APPLICATION SPECIFICATION
CTX64 MAT SEAL RECEPTACLE CRIMP TERMINAL (7.0mm pitch)
1.0 SCOPE
This specification details the crimping information and common practices of general crimps for the Molex
CTX64 mat seal receptacle terminal. Please refer to the sales drawing SD-34803-002 for additional
part information. The information in this document is for reference and benchmark purposes only.
Customers are required to complete their own validation testing if tooling and/or wire is different than what
is shown in
this specification.
All measurements are in millimeters and Newtons unless specified otherwise.
Terminals shown in this document are generic representations. They are not intended to be an image of any
terminal listed in the scope.
2.0 PRODUCT DESCRIPTION
DEFINITION OF TERMS:
1
BEND UP
4
ROLLING
3
TWISTING
BEND
DOWN
CONDUCTOR CRIMP
2
INSULATION CRIMP
FRONT BELL MOUTH
6 (not shown)
5
REAR
BELL MOUTH
Figure 1
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ECR/ECN INFORMATION: TITLE:
EC No: UAU2016-1050
DATE: 2016 / 01 / 05
DOCUMENT NUMBER:
AS-502306-002
CTX64 MAT SEAL
RECEPTACLE 7.0mm PITCH
APPLICATION SPECIFICATION
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TEMPLATE FILENAME: CRIMP_SPEC[SIZE_A](V.1).DOC
APPLICATION SPECIFICATION
DEFINITIONS OF TERMS (CONT.):
9
L
STRIP LENGTH
K
7
K
L
CONDUCTOR BRUSH
CUT-OFF TAB
END OF INSULATION
Figure 2
INSULATION
CRIMP WIDTH
(ICW)
CONDUCTOR
CRIMP WIDTH
(CCW)
11
13
INSULATION
CRIMP HEIGHT
(ICH)
CONDUCTOR
CRIMP HEIGHT
(CCH)
12
10
SECTION L-L
SECTION K-K
Figure 3
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EC No: UAU2016-1050
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DOCUMENT NUMBER:
AS-502306-002
CTX64 MAT SEAL
RECEPTACLE 7.0mm PITCH
APPLICATION SPECIFICATION
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APPLICATION SPECIFICATION
BELLMOUTH (FLARE)
5
6
The flare that is formed on the edge of the conductor crimp acts as a funnel for the wire strands. This funnel
reduces the possibility that a sharp edge on the conductor crimp will cut or nick the wire strands. A rear
bellmouth is required on the conductor crimp. A front bellmouth is optional. Caution: Excessively large
bellmouths will reduce crimp area and reduce pull forces. See Table 3 for bellmouth specifications.
Bellmouth too large
Reduced Crimp Area, Lower Pull Forces
Bellmouth per specification
Bad Crimp
Good Crimp
Figure 4
CUT-OFF TAB 7
This is the material that protrudes outside the insulation crimp after the terminal is separated from the carrier
strip. A cut-off tab that is too long may expose a terminal outside the housing; it may fail electrical spacing
requirements. See Table 3 for cut-off tab length specifications. Caution: Burrs on the cut-off tab are not
allowed as they have the potential to cut mat seals.
7b
ab 5
Figure
7a
b
CONDUCTOR BRUSH 8
The conductor brush is made up of the wire strands that extend past the conductor crimp on the contact side
of the terminal. This helps ensure that mechanical compression occurs over the full length of the conductor
crimp. The conductor brush should not extend into the contact area or above the conductor crimp/transition
wall height (whichever is tallest). CAUTION: Excessive conductor brush extended above the transition/crimp
area can cause terminal retention issues inside plastic cavity and potentially could compromise/tear the
glands of the mat seal.
8a
b
8b
b
Figure 6
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EC No: UAU2016-1050
DATE: 2016 / 01 / 05
DOCUMENT NUMBER:
AS-502306-002
CTX64 MAT SEAL
RECEPTACLE 7.0mm PITCH
APPLICATION SPECIFICATION
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APPLICATION SPECIFICATION
For the CTX64 receptacle terminal, the conductor brush extension past the conductor crimp must be greater
than 0.2mm and less than 1.0mm. And, depending on where the brush ends, it must be either below the
conductor crimp height or transition wall; whichever is taller. See Figure 7 for an example of brush height
boundary.
Crimp height taller than transition
wall; end of brush to be below
crimp height boundary
Crimp height shorter than
transition wall; end of brush to be
below crimp height/transition wall
boundary
1.0mm
0.2mm
1.0mm
0.2mm
Figure 7
CONDUCTOR STRIP LENGTH 9
The strip length is determined by measuring the exposed conductor strands after the insulation is removed.
The strip length determines the conductor brush length when the end-of-insulation position is centered in the
transition area between conductor and insulation crimps. See Table 3 for the length requirement.
CAUTION: Care must be taken not to leave indentations on the wire strands during the strip and cut operation
as this can compromise the effectiveness of the mat seal and can result in leaks.
CONDUCTOR CRIMP
This is the metallurgical compression of a terminal around the wire's conductor. This connection creates a
common electrical path with low resistance and high current carrying capabilities.
CONDUCTOR CRIMP HEIGHT 10
The conductor crimp height is measured from the top surface of the formed crimp to the bottom most radial
surface. Do not include the extrusion points in this measurement. Measuring crimp height is a quick, nondestructive way to help ensure the correct metallurgical compression of a terminal around the wire's conductor
and is an excellent attribute for process control. The crimp height specification is typically set as a balance
between electrical and mechanical performance over the complete range of wire stranding and coatings, and
terminal materials and plating. Although it is possible to optimize a crimp height to individual wire strands and
terminal plating, one crimp height specification is normally created. See Table 2 for crimp height
specifications.
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ECR/ECN INFORMATION: TITLE:
EC No: UAU2016-1050
DATE: 2016 / 01 / 05
DOCUMENT NUMBER:
AS-502306-002
CTX64 MAT SEAL
RECEPTACLE 7.0mm PITCH
APPLICATION SPECIFICATION
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APPLICATION SPECIFICATION
INSULATION CRIMP HEIGHT 12
Insulation crimp heights are specified in Table 2. CTX64 receptacle terminal insulation grips are designed to
accommodate multiple wire sizes. Even though the insulation grip may completely surround a smaller wire
and only partially surround a larger wire, an acceptable insulation crimp is still provided.
The insulation crimp should be visually evaluated to confirm it provides adequate compression on the wire. It
should also be evaluated by sectioning through the center of the crimped insulation grip. The grip should
compress the wire but not pierce it or otherwise damage the integrity of the insulation. The grip should not
contact the conductors under any circumstance. Mechanically, the insulation grip should withstand repeated
flexing of the wire as shown in Figure 8 without pulling out of the grip. The wire is flexed 5 times each in two
perpendicular planes in the following sequence: b to a, a to b, b to c, c to b, then repeat (see Figure 8).
Once the optimum setting for an insulation crimp height is determined, it is important to document it. The
operator can then check it as part of the setup procedure.
a
b
c
20 x wire diameter or
60mm min
Figure 8
EXTRUSIONS (ANVIL FLASH / BURR) 14
These are the small flares that form on the bottom of the conductor crimp resulting from the clearance
between the punch and anvil tooling. If the anvil is worn or the terminal is over-crimped, excessive extrusion
can result.
An uneven extrusion may also result if the punch and anvil are misaligned, if the feed is misadjusted or if there
is insufficient or excessive terminal drag. CAUTION: Anvil Flash has the potential to damage mat seals and
should be maintained within specifications (see Figure 9 and Table 3).
14
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EC No: UAU2016-1050
DATE: 2016 / 01 / 05
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ANVIL
FLASH
Figure 9
CTX64 MAT SEAL
RECEPTACLE 7.0mm PITCH
APPLICATION SPECIFICATION
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APPLICATION SPECIFICATION
INSULATION GRIP STEP 15
The insulation grip step is the designed offset between the conductor grip and the insulation grip which must
be met by the crimp process (see Figure 10 and Table 3).
15 Figure 10
J
J1
J2
END-OF-INSULATION POSITION
This is the location of the insulation in relation to the transition area between the conductor and insulation
crimps. Equal amounts of the conductor strands and insulation needs to be visible in the transition area. The
end-of-insulation position ensures that the insulation is crimped along the full length of the insulation crimp
and that no insulation gets crimped under the conductor crimp. The end-of-insulation position is set by the
wire stop and strip length for bench applications. For automatic wire processing applications the end-ofinsulation position is set by the in/out press adjustment (see Figure 2).
WING DISSYMMETRY 16
Wing dissymmetry is the crimped offset between the ends of core wings (see Figure 11 and Table 3).
SPACE BETWEEN WING TIPS AND CRIMP BOTTOM 17
The space between the crimp wing tips and the bottom of the crimp is designed to assure no contact between
wing tips and the crimp bottom (see Figure 11 and Table 3).
17
16
Figure 11
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EC No: UAU2016-1050
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DOCUMENT NUMBER:
AS-502306-002
CTX64 MAT SEAL
RECEPTACLE 7.0mm PITCH
APPLICATION SPECIFICATION
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APPLICATION SPECIFICATION
CRIMP BULGE 18
Caution needs to be taken with the crimp tooling to prevent a bulge in the transition area during crimping. The
transition should generally flow smoothly from the conductor crimp to the terminal box. Any bulge must not
exceed the width shown in Table 3. See Figure 12 for an example of crimp bulge.
18
Good Crimp (No Bulge)
Bad Crimp (Bulge)
Figure 12
WIRE CONDITION AFTER CRIMP
The wire, after crimping, should not have any scratches, grooves or dents. Such imperfections act as a leak
path at the junction between the wire and the mat seal. At a minimum, check the condition of the wire on a
sample length of 26mm as shown in Figure 13.
26mm MIN
4mm
Figure 13
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EC No: UAU2016-1050
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DOCUMENT NUMBER:
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No scratches,
grooves or dents
permitted on this
region of the wire
after crimping
CTX64 MAT SEAL
RECEPTACLE 7.0mm PITCH
APPLICATION SPECIFICATION
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APPLICATION SPECIFICATION
3.0 PRODUCT SPECIFICATIONS
Table 1
Terminal
Family
CTX64
REVISION:
C1
Gender
Receptacle
Sealing
Plating
Special
Characteristics
Sn
Standard Performance
Tin (Std. Sn)
Sn
High Performance
Tin (HP Sn)
Ag
High Performance
Silver (HP Ag)
Sn
Standard Performance
Tin (Std. Sn)
Sn
High Performance
Tin (HP Sn)
Ag
High Performance
Silver (HP Ag)
Insulation
Diameter
Range
(mm)
Grip
Size
Wire Range
S
0.22 – 0.35 mm
22 AWG
L
0.5 – 0.85 mm
20 AWG
2
1.1 – 1.65
Mat Seal
ECR/ECN INFORMATION: TITLE:
EC No: UAU2016-1050
DATE: 2016 / 01 / 05
DOCUMENT NUMBER:
AS-502306-002
CTX64 MAT SEAL
RECEPTACLE 7.0mm PITCH
APPLICATION SPECIFICATION
2
1.4 – 1.9
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APPLICATION SPECIFICATION
Table 2
Molex Product Attribute
Grip
Size
Validated Wire
Special Characteristics
Standard Performance Tin
Wire Type
Wire Size
TXL3,c
22 AWG
Conductor
Barrel
Insulation Barrel
CCH
± 0.05
ICH
CC
W
Pull Out
Force
(N) MIN
ICW
0.69 ± 0.03
High Performance Tin
1.8 MAX
60
0.72 ± 0.03
FLRY-A1,3,e
S
B2M
PSA FTP:00949_12_00996
Standard Performance Tin
AVSS2,b
Standard Performance Tin
High Performance Tin
1,a
0.22mm2 0.65 ± 0.03
1.46 ± 0.04
0.30mm2 0.75 ± 0.03 (1.3)
PSA FTP: AEEV_AREF08_0909 ( A3d )
PSA FTP: AEEV_AREF08_1035 ( A3d )
ACOME T3-ZHID
PSA FTP: 00949_10_00766
0.35mm
2
TXL3,c
1.62 ± 0.04
[1.7 MAX4]
20 AWG
ACOME T3-ZHID1,3,a,e
PSA FTP: 00949_10_00767
High Performance Silver
Standard Performance Tin
AVSS2,b
Standard Performance Tin
High Performance Tin
ACOME T3-ZHID1,3,a,e
PSA FTP: 00949_10_00768
High Performance Silver
ACOME T3-ZHID1,a,e
ACOME FLR2XA3ZH-A1,e,g
PSA FTP: 00949_10_00768
Standard Performance Tin
High Performance Tin
High Performance Silver
PSA FTP: AEEV_AREF07_0821 (CE31,f )
Standard Performance Tin
AVSS2,b
60
0.69 ± 0.03
ACOME T3-ZHID1,a,e
PSA FTP: 00949_10_00766
Standard Performance Tin
High Performance Tin
Standard Performance Tin
High Performance Tin
(1.45)
[1.6 MAX4]
1.8 MAX
1.90 ± 0.05
1,3,a,e
High Performance Silver
L
35
Standard Performance Tin
0.50mm
2
0.95
2.0 MAX
90
70
0.95
1.76 ± 0.04
[2.0 MAX4]
2.0 MAX
90
1.05
0.75mm2
(1.75)
[1.9 MAX4]
(1.4)
0.95
90
2.0 MAX
1.07
0.85mm2
1.10
130
The above specifications are guidelines to an optimum crimp. Crimp heights/widths are applicable for punch/anvil tooling shown in
Figures 15 – 18.
Pull force should be measured with no influence from the insulation crimp.
Customers are required to complete their own validation testing if tooling and/or wire is different than what is shown in this specification.
4
Values in brackets are the maximum size permitted for insulation crimp height/width for terminals crimped to wires other than those
shown in Table 2 above.
Terminal crimps were validated to following specifications:
1
PSA STE 96 341 150 99, B21 7050
2
RSA 36-05-019, 36-05-036 (Mechanicals and Visuals Only)
3
USCAR-21
Wires are in accordance with following specifications:
a
PSA B25 1110: NFS-Conventional electrical conductor
b
JASO D 6111: AVSS type
c
SAE J1128: TXL type
d
PSA B25 1110: Augmented Insulation (0.5mm2 insulation on 0.35mm2 conductor)
FTP: AEEV_AREF08_1035 for Nexans wire
FTP: AEEV_AREF08_0909 for Acome wire
e
ISO 6722: Thin wall type
f
PSA 96 904 053 99: electrical sealing wire and FTP: AEEV_AREF07_0821 (0.75mm2)
g
GMW 15626: Single-Core Stranded ISO Cable
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EC No: UAU2016-1050
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DOCUMENT NUMBER:
AS-502306-002
CTX64 MAT SEAL
RECEPTACLE 7.0mm PITCH
APPLICATION SPECIFICATION
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APPLICATION SPECIFICATION
Table 3
Specifications
Balloon #
Description
Requirement
1
Bend Up
1° MAX
2
Bend Down
2° MAX
3
Twisting
4° MAX
4
Rolling
6° MAX
5
Rear Bell Mouth
0.20 – 0.55
6
Front Bell Mouth
Not Required
7
Cut-Off Tab
8
b
No Burrs
a
0.2 – 1.0
b
Not to extend above conductor
crimp/transition height
Conductor Brush
Conductor Strip Length
4.0 – 4.5 for reference
10
Conductor Crimp Height
See Table 2
11
Conductor Crimp Width
See Table 2
12
Insulation Crimp Height
See Table 2
13
Insulation Crimp Width
See Table 2
14
Conductor Anvil Flash
0.10 MAX
Insulation Grip Step
0.20 ± 0.05
From J1-J2 (see Figure 9)
16
Wing Dissymmetry
17
Space Between Wing Tips
and Crimp Bottom
18
C1
0.30 MAX
9
15
REVISION:
a
EC No: UAU2016-1050
DATE: 2016 / 01 / 05
AS-502306-002
Wire Size < 0.22mm
2
No Contact
Wire Size > 0.35mm
2
0.10 MIN
Crimp Bulge
ECR/ECN INFORMATION: TITLE:
DOCUMENT NUMBER:
0.20 MAX
Not to exceed conductor crimp width
CTX64 MAT SEAL
RECEPTACLE 7.0mm PITCH
APPLICATION SPECIFICATION
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APPLICATION SPECIFICATION
4.0 REFERENCE DOCUMENTS
Reference documentation for general practices is located on the website per the below links:
1. Molex Quality Crimping Handbook http://www.molex.com/images/products/apptool/qual_crimp.pdf
2. Molex-Recognizing Good Crimps http://www.molex.com, search for Application Tooling
5.0 PROCEDURE
5.1 GENERAL MEASUREMENT AND EVALUATION REQUIREMENTS
Crimp Height Measurement (Extrusion Evaluation)
1. Complete tool set-up procedure.
2. Crimp a minimum of 5 samples.
3. Place the flat blade of the crimp micrometer across the center of the dual radii of the conductor crimp.
Do not take the measurement near the conductor bell mouth (see Figure 14).
4. Rotate the micrometer dial until the point contacts the bottom most radial surface
Figure 14
6.0 CRIMP TOOLING GEOMETRY
The crimp tooling information shown below is based on the tooling that Molex used to perform validation
testing to establish recommended crimp height and widths. The user is responsible for validating crimp
performance based on tooling, equipment and wire that is being used.
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EC No: UAU2016-1050
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DOCUMENT NUMBER:
AS-502306-002
CTX64 MAT SEAL
RECEPTACLE 7.0mm PITCH
APPLICATION SPECIFICATION
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APPLICATION SPECIFICATION
Table 4 (see Figure 15 for geometry)
Wire Application
Grip Size
Wire Size
22AWG
2
0.22mm
2
0.30mm
2
0.35mm
20AWG
2
0.50mm
2
0.75mm
2
0.85mm
S
L
Conductor Punch
A
B
C
D
0.35
1.30
0.60
0.30
0.38
1.40
0.64
0.32
General Tolerances
(unless specified)
2 PLACES
± 0.13
1 PLACE
± 0.25
ANGULAR
± 0.5°
Figure 15
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CTX64 MAT SEAL
RECEPTACLE 7.0mm PITCH
APPLICATION SPECIFICATION
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APPLICATION SPECIFICATION
Table 5 (see Figure 16 for geometry)
Wire Application
Grip Size
L
E
F
G
H
J
1.45
0.725
2.40
2.00
1.12
1.75
0.875
2.50
2.50
0.79
Wire Size
22AWG
2
0.22mm
2
0.30mm
2
0.35mm
20AWG
2
0.50mm
2
0.75mm
2
0.85mm
S
Insulator Punch
General Tolerances
(unless specified)
2 PLACES
± 0.13
1 PLACE
± 0.25
ANGULAR
± 0.5°
Thickness
2.70 ± 0.02
Figure 16
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CTX64 MAT SEAL
RECEPTACLE 7.0mm PITCH
APPLICATION SPECIFICATION
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APPLICATION SPECIFICATION
Table 6 (see Figure 17 for geometry)
Wire Application
Grip
Wire Size
Size
S
L
22AWG
2
0.22mm
2
0.30mm
2
0.35mm
20AWG
2
0.50mm
2
0.75mm
2
0.85mm
Anvils
L
M
N
P
R
U
W
1.30
0.05
1.40
0.13
1.00
0.15
0.20
1.40
0.05
1.70
0.19
1.20
0.20
0.20
Conductor Anvil
General Tolerances
(unless specified)
2 PLACES
± 0.13
1 PLACE
± 0.25
ANGULAR
± 0.5°
Insulator Anvil
Conductor Anvil
Insulator Anvil
Figure 17
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CTX64 MAT SEAL
RECEPTACLE 7.0mm PITCH
APPLICATION SPECIFICATION
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APPLICATION SPECIFICATION
7.0 CRIMP STRAIGHTNESS
A sample method for maintaining crimp straightness is shown in Figure 18 below.
Figure 18
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CTX64 MAT SEAL
RECEPTACLE 7.0mm PITCH
APPLICATION SPECIFICATION
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APPLICATION SPECIFICATION
8.0 APPLICATION TOOLING
Application Tooling for the CTX64 Receptacle Terminal can be obtained directly from Molex.
To find the proper and latest Molex Application Tooling:
1. Go to http://www.molex.com
2. Enter the terminal / connector part number into the search box and select the “Go” button.
a. Molex part numbers can also be found by searching on the product description.
3. Review the Application Tooling available on the right side of the product window.
a. It may be necessary to scroll down on the right side of the terminal / connector
product page to view all the tooling options.
b. Hand tools and manual type tools require the loose terminal / connector part number
to be used in the search.
c. Applicator or semi-automatic type tools require the reeled terminal / connector part
number to be used in the search.
4. Select the tool part number link
5. Review the tooling page for general tool information
6. Open the link for the Application Tooling Specification (ATS) (located on the left under
Specifications & Other Documents) for additional details such as:
a. Termination specifications: crimp height, pull force, wire strip length, insulation
diameter, etc.
b. Tool information: tool diagram, tool parts list, repair parts, perishable parts list.
7. Order Molex Application Tooling through your preferred distributor
Notes:
1. Hand crimp tooling can only be used with certain wires and terminal part numbers. Check the
Application Tooling Specification Sheet on the Molex website for details.
2. Application Tooling product numbers are subject to change without prior notice. Customers are
advised to check the Molex website for the most up-to-date information.
3. Molex FineAdjust™ and MiniMac™ Application Tooling requires the use of left payoff (“D”
Wind) parts.
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DOCUMENT NUMBER:
AS-502306-002
CTX64 MAT SEAL
RECEPTACLE 7.0mm PITCH
APPLICATION SPECIFICATION
SHEET No.
16 of 16
CREATED / REVISED BY:
CHECKED BY:
APPROVED BY:
J.Burgio
J.Pruneau
B.Moser
TEMPLATE FILENAME: CRIMP_SPEC[SIZE_A](V.1).DOC