ISO/TC 22/SC 32/WG 1 - Ignition Equipment
• Current Stage: 9093 - International Standard confirmed
• Completion Date: 17-Jun-2021

Relations

• Revises: ISO 6856:1990 - Road vehicles — Unscreened high-tension ignition cable assemblies — General requirements and test methods
• Effective Date: 15-Apr-2008

Standards Content (Sample)

INTERNATIONAL ISO
STANDARD 6856
Third edition
2005-02-15

Road vehicles — Unscreened
high-voltage ignition cable assemblies —
Test methods and general requirements
Véhicules routiers — Assemblages de câbles d'allumage haute tension
non blindés — Méthodes d'essai et exigences générales




Reference number
ISO 6856:2005(E)
©
ISO 2005

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ISO 6856:2005(E)
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©  ISO 2005
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ii © ISO 2005 – All rights reserved

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ISO 6856:2005(E)
Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards bodies
(ISO member bodies). The work of preparing International Standards is normally carried out through ISO
technical committees. Each member body interested in a subject for which a technical committee has been
established has the right to be represented on that committee. International organizations, governmental and
non-governmental, in liaison with ISO, also take part in the work. ISO collaborates closely with the
International Electrotechnical Commission (IEC) on all matters of electrotechnical standardization.
International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 2.
The main task of technical committees is to prepare International Standards. Draft International Standards
adopted by the technical committees are circulated to the member bodies for voting. Publication as an
International Standard requires approval by at least 75 % of the member bodies casting a vote.
Attention is drawn to the possibility that some of the elements of this document may be the subject of patent
rights. ISO shall not be held responsible for identifying any or all such patent rights.
ISO 6856 was prepared by Technical Committee ISO/TC 22, Road vehicles, Subcommittee SC 1, Ignition
equipment.
This third edition cancels and replaces the second edition (ISO 6856:1990), which has been technically
revised.

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INTERNATIONAL STANDARD ISO 6856:2005(E)

Road vehicles — Unscreened high-voltage ignition cable
assemblies — Test methods and general requirements
1 Scope
This International Standard specifies test methods and general requirements for unscreened high-voltage
ignition cable assemblies, and is applicable to all such assemblies used in road vehicle applications.
2 Normative references
The following referenced documents are indispensable for the application of this document. For dated
references, only the edition cited applies. For undated references, the latest edition of the referenced
document (including any amendments) applies.
ISO 9227, Corrosion tests in artificial atmospheres — Salt spray tests
ISO 3808-2, Road vehicles — Unscreened high-tension ignition cables — Part 2: Cable classes, types,
applicable tests and special requirements
3 Test methods
3.1 General
3.1.1 Preconditioning
Precondition all test samples at (23 ± 5) °C and at 10 % to 75 % relative humidity for 24 h before starting any
test sequence.
3.1.2 General test conditions
All tests shall be carried out at an ambient temperature of (23 ± 5) °C, unless otherwise specified.
Each test sequence shall be started with unused test samples.
Cables shall be in accordance with ISO 3808-2, and the cable(s) used shall be noted in the test report.
Cable attachment shall be performed in accordance with customer requirements and/or industry specification.
During the whole test sequence, no lubrication or other additional means on the contact surface making
possible better test results shall be permitted. Production-related remains of lubricants on the contacts are
allowed.
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ISO 6856:2005(E)
3.1.3 Visual examination
3.1.3.1 Test
Carry out visual examination with the naked eye, corrected, if necessary, to give normal strength of vision and
normal colour perception, at the most favourable viewing distance and with suitable illumination.
3.1.3.2 Requirements
Visual examination in accordance with 3.1.3.1 shall allow identification, appearance, workmanship and finish
of the item to be checked against the relevant specification.
During visual examination, special care shall be taken to ensure that — as a minimum requirement —
no cracking, significant discoloration, deformation or (where applicable) ingress of water is in evidence.
3.2 Insertion and removal forces of high-voltage connectors
3.2.1 General
The insertion and removal forces shall be measured at an ambient temperature of (23 ± 5) °C, using a gauge
as shown in Figure 1, 2, 3 or 4 dependant on the high-voltage connector type.
The gauge and the connector to be measured shall be dry and clean.
Insertion and removal forces shall be the forces between the high-voltage terminal of the ignition coils, the
distributors or the spark-plugs and the cable connector. Any other force from covers or boots shall not be
taken into account.
Perform ten insertions and removals.
3.2.2 Insertion force
The insertion force shall be measured at the first insertion.
Maximum value: 80 N
3.2.3 Removal force
3.2.3.1 Test
The removal force measurement shall be carried out by using a suitable test apparatus at a constant test
speed of 100 mm/min or 200 mm/min or 500 mm/min. The exact speed used shall be agreed between
customer and supplier and recorded in the test report.
The removal force shall be measured at the tenth removal.
3.2.3.2 Requirements
Maximum value: 70 N
Minimum value: 20 N
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ISO 6856:2005(E)
Dimensions in millimetres
Surface roughness values in micrometres

The gauge shall be of hardened steel.
NOTE The tolerances given for the gauge dimensions also include wear tolerances. Dimensions A and D are the
most critical.
a
Tangential slope from diameter A to radius D.
b
Tangential slope from radius D to radius F. The value of F is implicitly determined by the values of dimensions A, B, C,
D and E.
Figure 1 — Gauge for measurement of insertion and removal forces of high-voltage connectors —
Socket type high-voltage connection for ignition coils and distributors
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ISO 6856:2005(E)
Dimensions in millimetres
Surface roughness values in micrometres

The gauge shall be of hardened steel.
The tolerances given for the gauge dimensions also include wear tolerances.
+1 °
Dimension (6,4 mm ± 0,005 mm) and angle 15 are the most critical.
0
Figure 2 — Gauge for measurement of insertion and removal forces of high-voltage connectors —
Spark-plugs with solid-post terminals, and ignition coils and distributors
with plug-type high-voltage connections
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ISO 6856:2005(E)
Dimensions in millimetres

The gauge shall be of hardened steel.
The tolerances given for the gauge dimensions also include wear tolerances.
Figure 3 — Gauge for measurement of insertion and removal forces of high-voltage connectors —
Ignition coils and distributors (5 mm cable type)
Dimensions in millimetres

The gauge shall be of hardened steel.
The tolerance given for the outside diameter of the gauge threaded part also
...