1924968-1.

Application Specification 114-13183 Generation Y 0.64 mm Contacts 11 JUN 18 Rev U NOTE All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters. Unless otherwise specified, dimensions have a tolerance of ±0.13 mm 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 Generation Y 0.64 mm Contacts. These contacts will accept symmetrical constructed (Type “A”) wire in a wire size range of 0.13 and 0.35 to 0.75 mm [26 and 22-18 AWG] as shown in the table in Figure 2. When corresponding with TE Connectivity Personnel, use the terminology provided in this specification to facilitate inquiries for information. Basic terms and features of this product are provided in Figure 1. Orientation Feature Carrier Strip Insulation Barrel Serrations Serrations Wire Barrel Terminal Box Insulation Barrel Blade Mating End Wire Barrel Orientation Feature Continuity Test Probe Target Area Figure 1 2. REFERENCE MATERIAL 2.1. Revision Summary  Updated Section L, Side-to-Side bend to 2 degrees to match details in Figure 5. 2.2. Customer Assistance Reference Product Base Part Numbers 1456841 (socket), 1924275 (blade) and Product Code M008 are representative of Generation Y 0.64 mm Contacts. Use of these numbers will identify the product line and help you to obtain product and tooling information. Such information can be obtained through a local TE Representative, by visiting our website at www.te.com, or by calling PRODUCT INFORMATION or the TOOLING ASSISTANCE CENTER at the numbers at the bottom of this page. © 2018 TE Connectivity family of companies All Rights Reserved *Trademark 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.te.com. TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners. 1 of 8 114-13183 2.3. Drawings Customer Drawings for product part numbers are available from our website at www.te.com. If there is a conflict between the information contained in the Customer Drawings and this specification or with any other technical documentation supplied, the information contained in the Customer Drawings takes priority. 2.4. 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: 408-3295 408-7424 408-8040 408-8053 408-8059 408-9816 408-10227 408-10389 409-5128 409-5842 409-5866 Preparing Reel of Contacts for Application Tooling Checking Terminal Crimp Height or Gaging Die Closure Heavy Duty Miniature Quick-Change Applicators (Side Feed Type) Conversion Guide for Miniature Quick-Change Applicators General Preventative Maintenance for Applicators Handling of Reeled Products PRO-CRIMPER* III Hand Tool 2063291-1 with Die Assembly 2063291-2 Ocean Side-Feed Applicators Basic AMP-O-LECTRIC* Model “K” Terminating Machine 471273-[ ] AMP-O-LECTRIC Model “G” Terminating Machines 354500-[ ] AMPOMATOR* CLS IV Lead-Making Machine 3. REQUIREMENTS 3.1. Safety Do not stack product shipping containers so high that the containers buckle or deform. 3.2. Storage A. Ultraviolet Light Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the product material. B. Reeled Contacts When using reeled contacts, store coil wound reels horizontally and traverse wound reels vertically. C. Shelf Life The product should remain in the shipping containers until ready for use to prevent deformation to components. The product should be used on a first in, first out basis to avoid storage contamination that could adversely affect performance. D. Chemical Exposure Do not store product near any chemical listed below as they may cause stress corrosion cracking in the material. Alkalies Amines Ammonia Carbonates Citrates Nitrites Phosphates Citrates Sulfur Nitrites Sulfur Compounds Tartrates 3.3. Materials The socket contact is made from a copper alloy. Contacts are available with tin plate. 3.4. Wire Size and Preparation The contacts will accept symmetrically stranded metric and AWG wire sizes as shown in the tables in Figure 2. CAUTION DO NOT nick, scrape, or cut the wire conductor during the stripping operation. Rev U 2 of 8 114-13183 NOTE 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. Insulation Wire Conductor ICW WCH ICH Insulation Diameter Strip Length WCW Wire Barrel NOTE: Not to Scale TABLE 2A WIRE SIZE WIRE BARREL INSULATION BARREL AWG INSULATION DIAMETER STRIP LENGTH† WCH WCW ICH ±0.10 ICW ±0.05 0.13 26 0.85-1.05 4.0-4.5 0.68 ±0.02 1.067 ±0.05 1.30 ±0.05 1.30 2 x 0.13 2 x 26 0.85-1.05 4.3-4.5 0.84 ±0.02 1.168 ±0.05 1.90 ±0.05 1.60 0.35 22 1.10-1.40 4.0-4.5 0.91 ±0.03 1.168 ±0.05 1.60 ±0.05 1.60 0.35 22 1.50-1.85 4.0-4.5 0.90 ±0.05 1.40 ±0.10 2.00 1.60 0.50 20 1.50-1.85 4.0-4.5 0.95 ±0.05 1.40 ±0.10 1.90-2.30 1.60 0.75 18 1.60-2.06 4.0-4.5 1.05 ±0.05 1.60 ±0.05 2.25 1.60 mm2 †Strip length is dependent on wire and insulation type used. Actual strip length may vary from the value provided above so long as the requirements of Figure 3 are met. TABLE 2B (APPLICABLE WIRE DATA) WIRE SIZE mm2 AWG WIRE STRUCTURE NUMBER OF STRANDS MAX DIA OF STRANDS CMA CALCULATED INSULATION DIAMETER 0.13● 26 Symmetrical 7 0.16 277.8 0.85-1.05 0.35 22 Symmetrical 7 0.27 791 1.10-1.85 0.50 20 Symmetrical 7 0.32 976.5 1.50-1.85 0.75 18 Symmetrical 19 0.24 1696.3 1.60-2.06 These crimp dimensions and terminal qualification are based on wire that is of symmetrical Type “A” construction. See table 2B above. It is the responsibility of the user to perform crimp qualification for any deviations from these parameters. ●Qualification completed with Delphi M5647 (CuMg02) wire. Figure 2 3.5. Crimped Contact Requirements The contact shall be located in desired tooling and crimped according to the instructions packaged with that tooling. See Section 5, TOOLING, of this document for details on tooling options. CAUTION Wire insulation shall NOT be fully cut or broken during the crimping operation, nor shall the insulation be crimped into the contact wire barrel. Reasonable care should be taken by tooling operators to provide undamaged wire terminations. CAUTION Wire stripping tool jaws may leave corrugated indentations on the surface of the wire insulation. This is especially severe with cross-linked polyethylene (high temperature) insulation. 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. Rev U 3 of 8 114-13183 NOTE Wire brush height must not be above the wire barrel crimp. B. Effective Crimp Length For optimum crimp effectiveness, the crimp must be within the area shown and must meet the crimp dimensions provided in Figure 3. 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 The rear bellmouth shall be as shown and conform to the dimensions given in Figure 3. It is preferred that no front bellmouth exist. However, if the tooling has strand compressor, then there can be 0.15 mm maximum front bellmouth. NOTE Upcoming strands are not permissible under any circumstance if product is being used in a sealed system. Conductor Extension Flush to 1.00 No Front Bellmouth Preferred. 0.15 mm Max if Application Tooling Has Strand Compressor. Absolutely No Upcoming Strands. 0.13 mm² (26 AWG) 0.3-0.7 Front Bellmouth Permissible. Effective Crimp Length Wire Barrel Closed at Seam with No Strands Protruding or Showing Rear Bellmouth 0.3-0.7 X Wire Barrel Crimp Width (WCW) Wire Insulation and Conductors Must Both be Visible in This Area X Wire Barrel Crimp Height (WCH) 0.25 Max Wire Barrel Flash 0.03 Max Section X-X NOTE: Socket contact shown, same dimensions for blade contact. Cutoff Tab 0.20 Max 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. Rev U 4 of 8 114-13183 G. Insulation Barrel Crimp The insulation barrel shall grip the insulation firmly without fully cutting into it. Care must be taken to prevent cutting, nicking, or scraping of the insulation. Insulation crimp shall comply with width dimensions provided in Figure 2. H. Wire Location The wire conductor and insulation must be visible in the transition area between the wire and insulation barrels. I. Conductor Extension The conductor may extend beyond the wire barrel to the maximum shown. No strands may extrude over the height of the conductor crimp. NOTE Conductor extension may need to be kept to a minimum to avoid upcoming strands, especially when dealing with sealed applications. J. Wire Barrel Seam The wire barrel seam must be closed with no evidence of loose wire strands visible in the seam. K. Twist and Roll There shall be no twist, roll, deformation or other damage to the mating portion of the crimped contact that will impair usage of the contact. See Figure 4. 5° Max Twist/Roll Wire Barrel Figure 4 L. Straightness The force applied during crimping may cause some bending between the crimped wire barrel and the mating portion of the contact. Such deformation is acceptable within the limits provided in Figure 5.  Upward bend of the crimped contact shall not exceed 2°  Downward bend of the crimped contact is not acceptable  Side-to-side bend of the crimped contact shall not exceed 2°  Deformation of the terminal box after crimping is not acceptable NOTE Periodic inspections must be made to ensure crimped contact information is consistent as shown. 3.6. Contact Repair Once a contact has been damaged, it cannot be used. It must be cut from the wire and replaced with a new contact. Recommend using extraction tool made from the dimensions provided in Figure 6 to remove the terminal from the connector. If the TPA is removed to facilitate terminal removal, then the wider blade is recommended. If the TPA is pulled back to a pre-stage position, but remains in the connector, then the narrower blade is required. Refer to the individual connector instruction sheet for insertion and removal procedures. Rev U 5 of 8 114-13183 Socket Straightness Blade Straightness 2° Max 2° Max 2° Max 2° Max 0° Max 0° Max Acceptable Not Acceptable Not Acceptable Figure 5 NOTE The smaller tool width, as defined by dimension letter “A”, can be used with the TPA removed. However, it will be difficult to find the plastic connector latch and this tool may slip off of the latch. DANGER The tool described is small and sharp. Care should be taken to cap the tool to prevent personal injury or damage to the tool. 0.93 ±0.05 60° ±3° 12.2 Min for Female Terminals 30.2 Min for Male Terminals DIM “A” 1.10 1.55 R 0.10 TPA Status Present Removed Dim “A” ±0.05 Figure 6 4. QUALIFICATIONS Generation Y 0.64 mm Contacts are SAE/USCAR21 Qualified. This contact is not required to be agency approved. 5. TOOLING (See Figure 7)  Applicators  Rev U 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. Hand Tools Hand crimping tools are designed for prototype, low-volume applications, and repair. 6 of 8 114-13183  Power 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. AMP-O-LECTRIC Model “K” Terminating Machine 565435-[ ] AMP-O-LECTRIC Model “G” Terminating Machine 354500-[ ] PRO-CRIMPER III Hand Tool Assembly 2063291-1 AMPOMATOR CLS IV Lead-Making Machine 217500-[ ] Heavy Duty QuickChange MiniApplicator (Typical) WIRE SIZE mm2 AWG 0.13 --- --- 26 2 x 0.13 --- --- 2 x 26 0.35 --- --- 22 0.35 --- --- 22 0.50 --- --- 20 0.75 --- --- 18 INSUL DIA TERMINAL P/N (Typ)▪ 0.85-1.05 APPLICATOR (DOCUMENT) for POWER UNIT (DOCUMENT) CLS 217500-[ ] (409-5866) MODEL “K” 565435-[ ] (409-5128) MODEL “G” 354500-[ ] (409-5842) 1924955-7 1924968-7 1855452-1 (408-8040) 1855452-2 (408-8040) 1855452-3 (408-8040) 0.85-1.05 1924955-8 1924968-8 1855453-1 (408-8040) 1.10-1.40 1924955-8 1924968-8 1.50-1.85 1924955-3 1924968-3 1385873-1 (408-8040) 1.50-1.85 1924955-3 1924968-3 1385873-1 (408-8040) 1.60-2.06 1924955-4 1924968-4 1852097-1 (408-8040) 2151831-[ ] (408-10389) Preferred† 1855453-2 (408-8040) 1855453-3 (408-8040) 2151832-[ ] (408-10389) Preferred† 2266673-[ ] (408-10389) 1385873-2 (408-8040) 1385873-3 (408-8040) 1385873-3 (408-8040) 2151725-[ ] (408-10389) Preferred† 1852097-2 (408-8040) (408-10227) ------- 2151725-[ ] (408-10389) Preferred† 1385873-2 (408-8040) HAND TOOL 1852097-3 (408-8040) 2151830-[ ] (408-10389) Preferred† 2063291-1 2063291-1 2063291-1 †See applicator drawing for appropriate dash number based on application equipment needs. ▪This typical terminal part number list is for reference only. To ensure you have the proper applicator for the terminal part number, visit the TE Applicator Look-Up Application at the address: http://www.te.com/en/products/application-tooling/applicator-search.html Figure 7 Rev U 7 of 8 114-13183 6. VISUAL AID The illustration below shows a typical application of this product. 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. NOTE: SOCKET CONTACT SHOWN, BLADE CONTACT HAS SAME REQUIREMENTS. WIRE STRANDS AND ILLUSTRATION SHALL BOTH BE VISIBLE IN THIS AREA NO UPCOMING STRANDS NO BURRS ON CUTOFF TAB MATING END NOT DAMAGED OR BENT REAR BELLMOUTH MUST BE VISIBLE MINIMAL FRONT BELLMOUTY MINIMAL WIRE BARREL FLASH FIGURE 8. VISUAL AID Rev U 8 of 8