Automotive Connectors

For the past 50 years, KST has literally stamped its reputation as a leading global manufacturer of electrical terminals and automotive connectors.

At KST, we design and manufacture a huge range of automotive connectors that are engineered for reliability and undergo a battery of tests to ensure the transmission of power, and signal under extreme conditions. Our different types of connectors are designed to reduce application size and power usage while providing increased performance. Our automotive connectors are designed and built to withstand harsh conditions on the freeway as well as off-road. Across our portfolio of connectors, we offer robust solutions for ensuring connectivity in critical systems.

Series Name

Series Name

The Series Name Field is an important field containing a tab-size prefix as well as generic aftermarket descriptions. These variables are important to understand and will help you find the product you are looking for.

Tab

The terminals used in automotive connectors have different-sized Tab series ranging from 020 to 375.

The series “tab” refers to the width of the blade of the male terminal in inches. The terminal system consists of tabs (male) and receptacles (female).

In consideration for global markets, our KST Series names, where applicable, include tab sizes in inches followed by metric size in quotations.

Aftermarket

KST has many aftermarket connectors that can be mated with brand-name automotive connectors. It is important to note that KST aftermarket automotive connectors are not equivalents. Our aftermarket automotive connectors mate with brand name connectors, but our certifications and connector portfolio are usually of a smaller subset of the original brand names product offering.

ABS – Anti-lock Braking System JAE – JAE OBD – On-board diagnostics
CMX – Control Module Connector JST – JST SMT – Sumitomo
DLF – Delphi KET – Korea Electric Terminal TYC – TE
ECU – Electronic Control Unit MLX – Molex YZK- Yazaki
FKW – Furukawa MPX – Multi-purpose Connector
ABS – Anti-lock Braking System KET – Korea Electric Terminal
CMX – Control Module Connector MLX – Molex
DLF – Delphi MPX – Multi-purpose Connector
ECU – Electronic Control Unit OBD – On-board diagnostics
FKW – Furukawa SMT – Sumitomo
JAE – JAE TYC – TE
JST – JST YZK- Yazaki
AMP (A)

AMP (A)

The stated current rating is the maximum the contact can carry continuously in optimum conditions.  Cross-referencing supported AWG and terminal material offerings against AMP (A) will help you determine the combination of wire and terminal you will need to achieve the derating factor. The terminal derating factor is applied to reduce your specified cable’s current carrying capacity).  

M|F Terminal Material

M|F Terminal

This data header/column shows the current product offerings which may include male and female terminals, made from one or more of the following materials:

0 – Brass materials support connection temperatures of 110°C.  Unplated brass is often used in optimal environments and application conditions.

1 – Copper Alloy materials support connection temperatures of over 120°C depending on the type. Unplated Copper Alloy is more expensive but provides a higher range of operating temperatures and malleability.

2 – Phosphor Bronze materials support connection temperatures of 130°C. Phosphor bronze is used in applications where brass would normally be susceptible to corrosion, for example in subzero freezing environments or when ammonia is present.

3 –Beryllium copper exhibits a wide range of properties, including:

  • High electrical and thermal conductivity
  • Non-sparking and non-magnetic characteristics
  • High ductility and excellent formability with regard to forming, machining, and metalworking processes
  • Higher resistance to corrosion and oxidation than steel
  • Higher durability than most copper alloys (resists wear and galling)
  • Retention of properties in extremely low or extremely high temperatures
  • Suitability for precipitation-hardening operations

4 – Copper is a good conductor and is malleable. It is often used in combination with other materials such as stainless steel to achieve a greater operating temperature range while providing increased tensile strength and durability.

5 – Stainless Steel is usually used in combination with other materials such as copper to achieve an operating temperature range and good conductivity while maintaining tensile strength and durability. High fatigue strength—also known as endurance strength—making it suitable for heavy cyclic load applications

M|F Housing

M|F Housing

This data header/column shows the current male and female housing offerings as well as all of the pole variants currently available. If you do not find the housing and variant that you require, please don’t hesitate to enquire about the possibility of a customized solution.

AWG | mm²

AWG / mm²

Wire size is usually measured in American wire gauge (AWG), a standard for non-ferrous wire conductor sizes. The term “gauge” refers to the wire’s diameter. The higher the gauge number, the smaller the diameter and the thinner the wire. As a rule, thicker wire carries more current because there is less electrical resistance over a given length.

A.W.G. 28(.08) 26(.13) 24(.02) 22(.03) 20(.05) 18(.85) 16(1.25) 14(2.0) 12(3.0) 10(6.0)
AMP (A) 0.7 1 2 3 4 7 10 15 20 24

AWG / mm²

Wire size is usually measured in American wire gauge (AWG), a standard for non-ferrous wire conductor sizes. The term “gauge” refers to the wire’s diameter. The higher the gauge number, the smaller the diameter and the thinner the wire. As a rule, thicker wire carries more current because there is less electrical resistance over a given length.

A.W.G. AMP (A)
28(.08) 0.7
26(.13) 1
24(.02) 2
22(.03) 3
20(.05) 4
18(.85) 7
16(1.25) 10
14(2.0) 15
12(3.0) 20
10(6.0) 24
Sealed

Sealed

Environmentally sealed connectors are a required interconnect solution for automobiles, heavy-industrial, and agriculture machines,  where extreme environments could compromise your critical power and signal applications.

Environmentally sealed connectors have an interface seal to keep contaminants such as water, dust, and dirt from entering the housing, and compromising the terminal connection.

IPXX

IP ratings are determined by their ability to protect against dust and dirt. The first number, 1 through 6) indicates the connector’s ability to withstand the ingress of dust. The second number indicates the level of protection when immersed in water for a specified amount of time and depth (1 through 8). When comparing, IP67 and IP68, they both provide protection against dust but with the IP67, the connector can only be submerged at 1 meter for 30 minutes while with the IP68, the connector was submerged at a depth of more than 1 meter for  30 minutes. In the case of IP68, the manufacturer must specify the depth at which the connector was submerged.

kPa

for kPa ratings, a rating of 10 kPa indicates that a connector was submerged at a depth of 1 meter for one hour. Increments of 10kPa are equivalent to an additional meter.  A rating of 100 (50) indicates that the connector was successfully tested to 10 meters (Initial), and after the connector was subjected to an aging process, the final depth that the connector was able to withstand was 5 meters for one hour (Final).

Note

Some of our connector series and terminals are listed as sealed however, their product set is not complete and hence they have not undergone IPXX or kPa testing.  Nonetheless, the original branded product is waterproof, and our aftermarket product offerings are made to mate and seal with these brand-named products. In the case of sealed housings, we can provide IPXX and/or kPa waterproof testing based on each customer’s scenario and initial offerings and requirements. For instance, a customer can bring a brand-name male housing to KST, and match it with one of our aftermarket female housings, terminals, and components, and we could provide a testing report for the assembled connector to insure it will function to the required specifications.

Terminals that are marked as sealed can be made into a continuous reel of sealed terminals, with seals provided by the customer or KST.

Wire-to-Wire

Wire-to-wire

KST Wire-to-Wire solutions provide a variety of cable/wire types and sizes with numerous options to fit your application needs across most industries. Wire-to-wire connectors are used to connect two wire-terminated connectors. They are used as electrical connectors, electronic connectors, and computer connectors. General specifications for a wire-to-wire connector include mating combination or gender, number of circuits or positions, and wire size.

Wire-to-Board

Wire-to-board

Wire-to-board connectors typically use crimp technology to allow the connection of a wire to a printed circuit board (PCB). Once the connector has been crimped to the wire, the contacts or terminals can then be inserted into the corresponding housing to complete the interconnect.  Wire-to-board connectors are largely used due to their flexibility and reliability. KST’s connectors can be used in low-profile designs which offer connectivity for systems in which space is restricted and require a more compact solution.

Wire-to-board connectors are used to provide an inexpensive solution to route power between PCBs. These types of connectors can be used in the industrial, automotive, commercial, and telecommunication industries. Along with this new development, wire-to-board connectors have become more suitable for automated surface mount assembly allowing for a quicker assembly process. Even further, these connectors provide long-term reliable service for their applications. Overall, wire-to-board connectors offer simple, robust solutions while remaining cost-effective.

KST provides robust, modular, compact connector solutions to anticipate and meet the growing demands our customers face. Wire-to-board solutions are available with current ratings up to 18A and manufactured within a fully integrated process from product production to packaging, demonstrating our commitment to quality to meet customer needs in diverse markets including Industrial, Communication and data, Medical, Consumer, Automotive, and many more.

Wire-to-Device

Wire-to-device

KST has worked with many customers who have brought their wire harness projects to us, looking for a single housing solution to mate with their devices. Please browse our female housing wire-to-device portfolio to find a connector that is suitable for you.

Hybrid

Hybrid

Hybrid connectors reduce the number of connectors and cables needed for advanced agricultural machinery and other heavy equipment. A single modern hybrid connector can do the work of two, four, six, or even more traditional connectors.

Today’s transportation, agricultural, and construction vehicles come feature-rich with computers, GPS systems, and an array of other electronic features. Equipping these heavy-duty systems with separate cables for signal and power can be costly and time-consuming, requiring wire harnesses that are heavier and more complex. In response, manufacturers have developed hybrid connectors that can handle both signal and current, reducing the number of connectors and cables required. Hybrid connectors are smaller and more lightweight than traditional connectors that handle only signal or power. Once installed, hybrid connectors reduce the number of connection points, providing more efficiency when troubleshooting or repairing the electrical system.

ECU

ECU

ECU connectors are suitable for connecting with BCM, BMS, ECM, PCM, SCM, TAC, TCM, and other automotive control modules.

KST ECU connectors are low profile,  wire-to-board, sealed connectors. They provide a mechanical lock system designed to endure extreme vibration and meet extended life requirements. The mechanical lock system provides an audible click when the connector is inserted into a housing. It can be used for a wide range of applications including automobiles, motorcycles, industrial, agriculture, and marine equipment where a waterproof connector is required.

This industrial-grade connector has a lock assembly providing greater wire retention while preventing wire deformation and pinching. These connectors have been tested for IPX7 of IEC 60529 provide certified protection.

ABS

ABS

Given their position, ABS connectors are particularly vulnerable to contamination from dirt and moisture. That’s why KST ABS connectors are sealed, to lock out dirt, water, chemicals, and other contaminants. In addition, plated terminals are specified to provide corrosion protection and improved conductivity.

Extreme Environment Testing


Water, heat, and vibration can affect a connector’s performance, so we subject all our connectors to extensive thermal, shock, and vibration testing to ensure standardized performance. With test temperatures ranging from -40ºC to 140ºC, they’ll perform even in the most harsh environments, delivering stable and reliable performance in this critical system.

Easy installation

KST connectors are designed to meet or exceed the specifications of the original equipment. With standard mounting and wire lengths, technicians can quickly and easily fit and install.

Agriculture

Agriculture

Connectors used in agriculture applications reduce the number of connectors and cables needed for in advanced agricultural machinery. A single modern agriculture connector can do the work of two, four, six, or even more traditional connectors.

Today’s agricultural vehicles come feature-rich with computers, GPS systems, and an array of other electronic features. Equipping these heavy-duty systems with separate cables for signal and power can be costly and time-consuming, requiring wire harnesses that are heavier and more complex. In response, manufacturers have developed hybrid connectors that can handle both signal and current, reducing the number of connectors and cables required. Hybrid connectors are smaller and more lightweight than traditional connectors that handle only signal or power. Once installed, hybrid connectors reduce the number of connection points, providing more efficiency when troubleshooting or repairing the electrical system.

Automotive Connector Certifications
Automotive Connector Certifications

Automotive Connectors

025-JST-JWPF-Series Automotive Connectors

025(0.64) JST JWPF Series

This JST style afternmarket waterproof connector series is a wire-to-board, wire-to-wire, sealed connector providing waterproof performance when used with a rubber seal.
060-TYC Superseal Serie Automotive Connectors

060(1.5) TYC Superseal Series

Automotive connectors must combine durability, reliability, performance, support emerging technologies and yet be easy to assemble, install and come in ultra-small, lightweight enclosures.
060-DT Pin Type Socket Series Automotive Connectors

060(1.5) DT Pin Type Socket Series

DT Pin Type Plug and Receptacle Series is a wire-to-wire, wire-to-board, sealed connector solution.
Provides (IPX7 of IEC 60529) Waterproof

090-SMT MT Series Automotive Connectors
090(2.3) SMT MT Series
090(2.3) SMT MT Series is a compact wire-to-wire sealed connector solution.
Provides (IPX7 of IEC 60529) Waterproof
025-JST-JWPF-Series Automotive Connectors

025(0.64) JST JWPF Series

This JST style afternmarket waterproof connector series is a wire-to-board, wire-to-wire, sealed connector providing waterproof performance when used with a rubber seal.
060-TYC Superseal Serie Automotive Connectors

060(1.5) TYC Superseal Series

The TYC Superseal Series is an aftermarket solution suitable for wire-to-wire, wire-to-board, wire-to-device sealed connector applications.
060-DT Pin Type Socket Series Automotive Connectors

060(1.5) DT Pin Type Socket Series

DT Pin Type Plug and Receptacle Series is a wire-to-wire, wire-to-board, sealed connector solution.
Provides (IPX7 of IEC 60529) Waterproof

090-SMT MT Series Automotive Connectors
090(2.3) SMT MT Series
090(2.3) SMT MT Series is a compact wire-to-wire sealed connector solution.
Provides (IPX7 of IEC 60529) Waterproof
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