Application Specification
114--10005
LOC B
1of 8
E2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
TOOLING ASSISTANCE CENTER 1--800--722--1111
PRODUCT INFORMATION 1--800--522--6752
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com
Type XII Contacts 09 NOV 09 Rev J
All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters [and
inches]. Unless otherwise specified, dimensions have a tolerance of +0.13 mm [+.005 in.] and angles have a tolerance
of +2_. Figures and illustrations are for identification only and are not drawn to scale.
1. INTRODUCTION
This specification covers the requirements for application of Type XII Male and Female Contacts. These
contacts have a wire size range of 10 through 16 AWG with an insulation diameter range of 3.43 to 5.59 mm
[.135 to .220 in.]. Type XII Contacts are terminated with hand held tooling or automatic machines, and are used
in various types of connector housings designed with power circuit cavities.
Figure 1 provides terminology for contact features that will be used throughout this specification. Use of these
terms will facilitate assistance when corresponding with Tyco Electronics Representatives.
Figure 1
Serrated
Wire Barrel
Insulation
Barrel
Contact Assist
Spring
Contact
Body
Contact
Latch
MaleFemale
Serrated
Wire Barrel
Cutoff Tab
Insulation
Barrel
Contact
Body
Contact
Latch
Cutoff Tab
2. REFERENCE MATERIAL
2.1. Revision Summary
This paragraph is reserved for a revision summary of changes and additions made to this specification. The
following changes were made for this revision.
SUpdated document to corporate requirements
SNew logo and format
2.2. Customer Assistance
Reference Part Number 66741 and Product Code 5016 are representative numbers of Type XII Contacts. Use
of these numbers will identify the product line and expedite your inquiries through a service network
established to help you obtain product and tooling information. Such information can be obtained through a
local Tyco Electronics Representative or, after purchase, by calling the Tooling Assistance Center or Product
Information number at the bottom of this page.
NOTE
i
Type XII Contacts 114- 10005
Rev J2 of 8 Tyco Electronics Corporation
2.3. Drawings
Customer Drawings for specific products are available from the service network. The information contained in
Customer Drawings takes priority if there is a conflict with this specification or with any other technical
documentation supplied by Tyco Electronics.
2.4. Specifications
Product Specification 108--10037 provides product performance requirements and test information.
2.5. Instructional Material
The following list includes available instruction sheets (408--series) that provide assembly procedures for
operation, maintenance and repair of tooling; and customer manuals (409--series) that provide setup,
operation, and maintenance of machines. A variety of documentation for Type XII Contacts are available from
Tyco Electronics. Contact the FAX/Product Information Center number at the bottom of page 1.
Document Number Document Title
408--2095 Hand Crimping Tool 69710--1
408--3295 Preparing Reel of Contacts for Applicator Tooling
408--4190 C--Head Pneumatic Adapter 318161--[ ]
408--4321 Pneumatic CERTI--CRIMP* Tool Holder 356304--1
408--7175 Crimping Die Assemblies 90140--1, 90140--2, 90145--1, and 90145--2
408--7276 Extraction Tool 91019--3 for Type XII Contacts
408--7424 Checking Contact Crimp Height
408--8040 Heavy Duty Miniature Quick--Change Applicators (Side--Feed Type)
408--8053 Miniature (Mini) and Quick--Change Applicators
408--8059 General Preventative Maintenance for Applicators
408--9816 Handling of Reeled Products
409--5128 AMP--O--LECTRIC* Model “K” Terminating Machine 1--471273--3
409--5862 626 Pneumatic Tooling Assemblies 189721--[ ] and 189722--[ ]
3. REQUIREMENTS
3.1. Storage
The contacts should remain in the shipping containers until ready for use to prevent deformation of the contact.
The contacts should be used on a first in, first out basis to avoid storage contamination that could adversely
affect current transmission. These contacts have a shelf life of two years from date of manufacture.
Extra protection should be given to silver plated contacts to minimize tarnishing when exposed to the environment.
When loose piece or reeled silver plated contacts are not in use, they should be stored in a plastic bag or other sealed
container.
3.2. Wire Selection and Preparation
A. Wire Type
The contacts will accept copper fused--stranded or stranded conductor wire within the range of 10 through
16 AWG.
B. Preparation
The wire must be stripped to the dimension provided in Figure 2.
Do not nick, scrape, or cut the wire conductor during the stripping operation.
Figure 2
Strip Length
Conductors
Insulation
Note: Not to Scale
WIRE SIZE
(AWG)
STRIP LENGTH
+0.79 [+.031]
10
16--12
8.33 [.328]
7.14 [.281]
CAUTION
!
CAUTION
!
Type XII Contacts 114- 10005
Rev J 3 of 8Tyco Electronics Corporation
3.3. Chemical Exposure
Do not store contacts near any chemicals listed below as they may cause stress corrosion cracking in the
contacts.
Alkalies Carbonates Phosphates Citrates Tartrates
Amines Citrates Sulfides Nitrites
Ammonia Nitrites Sulfur Compounds
3.4. Cutoff Tab
Cutoff tabs are the remaining portion of the carrier strip after the contact is cut from the strip. The following
dimensional requirements will ensure proper application for these contacts.
1. The cutoff tab must not exceed the dimension shown in Figure 3.
2. The burr resulting from the cutoff tab shearing must not exceed the dimension shown in Figure 3.
3.5. Terminating
Select the contact to be crimped for the wire size being used. Crimp the contact according to the instructions
packaged with that tooling (refer to Section 5, TOOLING).
3.6. Crimped Contact Requirements
A. Effective Crimp Length
For optimum crimp effectiveness, the crimp must be within the area shown in Figure 3 and must meet the
crimp dimensions provided in the table in Figure 2. Effective crimp length is defined as that portion of the
wire barrel, excluding bellmouth(s), fully formed by the crimping tool. Instructions for adjusting, repairing,
and inspecting tools are packaged with the tools.
Each crimp dimension represents the functional range of a wire/contact combination. There are tool designs available
to meet various application requirements. The developed crimp configuration is unique for each tool design and is
acceptable provided the crimp height is within the functional range. For crimp dimensions of a specific tool, refer to
instruction sheet packaged with manual tools and applicator log packaged with power tools.
B. Wire Conductor Location
After crimping, the end of the wire conductor must be flush with or extend 1.27 mm [.050 in.] from the front
end of the contact wire barrel. Both the insulation and the conductor must be visible between the insulation
barrel and wire barrel. Care must be taken not to allow the wire insulation to be crimped in the wire barrel.
RefertoFigure3.
C. Contact Assist Spring
The contact assist spring on female contacts must be straight and not deformed.
D. Wire Barrel Seam
The seam between the two sides of the wire barrel must be completely closed and there must be no
evidence of loose wire strands or wire strands visible in the seam.
E. Wire Barrel Flash
Wire barrel flash is the formation that may appear on both sides of the wire barrel as the result of the
crimping process. It must not exceed the dimension provided in Figure 3.
F. Wire Barrel and Insulation Barrel Crimp
The crimp applied to the wire barrel and insulation barrel of the contact is the most compressed area and
is most critical in ensuring optimum electrical and mechanical performance of the crimped contact. The
contact wire barrel and insulation barrel height and width must be within the dimensions provided in
Figure 3.
G. Bellmouths
The rear bellmouth length must be within 0.51 to 1.27 mm [.020 to .050 in.] and the front bellmouth must
not exceed 0.51 mm [.020 in.]. Refer to Figure 3.
NOTE
Type XII Contacts 114- 10005
Rev J4 of 8 Tyco Electronics Corporation
Wire Barrel
Seam
Insulation
Barrel
Rear Bellmouth
0.51--1.27 [.020--.050]
Front Bellmouth
0.51 [.020] (Max)
Wire Barrel Flash
0.25 [.010] (Max)
Cutoff Tab
0.63 [.025] (Max)
Contact Assist
Spring
Crimped Male
Contact
Crimped Female
Contact
Wire Conductor Location
1.27 [.050] (Max)
Burr Area
0.25 [.010]
Both Wire and Insulation
Must Be Visible in
Transition Area
A
A
Section A- A
Crimp Width
(See Table)
Crimp Height,
(See Table)
Effective Crimp Length
Rear
Bellmouth
Front
Bellmouth
WIRE CONTACT
SIZE INSULATION WIRE BARREL CRIMP INSULATION BARREL CRIMP (REF)
S
I
Z
E
(AWG)
I
N
S
U
L
A
T
I
O
N
DIAMETER HEIGHT WIDTH WIDTH
16 2.08--2.24
[.082--.088]
14 3.68--4.06
[.145--.160]
2.29--2.44
[.090--.096]
3.48--3.63
[.137--.143]
5.26--5.41
[.207--.213]
12
[
5
6
0
]
2.18--2.59
[.086--.102]
[
3
3
]
[
0
3
]
10 4.83--5.59
[.190--.220]
2.72--2.92
[.107--.115]
5.26--5.41
[.207--.213]
5.08--5.84
[.200--.230]
Figure 3
Type XII Contacts 114- 10005
Rev J 5 of 8Tyco Electronics Corporation
H. Alignment
1. Up and Down
The crimped portion, including cutoff tab and burr, must not be bent beyond the limits shown in Figure 4.
2. Side--to--Side
The crimped portion must not be bent from one side to the other beyond the limits shown in Figure 4.
Figure 4
Up and Down Alignment
Side- to- Side Alignment
7.14 [.281]
(Max)
5.97 [.235]
(Max)
Datum Line
Datum Line
I. Twist and Roll
There should be no twist or roll of the wire barrel or mating portion of the crimped contact that would cause
overstress or impair usage. See Figure 5.
Uncrimped Portion
Crimped Portion
Avoid
Twist and Roll
Datum Line
F
i
gu
r
e5
Type XII Contacts 114- 10005
Rev J6 of 8 Tyco Electronics Corporation
3.7. Repair
Contacts are not repairable once a termination has been made. Any defective contact should be removed and
replaced with a new one. Do not reterminate a contact.
4. QUALIFICATION
Type XII Contacts do not require any agency certification.
5. TOOLING
Type XII Contacts can be terminated to wire using manual or pneumatic hand held crimping tools or
semi--automatic terminating bench mounted machines. The wire size range of the contact will dictate the
tooling to use. Once a contact is crimped, it can be inserted into the housing without the use of a tool. An
extraction tool has been designed to remove contacts that have been inserted into a housing.
A description, an illustration, a part number, and the instruction material for each tool is provided in the
following text and illustration.
5.1. Extraction Tool
This tool is designed to release the locking latch of Type XII Contacts from the housing without overstressing
the latch.
5.2. Die Assemblies
Various die assemblies have been developed to cover the full wire size range for the Type XII Contacts. They
are designed to be used in manually and pneumatically operated tools. The wire size range and applicable die
assemblies are provided in Figure 6.
5.3. Hand Crimping Tool Frame
The hand crimping tool frame features a tool handle frame assembly with a C--head configuration that provides
interchangeability of die assemblies. These tools have been designed for prototype and low volume application
of loose piece form contacts. A handle frame assembly and a typical crimping die assembly are shown in
Figure 6.
5.4. 626 Pneumatic Tool System
The pneumatic tool system features a pneumatic power unit, a tool holder assembly, and an adapter. This tool
system has been developed to reduce operator fatigue and provides interchangeability of die assemblies. The
system has been designed for prototype and medium--volume application of loose piece form contacts.
Components for the tool system which includes the C--head adapter for Type XII Contacts are provided in
Figure 6.
5.5. Semi- Automatic Machine
A. Applicator
Heavy Duty Quick Change Miniature Applicators have been designed for high--volume production. The
applicator is adjustable for the full wire size range of the Type XII Contacts.
B. Bench Mount Power Unit
The AMP--O--LECTRIC power unit is designed for terminating pre--stripped wires to reel--fed contacts. It is
designed to be bench mounted and used for high volume applications.
Type XII Contacts are designed to be crimped with application tools according to the instructional material
packaged with the tools. The recommended tools and instructional materials are provided in Figure 6.
CAUTION
!
Type XII Contacts 114- 10005
Rev J 7 of 8Tyco Electronics Corporation
Handle Assembly
69710--1
Extraction Tool
91019--3
Miniature Quick Change
Applicator 722762--2
AMP--O--LECTRIC
Power Unit 1--471273--3
Crimping Die
Assembly
(See Table)
Tool Holder Assembly
Without Ratchet 189928--1
With Ratchet 356304--1
C--Head Adapter
318161--1
Power Unit
Manual 189721--2
Foot Actuated 189722--2
626 Pneumatic Tool System
TOOLING (DOCUMENT)
WIRE SIZE
(AWG) CRIMPING DIE
ASSEMBLY
(408--7175)
HAND TOOL
FRAME
(408--2095)
APPLICATOR
(408--8040)
POWER UNIT
(409--5128)
626 PNEUMATIC
TOOLING
SYSTEM
EXTRACTION
TOOL
(408--7276)
10 90140--1
90140--2
16--14 90145--2 69710--1 722762--2 1--471273--3 SEE ABOVE 91019--3
14--12 90145--1
Figure 6
Type XII Contacts 114- 10005
Rev J8 of 8 Tyco Electronics Corporation
6. VISUAL AID
Figure 7 shows typical application of Type XII Contacts. This illustration should be used by production
personnel to ensure a correctly applied product. Applications which DO NOT appear correct should be
inspected using the information in the preceding pages of this specification and in the instructional material
shipped with the product or tooling.
FIGURE 7. VISUAL AID
WIRE BARREL SEAM MUST BE
CLOSED WITH NO PROTRUDING
WIRE STRANDS
WIRE AND INSULATION
MUST BE VISIBLE IN THIS
AREA
CONTACT ASSIST SPRING
MUST BE STRAIGHT
WITHOUT ANY EVIDENCE
OF DAMAGE
WIRE MUST BE VISIBLE AT
END OF WIRE BARREL AND
MUST NOT ENTER CONTACT
BODY
INSULATION MUST NOT BE
CUT, TORN, OR SCRAPED
BY INSULATION BARREL
CONTACT BODY MUST BE
STRAIGHT AND ALIGNED
WITH CRIMPED BARRELS
FRONT AND REAR BELLMOUTHS
MUST BE VISIBLE
NO EXCESSIVE WIRE
BARREL FLASH
CONTACT CUTOFF TAB MUST
BE STRAIGHT AND ALIGNED
WITH CRIMPED BARRELS
