Japan Aviation Electronics Industry, Ltd. No. Connector Division Title: JAHL-1594-E Page 1/13 Rev. DATE DCN No. By CHKD APRVD 1 15, Feb.,00 - J. Miyamoto M. Shinmyo T. Totani 2 20,Mar., 00 45765 J. Miyamoto M. Shinmyo T. Totani 3 28,Jul., 00 46565 J. Miyamoto N. Oiri T. Totani 4 23, Jul., 09 068385 Y. Obata N. Oiri 5 1, Mar., 11 071688 Y. Obata M. Kuroiwa N. Oiri Handling Manual for MX19 series connector Handling Manual Originating Dept.: Connector Div. 3rd Engineering Dept. Contents 1. Purpose 2. Applicable Items 3. Crimping 3-1. Applicable Wires 3-2. Stripping length of wire insulators 3-3. Part description 3-4. Criteria for judgment on conforming items 3-5 Criteria for judgment on non-conforming items 3-6 Other cautions for crimping process 4. How to insert 4-1. Contacts 4-2. Dummy Plug 5. How to withdraw contact 6. How to engage/ separate connector 7. Cautionary statement DCF-C-091C(97.10) JAE Connector Div. Proprietary. Copyright (c) 2000Japan Aviation Electronics Industry, Ltd. Japan Aviation Electronics Industry, Ltd. Connector Division No. JAHL-1594-E Page 2/13 1. Purpose This document provides the handling on MX19 series connectors. 2. Applicable items 2 3 4 2.1 Housing Table2-1 MX19 Connector Housing Terminals No. Type Product Name Pin Housing 2 (Fig.2-1) Socket Housing Pin Housing 4 (Fig.2-2) Socket Housing MX19002P51 MX19002P52 MX19002S51 MX19002S52 MX19004P51 MX19004P52 MX19004S51 MX19004S52 Color Black Gray Black Gray Black Gray Black Gray 2.2 Contacts and Dummy plug Type Pin contact Socket contact Dummy plug MX19002P5* Table2-2 MX19 Contacts and Dummy plug Product Name NOTE MX19P10K451 Sn platting MX19S10K451 Sn platting MX19000XD1 Color: Natural White MX19002S5* Fig.2-1 MX19 2-terminals type. Fig.2-3 Pin contact. DCF-C-091C(97.10) MX19004P5* Fig.2-3 Fig.2-4 FIg.2-5 MX19004S5* Fig.2-2 MX19 4-terminals type. Fig.2-4 Socket contact. Fig.2-5 Dummy plug. JAE Connector Div. Proprietary. Copyright (c) 2000Japan Aviation Electronics Industry, Ltd. Japan Aviation Electronics Industry, Ltd. Connector Division No. JAHL-1594-E Page 3/13 3. Crimping JAE's applicator is described on the following table. Table3-1 JAE Crimping Applicator Automatic Applicator Semi-automatic Applicator Type Product Name 3.1 Applicable Wires Applicable Wire Type CAVS0.3mm2 350-MX19-3B 350-MX19-2 5 Table3-2 Applicable Wire for MX19 connector Conductor construction Calc. Conductor of (No./Shape or size) cross-section [ mm2] 7/ Round Compressed 0.3717 CPTL 22 7/ 0.13 0.3717 CAVS0.5 mm2 AVSS0.5 mm2 7/ Round Compressed 7/ 0.13 0.5630 0.5630 Wire Insulator [mm] 1.4 1.5 1.57 (Reference Information) 1.6 1.7 1.6 1.7 3.2 Striping length of wire insulators Check the stripping length of wire insulators( refer to Fig.3-2.) On the wire treatment, must check the damaged insulator, damaged, missing and/ or disordered conductor (refer to Fig. 3-1.) Crack Fail Cutoff Short length Fail Fail Disordered wire strand Fail Pass Fig. 3-1 Defective wire treatment for crimpling. A Contact Name Length A [mm] MX19P10K451 MX19S10K451 2 2.5mm Wire Fig. 3-2 Stripping length for MX19 contact crimping DCF-C-091C(97.10) JAE Connector Div. Proprietary. Copyright (c) 2000Japan Aviation Electronics Industry, Ltd. Japan Aviation Electronics Industry, Ltd. Connector Division No. JAHL-1594-E Page 4/13 3.3 Part description 3.3.1 Pin Contact Bell-mouth Conductor Barrel Crimp height Insulation barrel Crimp height of wire insulator Fig.3-3 Part description of pin contact 3.3.2 Socket contact Bell-mouth Conductor barrel Crimp height Insulation barrel Crimp height of wire insulator Fig.3-4 Part description of Socket contact 3.4 Criteria for conformed crimping items 3 4 "Properly crimped contact" is as follows: 1. Meet the crimp height shown in Table 3-3. 2. The "Bell-mouth" (no crimping on conductor) is attached. 3. The tip of conductor stick out 0.5mm( or less) from "Conductor Barrel." 4. All conductor of wire is within the "Conductor Barrel". 5. Any wire insulator is NOT crimped into "Conductor Barrel." 6. No cracks and/ or burrs etc. is in crimping area. Table3-3 Appropriate Crimp Height Wire Type Crimp Height [mm] Crimp wide (Ref.)[mm] CAVS0.3mm2 CPTL 22 CAVS0.5 mm2 AVSS0.5 mm2 0.730.83 0.730.83 0.750.85 0.750.85 1.481.54 1.481.54 1.521.58 1.521.58 Crimp height of wire insulator [mm] 1.61.7 1.71.9 1.71.9 1.71.9 NOTE 1: Crimp height dimension is fabricated by JAE's applicator. NOTE 2: Crimp width/ height and crimp height of wire insulators are reference values only. DCF-C-091C(97.10) JAE Connector Div. Proprietary. Copyright (c) 2000Japan Aviation Electronics Industry, Ltd. Japan Aviation Electronics Industry, Ltd. Connector Division No. JAHL-1594-E Page 5/13 3.4 Criteria for judgment on non-conforming items 4 5 If a crimped MX19 contact has any following defective item, the crimping work is failure. DON'T use the failure crimping contact. Table3-4 Defective Items for Crimping Work Defective Item Example No. Incomplete wire insertion 1 Not fully inserted conductor(s) into "Crimp Barrel." Wire core Shortage of wire stripping 2 Inserted the wire "Crimp Barrel." insulator into Wire insulator is in "Crimp Barrel." Extrusion wire strand( s) Conductor(s) on of "Crimp Barrel. the OUTSIDE 3 Extrusion of conductor(s) Failure treatment of 5 stripping ( too longer). wire D Not completely inserted wire insulator into "Insulation Barrel." (Dimension "D" over 0.3mm.) 4 Over inserted( Dimension "E") the conductor(s) into Box. (Dimension "E" over 0.7mm from the conductor barrel end.) Incompletely inserted of wire insulation E Over inserted of conductor DCF-C-091C(97.10) JAE Connector Div. Proprietary. Copyright (c) 2000Japan Aviation Electronics Industry, Ltd. Japan Aviation Electronics Industry, Ltd. Connector Division No. JAHL-1594-E Table3-4 Defective Items for Crimping Work Defective Item Example No. Inclined Insulator Barrel 5 Page 6/13 X The incline over 0.3mm at any side. Bended( On axis) 6 P The angle "P" over 3 degrees, between crimping parts axis. Twisted 7 R The angle of center of conductor barrel to insulator barrel center has over 2.5 degrees. Burr after cut off the carrier 8 The burr after the cut off is over 0.2mm. Burr Without Bell-mouth 9 Failure of crimpling, "Bell-mouth" is not formed. No "Bell-mouth" Deformed of Insulator Barrel 10 K The deformation has the gap between insulator barrel over 0.3mm. DCF-C-091C(97.10) JAE Connector Div. Proprietary. Copyright (c) 2000Japan Aviation Electronics Industry, Ltd. Japan Aviation Electronics Industry, Ltd. Connector Division JAHL-1594-E Page 7/13 Table3-4 Defective Items for Crimping Work Defective Item Example Bend up/ down Y1 No. No. "Bend up(or down)" is based on the crimp barrel area. a. Bend-up(Pin contact) Y2 Failure case is dimension Y1 (or Y2) is over C1( or C2). Y1( or Y2): Pin contact's Bend up (or down) C1( or C2): Socket contact's Bend up( or down) b. Bend-down(Pin contact) Fig. Pin contact ----------------------------------------------------------------------------- C1 11 C2 a. Bend-up(Socket contact) b. Bend-down(Socket contact) Fig. Socket contact H2 Pin Contact F3 F14 >0.05mm H14 >0.15mm F4 12 F1 If you find a contact deformation (H14) of following, as shown in right figures, never use such as a crimped contact. Check and adjust( or repair) a crimpling machine( or a device.) In the case of a deformation is within 0.15mm but having dimensions F14 over 0.05 on a side, the crimping work is failed. H1 F2 End-face deformation H4 Socket Contact Deformation of contact rear end DCF-C-091C(97.10) JAE Connector Div. Proprietary. Copyright (c) 2000Japan Aviation Electronics Industry, Ltd. Japan Aviation Electronics Industry, Ltd. Connector Division No. JAHL-1594-E Page 8/13 4. Contact/ Dummy Plug Insertion 2 3 4.1 Contact Insertion 1. Visual inspection, the connector has no breakage, deformation, discoloration, and/or damage etc. 2. Aligned the axis and direction between a contact and a cavity. 3. Handling the wire of the near position of contact for not to be occurred bending. 4. Contact insertion is completely done until the terminal locking part sounded. (Check the terminal insertion by pulling the wire with little force.) NOTE: If the contact insertion is tight or incapable, DON'T force to insert, check the direction of contact. Tight( or incapable) insertion will cause a contact deformation, crack and/or disconnection. Socket housing Pin Housing Socket Terminal Pin contact Right way Wrong way Fig.4-1 Contact insertion Deformation Fig.4-2 Example, contact deformation by wrong contact insertion. DCF-C-091C(97.10) JAE Connector Div. Proprietary. Copyright (c) 2000Japan Aviation Electronics Industry, Ltd. Japan Aviation Electronics Industry, Ltd. Connector Division No. JAHL-1594-E Page 9/13 4.2 Dummy Plug Insertion 4 1. Check by visual inspection, the connector has no breakage, deformation, discoloration, and/or damage etc. 2. Aligned the axis between a dummy plug and a cavity. 3. Inserting a dummy plug into cavity, insertion is the end-face of dummy-plug by connector's. Acceptance Criteria: Base on the housing end-face, Dummy plug's end-face is within 0 +0.5/-0.5mm. NOTE: DON'T apply unnecessary force to on inserting dummy plug. Dummy Plug Housing's end-face +0.5 -0.5 0 Fig.4-3 Dummy Plug insertion a. Absence insertion b. over insertion Fig.4-4 Failure dummy plug insertion DCF-C-091C(97.10) JAE Connector Div. Proprietary. Copyright (c) 2000Japan Aviation Electronics Industry, Ltd. Japan Aviation Electronics Industry, Ltd. Connector Division 5. Contact withdraw No. JAHL-1594-E Page 10/13 2 1. Visual inspection, the connector has no breakage, deformation, discoloration, and/or damage etc. 2. Pushing lightly the wire with crimpling contact and keeping. 3. Inserting a "Withdrawing Tool" into a tool cavity, as following Fig.6-2 and Fig.6-3. 4. When the toe of withdrawing tool met the molding lance, release contact locking. And keeping. 5. Withdrawing the wire on straight axis. Withdrawing Tool Pin Housing Molding Lance Tool Cavity Withdrawing Tool Pin Contact Fig.5-1 Pin Contact Withdraw Socket Housing Molding Lance Withdrawing Tool Tool Cavity Socket Contact Withdrawing Tool Fig.5-2 Socket Contact Withdraw NOTE: Suitable dimension for withdrawing tool( JAE's withdrawing tool is "ET-MX19.") 16(MIN) 1.3 0.03 0.75 0.03 NOTE: DON'T snag a contact on grommet by forcedly withdrawing. NOTE: The limitation frequency for withdrawing at one cavity is 3 times. If you find any damage and deformation, DON'T use it, change to the new one. NOTE: DON'T apply unnecessary force on withdrawing. NOTE: Withdrawing tool insertion is only a "tool cavity," never inserting the contact cavity. DCF-C-091C(97.10) JAE Connector Div. Proprietary. Copyright (c) 2000Japan Aviation Electronics Industry, Ltd. Japan Aviation Electronics Industry, Ltd. Connector Division No. JAHL-1594-E Page 11/13 6. How to engage connector 6.1 Engaging 1. Check the contact insertion. 2. Check by visual inspection, the connector has no breakage, deformation, discoloration, and/or damage etc. in contacts and housing. 3. Aligned the direction with the engagement aperture. 4. Insert the connector into the housing until the lock parts sounded. NOTE: DON'T apply unnecessary force to connector on inserting/separating connector. NOTE: If housings insertion is tight or incapable, DON'T force to insert, check the direction of contact. Tight( or incapable) insertion will cause a connector deformation, crack and/or disconnection. Locking Part Lock Lever Fig.6-1 Connector insertion DCF-C-091C(97.10) JAE Connector Div. Proprietary. Copyright (c) 2000Japan Aviation Electronics Industry, Ltd. Japan Aviation Electronics Industry, Ltd. Connector Division No. JAHL-1594-E Page 12/13 6.2 Connector Separation Method Hold a Socket Housing, and pull out the connector straightly; 1: Depressing the lock arm of socket housing. 2: Releasing the engagement lock. NOTE: On separating the connector, DON'T pulling only wires and prying the connector. NOTE: In case of incapable of separation, DON'T force it to pull out. Check the engagement lock is released. NOTE: DON'T apply unnecessary force to connector on inserting/separating connector. Lock Lever Fig.6-2 Connector separation DCF-C-091C(97.10) JAE Connector Div. Proprietary. Copyright (c) 2000Japan Aviation Electronics Industry, Ltd. Japan Aviation Electronics Industry, Ltd. Connector Division No. JAHL-1594-E Page 13/13 7. Cautionary Statements Caution Comply strictly with the following matters because of possibility of physical damage and/or connector failures. Perform the engagement of connector straightly until the "click" sound. Be careful not to slide and/or pinch your fingers accidentally because some force may be applied to your fingers at the time of connector insertion/withdrawal. Moreover, DON'T pull a cable at the time of withdrawal. DON'T touch the contact area, or adhere any foreign materials on. When withdrawing a contact from the connector, be sure to use an exclusive tool. Exercise care to avoid injuring at the time of cable treatment, pre-mounting, soldering and using other tools. Care must be taken to prevent excessive current (over load) as this might be cause overheating and fire. DON'T disassemble each component of housing. DON'T insert anything other than the specified contacts to housing. For handling on connectors and contacts, comply with the provisions in this document. Unreasonable handling is not permissible. DCF-C-091C(97.10) JAE Connector Div. Proprietary. Copyright (c) 2000Japan Aviation Electronics Industry, Ltd. Mouser Electronics Authorized Distributor Click to View Pricing, Inventory, Delivery & Lifecycle Information: JAE Electronics: MX19004S52 MX19004S51 MX19004P52 MX19004P51 MX19P10K451 MX19S10K451 MX19002P51 MX19002P52 MX19002S52 MX19002S51 MX19S10K451-C100 MX19P10K451-C100