ECU- 1 1 mm Socket Contact 25 FEB 10 Rev E

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1 Applcaton Specfcaton ECU- 1 1 mm Socket Contact 25 FEB 10 Rev E All numercal values are n metrc unts [wth U.S. customary unts n brackets]. Dmensons are n mllmeters. Unless otherwse specfed, dmensons have a tolerance of and angles have a tolerance of +2_. Fgures and llustratons are fordentfcaton only and are not drawn to scale. 1. INTRODUCTION Ths specfcaton covers the requrements for applcaton of the ECU--1 1 mm Socket Contact. The ECU--1 1 mm Socket Contacts are used n the ECU--1 plug connector assembles. These requrements are applcable to hand or automatc machne crmpng tools. When correspondng wth Tyco Electroncs Personnel, use the termnology provded n ths specfcaton to facltate your nqury for nformaton. Basc terms and features of components are provded n Fgure 1. Insulaton Barrel Matng Porton Wre Barrel Locator Slot Fgure 1 2. REFERENCE MATERIALS 2.1. Revson Summary S Updated document to corporate requrements S New logo and format 2.2. Customer Assstance Reference Base Part Numbers , , , and and Product Code 2155 are representatve numbers that dentfy the ECU--1 1 mm Socket Contact product lne. These numbers are used n the customer servce network to access toolng and product applcaton nformaton. Ths servce s provded by your local Tyco Electroncs Representatve or, after purchase, by callng the Toolng Assstance Center number at the bottom of ths page Drawngs Customer Drawngs for specfc products are avalable from the responsble Engneerng department va the servce network. The nformaton contaned n the Customer Drawngs takes prorty f there s a conflct wth ths specfcaton or wth any other techncal documentaton suppled by Tyco Electroncs Instructonal Materal The followng lst ncludes avalable nstructon sheets (408--seres) that provde assembly procedures for product, operaton, mantenance and repar of toolng, as well as setup and operaton procedures of applcators; and customer manuals (409--seres) that provde setup, operaton, and mantenance of machnes. E2010 Tyco Electroncs Corporaton, Berwyn, PA TOOLING ASSISTANCE CENTER All Rghts Reserved PRODUCT INFORMATION TE logo and Tyco Electroncs are trademarks. *Trademark. Other product names, logos, or company names mght be trademarks of ther respectve owners. Ths controlled document s subject to change. For latest revson and Regonal Customer Servce, vst our webste at 1 of 6 LOC B

2 Document Number Document Ttle Applcaton and Mantenance for Hand Crmpng Tool Heavy Duty Mnature Quck--Change Applcators (Sde--Feed) Settng Shut--Heght on Model K II AMP--O--LECTRIC* Machne Applcaton and Mantenance for Hand Crmpng Tool AMP--O--LECTRIC Model K Termnatng Machne [ ] AMP--O--LECTRIC Model G Termnatng Machne [ ] AMPOMATOR* CLS IV+ Machne 3. REQUIREMENTS 3.1. Specal Consderatons Plug contact s equvalent to FordGG contact XL2T AA and s desgned for wre szes 20 through 18 AWG. Contact s equvalent to JaguarY contact 2X4T AA and s desgned for 22 AWG. Contacts wth a --4 suffx are reeled for the toolng lsted n Secton 5. Contact s desgned only for 20 AWG, sold strand, alumel and chromel thermocouple wre. Contact s desgned only for 16 and 18 AWG, SAEJ1128GXL wre Wre A. Wre Selecton The contacts wll accept wre szes 22 through 16 AWG. Wre nsulaton mnmum and maxmum dameters shall be as ndcated n Fgure 2. B. Wre Preparaton The wre strp length shall be as ndcated n Fgure 2. Reasonable care shall be taken durng the strppng operaton to ensure the conductor s not ncked, scraped, or cut. The appled crmp dmenson (wthn the functon range of the product) s dependent on the termnaton toolng beng used. Refer to the documentaton (applcator logs and nstructon sheets) suppled wth the termnaton toolng for the appled crmp heght. See Secton 5, TOOLING Crmped Contact Contacts shall be crmped n accordance wth the nstructonal materal packaged wth the toolng. Specfcatons for contact crmpng and nspecton are lsted n Fgure 2. A. Carrer Cutoff Tab CutofftabshallbeasshownnFgure2. B. Carrer Cutoff Burr Cutoff burr shall not exceed the dmensons as shown n Fgure 2. C. Wre Barrel Crmp Inspecton Contacts shall be crmped n accordance wth the nstructons packaged wth the toolng; refer to Fgure Crmp heght and wdth shall be as shown n Fgure The wre barrel seam shall be closed adequately to confne all strands of the wre. There shall be no loose wre strands. Wre strands should not be embedded n the seam of the wre barrel. 3. The front and rear bellmouth shall be as shown n Fgure Both nsulaton and conductor shall be vsble between the nsulaton barrel and wre barrel. Care shall be taken not to allow nsulaton to be crmped n the wre barrel. 5. Wre barrel flash shall not exceed the dmenson shown n Fgure 2. D. Insulaton Barrel Crmp Inspecton 1. Crmp wdth shall be as shown n Fgure 2. GGFord Motor Company YJaguar Cars Lmted, Coventry England 2 of 6 Tyco Electroncs Corporaton Rev E

3 2. Care shall be taken not to cut or break the nsulaton durng the crmpng operaton. CAUTION! Wre strppng tool jaws may leave corrugated ndentatons on the surface of the wre nsulaton. If these ndentatons occur at the locaton of the wre seal, leakage may result. Insulaton surfaces wthn 26 mm from the tp of the contact must be smooth and free of resdual ndentatons. It s mportant n any applcaton that the far end of the cable be sealed or otherwse solated from the envronment, and that the nsulaton s not cut or damaged. Care shall be taken to ensure that the wre nsulaton s not cut or broken durng the crmpng operaton, and to ensure that the nsulaton s not crmped nto the wre barrel. The ends of the nsulaton barrel shall be wrapped around the wre nsulaton, leavng no sharp ponts to damage the rubber wre seal. Wre Barrel Shall be Closed at Seam wth No Strands Protrudng or Showng Wre Strand Ends Must be Vsble n ths Area Wre Strands and Insulaton Shall Both be Vsble Rear Bellmouth Shall be 0.13 to 0.51 mm Front Bellmouth Shall be 0.25 mm Max. Wre Strands Must Not Exceed Heght of Wre Barrel Cutoff Burr Shall Not Exceed 0.08 mm Cutoff Tab Shall be Wre Barrel Flash Shall 0.13 to 0.38 mm Not Exceed 0.15 mm WIRE WIRE BARREL INSULATION BARREL SIZE STRIP SPECIFICATION NO. CRIMP LENGTH INSULATION CRIMP CRIMP CRIMP WIDTH HEIGHT mm 2 (WIRE TYPE) THICKNESS WIDTH HEIGHT AWG (REF) (REF) SAEJ1128GXL 0.58 Nom SAEJ1128GXL 0.58 Nom ESB -M1L123 -AGG 0.41 Nom MS WSB -M1L134 -A1GG 0.25 Nom WSS -M1L135 -A1GG 2.21 ESB -M1L123 -AGG 0.41 Nom 2.10 MS WSB -M1L134 -A1GG 0.25 Nom 1.85 WSS -M1L135 -A1GG ESB -M1L123 -AGG 0.41 Nom JED/510/84Y 0.22 Mn PP -20 -KX -SP -FW (Alumel and Chromel) 0.50 Nom GGFord Motor Company YJaguar Cars Lmted, Coventry England Fgure 2 Rev E Tyco Electroncs Corporaton 3 of 6

4 3.4. Algnment The axal concentrcty of the crmped contact shall fall nto an area defned by a 2.8 mm dameter crcle whose center s the centerlne of the contact as shown n Fgure mm Dameter There Shall be No Twst or Roll n Crmped Porton That Wll Impar Usage of the Contact Centerlne Fgure Repar/Replacement CAUTION Damaged contacts should not be used. If a damaged contact s evdent, t must be cut from the wre and replaced wth a new one. Contacts must not be re -termnated.! 4. QUALIFICATIONS ECU--1 1 mm Socket Contacts are not requred to be agency approved. 5. TOOLING Loose pece contacts are desgned to be crmped wth Hand Tool Ths hand tool s recommended only for AWG contact termnaton. Use Hand Tool for sold strand alumel and chromel wre. Use Hand Tool for contact , 16 and 18 AWG, SAEJ1128GXL wre. Strp form contacts are desgned to be crmped wth a mnature applcator used n a sem--automatc or automatc machne. Toolng, applcators, and nstructon materal are lsted n Fgure 4. The Model K AMP -O -LECTRIC Termnatng Machne and have been superseded by the Model G Termnatng Machne ( ). However, because of the large number of machnes and applcable applcators stll n use, the Model K s stll beng recommended. AMP -O -LECTRIC Model G Termnatng Machne Power Unt ( ) AMP -O -LECTRIC Model K Termnatng Unt ( ) Hand Crmpng Tools and ( and ) Quck -Change Mn -Applcator or ( ) AMPOMATOR CLS IV+ Lead -Makng Machne Power Unt ( ) Fgure 4 (cont d) Hand Crmpng Tool of 6 Tyco Electroncs Corporaton Rev E

5 WIRE SIZE INSULATION HAND TOOL APPLICATORV POWER UNITS mm 2 AWG THICKNESS (DOCUMENT) (DOCUMENT) (DOCUMENT) [ ] ( ) 0.52/ / ( ) [ ]DD ( ) ( ) NOM ( ) /1.0 18/ NOM For lmted prototypes and small producton quanttes for 18 and 20 AWG applcatons, use Hand Tool (Instructon Sheet ) h Dash 1 applcators are used wth AMPOMATOR automatc lead -makng machne. Dash 2 applcators are used wth the AMP -O -LECTRIC termnatng unt. Fgure 4 (end) Rev E Tyco Electroncs Corporaton 5 of 6

6 6. VISUAL AID Fgure 5 s to be used by producton personnel to ensure properly appled product. The vew shows requrements for correct applcatons. Applcatons whch DO NOT appear correct should be nspected usng the nformaton n the precedng pages of ths specfcaton and n the nstructonal materal shpped wth the product or toolng. FRONT AND REAR BELLMOUTH MUST BE VISIBLE WIRE AND INSULATION MUST BE VISIBLE IN THIS AREA WIRE BARREL SEAM MUST BE CLOSED WITH NO CONDUCTOR STRANDS SHOWING FIGURE 5. VISUAL AID 6 of 6 Tyco Electroncs Corporaton Rev E

Power Ring Connectors 19 FEB 10 Rev C

Power Ring Connectors 19 FEB 10 Rev C Applcaton Specfcaton 114-2087 Power Rng Connectors 19 FEB 10 Rev C All numercal values are n metrc unts [wth U.S. customary unts n brackets]. Dmensons are n mllmeters [and nches]. Unless otherwse specfed,