ISO 19642-4:2019

Overview

ISO 19642-4:2019 - Road vehicles - Automotive cables - Part 4 specifies the dimensions and requirements for single-core aluminium conductor cables intended for general-purpose vehicle applications with nominal system voltages up to 30 V a.c. or 60 V d.c.. It also applies to individual cores within multi-core cables and defines material, dimensional, electrical, mechanical and environmental requirements for aluminium-conductor automotive cables.

Key topics and requirements

• Voltage rating: Limited to ≤ 30 V a.c. and ≤ 60 V d.c. (suitable for low-voltage vehicle systems).
• Conductor material: Annealed or annealed-compressed aluminium or aluminium-alloy strands per EN 573 series and referenced specifications (examples in Annex A). Material properties (tensile strength, elongation, conductivity) and strand characteristics are prescribed or agreed between supplier and customer.
• Temperature classes: Defined temperature ratings (T1–T6) for aluminium conductor cables:
  • T1: −40 to 85 °C
  • T2: −40 to 100 °C
  • T3: −40 to 125 °C
  • T4: −40 to 150 °C
  • T5: −40 to 175 °C
  • T6: −40 to 200 °C
• Dimensional requirements: Specifications for insulation thickness, conductor diameter, cable outside diameter and cross-sectional area (CSA) with in-process measurement criteria.
• Electrical tests: Conductor resistance, temperature coefficient determination, dielectric withstand voltage (including after environmental exposure), insulation volume resistivity and insulation fault criteria.
• Mechanical tests: Strip force, abrasion resistance, finished cable breaking force, cyclic bending and flexibility tests.
• Environmental tests: Long-term and short-term heat ageing, thermal overload, high-temperature pressure tests, shrinkage, low-temperature winding, cold impact, humidity/temperature cycling, water and chemical resistance, ozone and flame propagation resistance. Test methods reference ISO 19642-2.
• Safety note: The standard includes a warning about hazardous materials/operations and expects users to follow appropriate safety practices.

Applications and users

ISO 19642-4:2019 is intended for:

• Automotive OEMs specifying low-voltage wiring harnesses and single-core cables for vehicle systems.
• Cable manufacturers and suppliers designing and producing aluminium single-core automotive cables and cores for multi-core assemblies.
• Test laboratories and quality engineers performing dimensional, electrical, mechanical and environmental verification per ISO 19642-2 methods.
• Procurement and compliance teams ensuring components meet vehicle-level temperature classes, voltage ratings and material standards.

Practical applications include low-voltage power distribution, signal return conductors, chassis connections and other general-purpose wiring in passenger cars, commercial vehicles and off‑highway equipment where aluminium conductors are preferred for weight and cost.

Related standards

• ISO 19642-1 - Vocabulary and design guidelines (series context)
• ISO 19642-2 - Test methods (referenced for all tests)
• EN 573-1 / EN 573-3 - Aluminium chemical composition and product forms
• ASTM B231 - Aluminium conductor specifications
• Historical references: ISO 6722-1 / ISO 6722-2 (older automotive cable standards still in use during transition)

Keywords: ISO 19642-4:2019, automotive cables, aluminium conductor, single core, 30 V AC, 60 V DC, cable dimensions, temperature classes, conductor resistance, insulation thickness, automotive wiring standard.