Application Specification
114--10004
LOC B
1of 10
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 III+ (Size 16) Contacts 14 SEP 09 Rev K
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 [+.005] 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 the application of Type III+ (Size 16) Contacts. These contacts
have a pin diameter of 1.57 mm [.062 in.]. A color dot appears on the loose piece or (loose piece only) contact
spring which designates the applicable wire size and matches the color dot above the hand tool crimping
section. These requirements apply to hand or automatic machine crimping tools for the insulated grip contacts.
When corresponding with Tyco Electronics Personnel, use the terminology provided on this specification to
help facilitate your inquiry for information. Basic terms and features of components are provided in Figure 1.
Figure 1
Posted Socket Solder Tab Pin Solder Type Socket
Socket
Insulation Grip Contacts
Pin
Locking Lance
Insulation Barrel Wire Barrel
Color Dot
(Loose Piece Only)
Insulation Barrel
Wire Barrel
2. REFERENCE MATERIAL
2.1. Revision Summary
SUpdated document to corporate requirements
SNew logo and format
2.2. Customer Assistance
Reference Base Part Number 66098 and Product Code 5022 are representative numbers of the Type III+
(Size 16) 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 Tyco Electronics Representative or, after purchase, by calling the Product Information
Center at the number at the bottom of this page.
NOTE
i
Type III+ (Size 16) Contacts 114- 10004
Rev K2 of 10 Tyco Electronics Corporation
2.3. Drawings
Customer Drawings for product part numbers are available from the service network. The information
contained in the Customer Drawings takes priority if there is a conflict with this specification or with any other
technical documentation supplied by Tyco Electronics.
2.4. Manuals
Manual 402--40 is available upon request and can be used as a guide in soldering. This manual provides
information on various flux types and characteristics along with the commercial designation and flux removal
procedures. A checklist is included in the manual as a guide for information on soldering problems.
2.5. Specifications
Product Specification 108--10042 provides product performance requirements and test information.
2.6. Instructional Material
The following list includes available instruction sheets (408--series) that provide assembly procedures for
product, operation, maintenance and repair of tooling, as well as setup and operation procedures of
applicators; and customer manuals (409--series) that provide setup, operation, and maintenance of machines.
Document Number Document Title
408--1216 Extraction Tools 305183--[ ]
408--1379 Selection Charts for Multimate Pin and Socket Contacts
408--3295 Preparing Reel of Contacts for Application Tooling
408--7347 Insertion Tools 91002--[ ]
408--7414 Hand Crimping Tool 90225--2
408--7424 Checking Terminal Crimp Height or Gaging Die Closure
408--7773 Hand Crimping Tool 90331--1
408--8039 Heavy Duty Miniature Quick--Change Applicators (End--Feed Type)
408--8040 Heavy Duty Miniature Quick--Change Applicators (Side--Feed Type)
408--8059 General Preventive Maintenance for Applicators
408--8547 CERTI--CRIMP* II Straight action Hand Tools
408--9640 Crimp Quality Monitor Applicators for Side--Feed and End--Feed Applications
408--9816 Handling of Reeled Products
409--5128 Basic AMP--O--LECTRIC* Model “K” Terminating Machine 565435--5
409--5842 AMP--O--LECTRIC Model “G” Terminating Machines 354500--[ ]
409--5852 AMPOMATOR* CLS III--G Lead--Making Machine 122500--[ ]
409--5866 AMPOMATOR CLS IV Lead--Making Machine 217500--[ ]
409--5870 Crimp Quality Monitors (CQM) for AMPOMATOR CLS IV Lead--Making Machines
409--5878 AMPOMATOR CLS IV+ Lead--Making Machine 356500--[ ]
409--10012 AMP--O--MATIC* Side Feed Stripper--Crimper III Machine 1320895--[ ]
409--10016 Entry Level Terminator (ELT) Machine 1338600--[ ]
409--10027 Stripping Modules 1490500 and 1490502
409--10029 Stripping Modules 1490501 and 1490503
3. REQUIREMENTS
3.1. Storage
A. Ultraviolet Light
Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the contacts.
B. Reel Storage
When using reeled contacts, store coil wound reels horizontally and traverse wound reels vertically.
C. Shelf Life
The contacts should remain in the shipping containers until ready for use to prevent deformation to the
contact. The contacts should be used on a first in, first out basis to avoid storage contamination that could
adversely affect signal transmissions.
Type III+ (Size 16) Contacts 114- 10004
Rev K 3 of 10Tyco Electronics Corporation
D. Chemical Exposure
Do not store contacts near any chemicals listed below as they may cause stress corrosion cracking in the
contacts.
Alkalies Ammonia Citrates Phosphates Citrates Sulfur Compounds
Amines Carbonates Nitrites Sulfur Nitrites Tartrates
Where the above environmental conditions exist, phosphor--bronze contacts are recommended instead of brass if
available.
3.2. Special Characteristics
The solder type and solder tab versions will accept various sizes of solid or stranded wire. For soldering
requirements, follow the recommendations of the wire manufacturer and soldering equipment manufacturer.
Refer to Manual 402--40.
3.3. Wire Selection and Preparation
The total wire size range for these contacts is 30 through 14 AWG. The wire must be stripped to the
dimensions shown in Figure 2.
The applied crimp dimension (within the functional range of the product) is dependent on the termination tooling being
used. Refer to the documentation (applicator logs and instruction sheets) supplied with the termination tooling for the
applied crimp height. See Section 5, TOOLING.
DO NOT nick, scrape, or cut the wire conductor during the stripping operation.
Conductor Insulation
Strip
Length
4.34--3.58
[.171--.141]
WIRE SIZE
,
INSULATION WIRE BARREL CRIMP INSULATION BARREL
W
I
R
E
S
I
Z
E
,
AWG
I
N
S
U
L
A
T
I
O
N
DIAMETER HEIGHT WIDTH
I
N
S
U
L
A
T
I
O
N
B
A
R
R
E
L
CRIMP WIDTH
3
0
2
6
0.36--0.76 [.014--.030] 1.05--0.89 [.0415--.035] 1.75--1.57 [.069--.062] 1.60--1.20 [.063--.047]
30--26 1.02--1.52 [.040--.060] 1.05--0.89 [.0415--.035] 1.75--1.57 [.069--.062] 1.98--1.58 [.078--.062]
26 0.89--1.40 [.035--.055] 0.84--0.74 [.033--.029] 1.57--1.40 [.062--.055] 1.98--1.58 [.078--.062]
2.03--2.54 [.080--.100] 1.04--0.86 [.041--.034] 1.75--1.57 [.069--.062] 3.25--2.85 [.128--.112]
2
4
1.52--3.43 [.060--.135] 0.97--0.76 [.038--.030] 1.75--1.57 [.069--.062] 3.25--2.84 [.128--.112]
24 1.02--2.03 [.040--.080] 1.05--0.86 [.0415--.034] 1.75--1.57 [.069--.062] 2.49--2.09 [.098--.082]
0.89--1.40 [.035--.055] 0.89--0.74 [.035--.029] 1.57--1.40 [.062--.055] 1.98--1.58 [.078--.062]
(
2
)
2
4
1.52--3.43 [.060--.135] 1.07--0.86 [.042--.034] 1.75--1.57 [.069--.062] 3.25--2.84 [.128--.112]
(
2
)
24 1.02--2.03 [.040--.080] 1.07--0.97 [.042--.038] 1.75--1.57 [.069--.062] 2.49--2.09 [.098--.082]
2.03--2.54 [.080--.100] 1.04--0.91 [.041--.036] 1.75--1.57 [.069--.062] 3.25--2.85 [.128--.112]
22 1.52--3.43 [.060--.135] 1.02--0.81 [.040--.032] 1.75--1.57 [.069--.062] 3.25--2.84 [.128--.112]
2
2
1.02--2.03 [.040--.080] 1.05--0.91 [.0415--.036] 1.75--1.57 [.069--.062] 2.49--2.09 [.098--.082]
Figure 2 (cont’d)
NOTE
i
NOTE
i
CAUTION
!
Type III+ (Size 16) Contacts 114- 10004
Rev K4 of 10 Tyco Electronics Corporation
WIRE SIZE
,
INSULATION WIRE BARREL CRIMP INSULATION BARREL
W
I
R
E
S
I
Z
E
,
AWG
I
N
S
U
L
A
T
I
O
N
DIAMETER HEIGHT WIDTH
I
N
S
U
L
A
T
I
O
N
B
A
R
R
E
L
CRIMP WIDTH
2.03--2.54 [.080--.100] 1.12--0.94 [.044--.037] 1.75--1.57 [.069--.062] 3.25--2.85 [.128--.112]
20 1.52--3.43 [.060--.135] 1.12--0.91 [.044--.036] 1.75--1.57 [.069--.062] 3.25--2.84 [.128--.112]
2
0
1.02--2.03 [.040--.080] 1.12--0.95 [.044--.0375] 1.75--1.57 [.069--.062] 2.49--2.09 [.098--.082]
1
8
2.79--3.81 [.110--.150] 1.37--1.24 [.054--.049] 2.46--2.29 [.097--.090] 4.16--3.76 [.163--.147]
18 2.03--2.54 [.080--.100] 1.35--1.24 [.053--.049] 2.20--2.03 [.087--.080] 3.25--2.85 [.128--.112]
1
6
2.79--3.81 [.110--.150] 1.55--1.24 [.061--.049] 2.46--2.29 [.097--.090] 4.16--3.76 [.163--.147]
16 2.03--2.54 [.080--.100] 1.47--1.24 [.058--.049] 2.20--2.03 [.087--.080] 3.25--2.85 [.128--.112]
1
4
2.79--3.81 [.110--.150] 1.78--1.68 [.070--.066] 2.46--2.29 [.097--.090] 4.16--3.76 [.163--.147]
14 2.03--2.54 [.080--.100] 1.78--1.68 [.070--.066] 2.46--2.29 [.097--.090] 3.25--2.85 [.128--.112]
Figure 2 (end)
3.4. Crimped Contact Requirements
The contact must be crimped onto the wire according to instructions packaged with applicable tooling. After
crimping, the contact should appear as shown in Figure 3. A typical pin contact is shown as it should appear
after crimping; these requirements apply equally to the socket contact.
The wire insulation must not be damaged during the crimping process.
A. Wire Barrel Crimp
The crimp applied to the wire portion 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
crimp height must be within the dimension provided in Figure 2.
B. 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 Figure 2. Effective crimp length shall be 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. See Section 5, TOOLING.
C. Bellmouths
Front and rear bellmouths shall be evident and conform to the dimensions given in Figure 3.
D. Cutoff Tabs
The cutoff tab shall be cut to the dimensions shown in Figure 3.
E. Burrs
The cutoff burr shall not exceed the dimensions shown in Figure 3.
F. Wire Barrel Flash
The wire barrel flash shall not exceed the dimensions shown in Figure 3, Section X--X.
G. Insulation Barrel Crimp
The insulation barrel shall grip the insulation firmly. A slight cut in the insulation by the insulation barrel is
permissible as this causes no problems in actual use. Insulation crimp shall comply to width and height
provided in Figure 3.
H. Wire Location
The wire conductor and insulation must be visible in the transition area between the wire and insulation
barrels.
CAUTION
!
Type III+ (Size 16) Contacts 114- 10004
Rev K 5 of 10Tyco Electronics Corporation
I. Conductor Extension
The conductor may extend beyond the wire barrel to the maximum shown.
J. Wire Barrel Seam
The wire barrel seam must be closed with no evidence of loose wire strands visible in the seam.
Periodic inspections must be made to ensure crimped contact formation is consistent as referenced.
Figure 3
0.08 [.003]
Max. Burr
Cutoff Tab
0.25 [.010]
Max.
0.25 [.010]
Max Wire
Barrel Flash
Section X- X
Wire Barrel
Crimp Width
Wire Barrel
Crimp Height
Insulation Barrel
Crimp Width
Wire Conductors and
Insulation Must Both be Visible
in This Area
0.81 [.032] Max
Conductor Location
Locking Lance Undamaged
Wire Barrel Seam
Closed with No Conductor Strands
Showing
0.20--0.64
[.008--.025]
Rear Bellmouth
0.51 [.020] Max
Front Bellmouth
X
X
Crimp Length
3.5. Axial Concentricity
The axial concentricity of a crimped contact must be within an area defined by the diameter of a circle that has
the same center as the centerline of the contact. The diameter of the circle will depend on the wire sizes. See
Figure 4. This measurement does not apply to posted contacts.
NOTE
i
Type III+ (Size 16) Contacts 114- 10004
Rev K6 of 10 Tyco Electronics Corporation
Figure 4
Circle Diameter
Contact and
Circle Diameter
Centerlines
Contact
WIRE
SIZE,
AWG
CIRCLE
DIAMETER
26 -- 20 3.40 [.134]
18 -- 14 4.16 [.164]
30 -- 28 3.40 [.134]
3.6. Posted Sockets
The posted sockets accept TERMI--POINT* Connectors or wrap--type terminations. They can accommodate
up to three terminations per post. For terminating requirements, follow the instructions pertaining to specific
choice of termination method and tooling types used.
3.7. Solder Tab Pin and Sockets
Observe all guidelines and procedures when solder type contacts are required. Solder, clean, and dry all wire
leads to the contacts according to the following:
A. Flux Selection
The wire lead and contact wire barrel interior shall be fluxed prior to soldering using a mildly active rosin.
Selection of the proper flux will depend on the type of pc board and other components mounted on the
board. Additionally, the flux will have to be compatible with the wave solder line, manufacturing, and safety
requirements.
B. Cleaning
After soldering, removal of fluxes, residues, and activators is necessary. Consult with the supplier of the
solder and flux for recommended cleaning solvents. The following is a list of common cleaners that will not
affect the connectors for the times and temperatures shown. See Figure 5.
Consideration must be given to toxicity and other safety and health requirements as recommended in the Material
Safety Data Sheet supplied by the solder cleaner solvent manufacturer.
CLEANER TIME
(
i
n
u
t
e
s
)
TEMPERATURES
(Maximum)
NAME TYPE (Minutes
)
CELSIUS FAHRENHEIT
ALPHA 2110 Aqueous 1132 270
BIOACT EC--7 Solvent 5100 212
Butyl CARBITOL Solvent 1Room Ambience
Isopropyl Alcohol Solvent 5100 212
KESTER 5778 Aqueous 5100 212
KESTER 5779 Aqueous 5100 212
LONCOTERGE 520 Aqueous 5100 212
LONCOTERGE 530 Aqueous 5100 212
Terpene Solvent Solvent 5100 212
Figure 5
C. Drying
When drying cleaned assemblies and pc boards, make certain that temperature limitations of --55_to
105_C[--67_to 222_F] are not exceeded. Excessive temperatures may cause housing degradation.
D. Soldering Guideline
Refer to Paragraph 2.4, Manuals, for information on soldering requirements.
DANGER
Type III+ (Size 16) Contacts 114- 10004
Rev K 7 of 10Tyco Electronics Corporation
3.8. Repair/Replace
Contacts are not repairable once a termination has been made. Any defective or damaged contact must be
removed and replaced with a new one.
Use Extraction Tool 305183 to remove individual contacts from housings for replacement or for relocation to
another housing cavity.
4. QUALIFICATION
No qualifications or approvals are required for Type III+ Contacts.
5. TOOLING
These contacts can be terminated to wire using hand, semi--automatic, or automatic crimping tools.
Recommended tooling is provided in Figure 6.
Tyco Electronics Tooling Engineers have designed machines for a variety of application requirements. For assistance
in setting up prototype and production line equipment, contact Tyco Electronics Tool Engineering through your local
Tyco Electronics Representative or call the Tooling Assistance Center number at the bottom of page 1.
SHand Crimping Tool
Hand crimping tools that accommodate the full wire size range are designed for prototype and
low--volume applications such as repair of damaged contacts.
SApplicator
Applicators are designed for the full wire size range of strip--fed, precision formed contacts, and provide
for high volume, heavy duty, production requirements. The applicators can be used in bench or floor
model power units.
Each applicator is shipped with a metal identification tag attached. DO NOT remove this tag or disregard the
information on it. Also, a packet of associated paperwork is included in each applicator shipment. This information
should be read before using the applicator; then it should be stored in a clean, dry area near the applicator for future
reference. Some changes may have to be made to the applicators to run in all related power units. Contact the Tooling
Assistance Center number located at the bottom of page 1 for specific changes.
SPower Units
A power unit is an automatic or semi--automatic device used to assist in the application of a product.
Power unit includes the power source used to supply the force or power to an applicator.
SInsertion/Extraction Tooling
Insertion Tools are designed for contacts crimped to small fragile wire. They are designed to stabilize the
contact during insertion. For use of Insertion Tool 91002 which may be used with these contacts, refer to
Instruction Sheet 408--7347. Extraction Tools are designed to release the locking lance inside the
connector housing without damaging the housing or contacts. For use of Extraction Tool 305183 which
may be used with these contacts, refer to Instruction Sheet 408--1216.
WIRE SIZE
RANGE, AWG
INSULATION
DIAMETER RANGE
HAND TOOL
(DOCUMENT)
APPLICATOR
(408--8040)
POWER UNIT
(DOCUMENT)
3
0
-
-
2
6
1.02--1.52 [.040--.060] 91515--1 (408--8547) 466598--2 565435--5 (409--5128)
1338600--3, --4 (409--10016)
3
0
--
2
6
0.36--0.76 [.014--.030] 90225--2 (408--7414) 466585--3 565435--5 (409--5128)
1338600--3, --4 (409--10016)
466321--3
122500--2, --3 (409--5852)
217500--1, --2 (409--5866)
356500--1, --2 (409--5878)
26--24 0.89--1.40 [.035--.055] 91515--1 (408--8547)
466321--4
354500--1 (409--5842)
565435--5 (409--5128)
1338600--3, --4 (409--10016)
466908--2 1320895--1, --3 (409--10012)
Figure 6 (cont’d)
NOTE
i
NOTE
i
Type III+ (Size 16) Contacts 114- 10004
Rev K8 of 10 Tyco Electronics Corporation
WIRE SIZE
RANGE, AWG
INSULATION
DIAMETER RANGE
HAND TOOL
(DOCUMENT)
APPLICATOR
(408--8040)
POWER UNIT
(DOCUMENT)
466323--3
122500--2, --3 (409--5852)
217500--1, --2 (409--5866)
356500--1, --2 (409--5878)
1.02--2.03 [.040--.080] 91505--1 (408--8547)
91515--1 (408--8547) 466323--4
354500--1 (409--5842)
565435--5 (409--5128)
1338600--3, --4 (409--10016)
466907--2 1320895--1, --3 (409--10012)
466324--1
122500--2, --3 (409--5852)
217500--1, --2 (409--5866)
356500--1, --2 (409--5878)
2.03--2.54 [.080--.100] 90225--2 (408--7414)
91523--1 (408--8547) 466324--2
354500--1 (409--5842)
565435--5 (409--5128)
1338600--3, --4 (409--10016)
24--20 466942--1 1320895--1, --3 (409--10012)
466383--4
354500--1 (409--5842)
565435--5 (409--5128)
1338600--3, --4 (409--10016)
466979--1 1320895--1, --3 (409--10012)
1.52--3.43 [.060--.135] 90331--1 (408--7773)
567363--1
122500--2, --3 (409--5852)
217500--1, --2 (409--5866)
356500--1, --2 (409--5878)
567363--2
354500--1 (409--5842)
565435--5 (409--5128)
1338600--3, --4 (409--10016)
567363--3 354500--1 (409--5842)
567806--1 1320895--1, --3 (409--10012)
466325--1
122500--2, --3 (409--5852)
217500--1, --2 (409--5866)
356500--1, --2 (409--5878)
18--16 2.03--2.54 [.080--.100] 91505--1 (408--8547)
91523--1 (408--8547) 466325--2
354500--1 (409--5842)
565435--5 (409--5128)
1338600--3, --4 (409--10016)
466906--1 1320895--1, --3 (409--10012)
466923--2G1320895--1, --3 (409--10012)
2
0
3
2
5
4
[
0
8
0
1
0
0
]
9
1
5
1
9
1
(
4
0
8
8
5
4
7
)
466326--3
122500--2, --3 (409--5852)
217500--1, --2 (409--5866)
356500--1, --2 (409--5878)
18--14
2.03--2.54
[
.080--.100
]
91519--1
(
408--8547
)
466326--4
354500--1 (409--5842)
565435--5 (409--5128)
1338600--3, --4 (409--10016)
2.79--3.81 [.110--.150] 91521--1 (408--8547)
567364--2
354500--1 (409--5842)
565435--5 (409--5128)
1338600--3, --4 (409--10016)
466958--1 1320895--1, --3 (409--10012)
GSee Instruction Sheet 408--8039.
Figure 6 (cont’d)
Type III+ (Size 16) Contacts 114- 10004
Rev K 9 of 10Tyco Electronics Corporation
Figure 6 (end)
Typical Heavy
Duty Mini (HDM)
Applicator
AMP--O--LECTRIC
Model “K” Terminating
Machine 565435--5
AMPOMATOR CLS
Lead--Making Machines
122500--[ ]; 217500--[ ];
356500--[ ]
AMP--O--MATIC Side Feed
Stripper--Crimper II
Machine 1320895--[ ]
Insertion Tool
91002--[ ]
Extraction Tool
305183--[ ]
Typical Hand Tool
ELT Machine 1338600--[ ] with
Optional Stripping Module
1490500--[ ] (Stripping Module
Only 1490502--[ ])
AMP--O--LECTRIC Model “G”
Terminating Machine 354500--[ ]
with Optional Stripping Module
1490501--[ ] (Stripping Module
Only 1490503--[ ])
Type III+ (Size 16) Contacts 114- 10004
Rev K10 of 10 Tyco Electronics Corporation
6. VISUAL AID
Figure 7 shows a typical application of a Type III+ (Size 16) Contact. 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.
FIGURE 7. VISUAL AID
CONTACT MUST
BE STRAIGHT
WIRE MUST BE FLUSH WITH
END OF WIRE BARREL, OR
PROTRUDE SLIGHTLY
WIRE AND INSULATION
MUST BE VISIBLE IN
THIS AREA
REAR BELLMOUTH
MUST BE VISIBLE
WIRE BARREL SEAM
MUST BE CLOSED,
WITH NO CONDUCTOR
STRANDS SHOWING
LOCKING LANCE MAY
NOT BE DEFORMED