Japan Aviation Electronics Industry, Ltd.
No.
Connector Division
Title:
JAHL-1594-E
Page 1/13
Rev.
DATE
DCN No.
By
CHKD
APRVD
1
15, Feb.,00
-
J. Miyamoto
M. Shinmyo
T. Totani
2
20,Mar., 00
45765
J. Miyamoto
M. Shinmyo
T. Totani
3
28,Jul., 00
46565
J. Miyamoto
N. Oiri
T. Totani
4
23, Jul., 09
068385
Y. Obata
－
N. Oiri
5
1, Mar., 11
071688
Y. Obata
M. Kuroiwa
N. Oiri
Handling Manual for
MX19 series connector
Handling Manual
Originating Dept.:
Connector Div. 3rd Engineering Dept.
Contents
1. Purpose
2. Applicable Items
3. Crimping
3-1. Applicable Wires
3-2. Stripping length of wire insulators
3-3. Part description
3-4. Criteria for judgment on conforming items
3-5 Criteria for judgment on non-conforming items
3-6 Other cautions for crimping process
4. How to insert
4-1. Contacts
4-2. Dummy Plug
5. How to withdraw contact
6. How to engage/ separate connector
7. Cautionary statement
DCF-C-091C(97.10)
JAE Connector Div. Proprietary.
Copyright © 2000，Japan Aviation Electronics Industry, Ltd.
Japan Aviation Electronics Industry, Ltd.
Connector Division
No.
JAHL-1594-E
Page 2/13
1. Purpose
This document provides the handling on MX19 series connectors.
2. Applicable items
2
3
4
2.1 Housing
Table2-1 MX19 Connector Housing
Terminals No.
Type
Product Name
Pin Housing
2
(Fig.2-1)
Socket Housing
Pin Housing
4
(Fig.2-2)
Socket Housing
MX19002P51
MX19002P52
MX19002S51
MX19002S52
MX19004P51
MX19004P52
MX19004S51
MX19004S52
Color
Black
Gray
Black
Gray
Black
Gray
Black
Gray
2.2 Contacts and Dummy plug
Type
Pin contact
Socket contact
Dummy plug
MX19002P5*
Table2-2 MX19 Contacts and Dummy plug
Product Name
NOTE
MX19P10K451
Sn platting
MX19S10K451
Sn platting
MX19000XD1
Color: Natural White
MX19002S5*
Fig.2-1 MX19 2-terminals type.
Fig.2-3 Pin contact.
DCF-C-091C(97.10)
MX19004P5*
Fig.2-3
Fig.2-4
FIg.2-5
MX19004S5*
Fig.2-2 MX19 4-terminals type.
Fig.2-4 Socket contact.
Fig.2-5 Dummy plug.
JAE Connector Div. Proprietary.
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Page 3/13
3. Crimping
JAE’s applicator is described on the following table.
Table3-1 JAE Crimping Applicator
Automatic Applicator
Semi-automatic Applicator
Type
Product Name
3.1 Applicable Wires
Applicable Wire Type
CAVS0.3mm2
350-MX19-3B
350-MX19-2
5
Table3-2 Applicable Wire for MX19 connector
Conductor construction
Calc. Conductor of
(No./Shape or size)
cross-section [ mm2]
7/ Round Compressed
0.3717
CPTL 22
7/ φ0.13
0.3717
CAVS0.5 mm2
AVSS0.5 mm2
7/ Round Compressed
7/ φ0.13
0.5630
0.5630
Wire Insulator [mm]
φ1.4 ～1.5
φ1.57
(Reference Information)
φ1.6 ～1.7
φ1.6 ～1.7
3.2 Striping length of wire insulators
Check the stripping length of wire insulators( refer to Fig.3-2.) On the wire treatment, must check the
damaged insulator, damaged, missing and/ or disordered conductor (refer to Fig. 3-1.)
Crack
Fail
Cutoff
Short length
Fail
Fail
Disordered
wire strand
Fail
Pass
Fig. 3-1 Defective wire treatment for crimpling.
A
Contact Name
Length A [mm]
MX19P10K451
MX19S10K451
2 ～2.5mm
Wire
Fig. 3-2 Stripping length for MX19 contact crimping
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3.3 Part description
3.3.1 Pin Contact
Bell-mouth
Conductor Barrel
Crimp height
Insulation barrel
Crimp height of wire insulator
Fig.3-3 Part description of pin contact
3.3.2 Socket contact
Bell-mouth
Conductor barrel
Crimp height
Insulation barrel
Crimp height of wire insulator
Fig.3-4 Part description of Socket contact
3.4 Criteria for conformed crimping items △△
3
4
"Properly crimped contact" is as follows:
1. Meet the crimp height shown in Table 3-3.
2. The “Bell-mouth” (no crimping on conductor) is attached.
3. The tip of conductor stick out 0.5mm( or less) from “Conductor Barrel.”
4. All conductor of wire is within the “Conductor Barrel”.
5. Any wire insulator is NOT crimped into “Conductor Barrel.”
6. No cracks and/ or burrs etc. is in crimping area.
Table3-3 Appropriate Crimp Height
Wire Type
Crimp Height [mm]
Crimp wide (Ref.)[mm]
CAVS0.3mm2
CPTL 22
CAVS0.5 mm2
AVSS0.5 mm2
0.73～0.83
0.73～0.83
0.75～0.85
0.75～0.85
1.48～1.54
1.48～1.54
1.52～1.58
1.52～1.58
Crimp height of
wire insulator [mm]
1.6～1.7
1.7～1.9
1.7～1.9
1.7～1.9
NOTE 1: Crimp height dimension is fabricated by JAE's applicator.
NOTE 2: Crimp width/ height and crimp height of wire insulators are reference values only.
DCF-C-091C(97.10)
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3.4 Criteria for judgment on non-conforming items △△
4 5
If a crimped MX19 contact has any following defective item, the crimping work is failure. DON’T use
the failure crimping contact.
Table3-4 Defective Items for Crimping Work
Defective Item
Example
No.
Incomplete wire insertion
1
Not fully inserted conductor(s) into
“Crimp Barrel.”
Wire core
Shortage of wire stripping
2
Inserted the wire
“Crimp Barrel.”
insulator
into
Wire insulator is
in “Crimp Barrel.”
Extrusion wire strand( s)
Conductor(s)
on
of ”Crimp Barrel.
the
OUTSIDE
3
Extrusion of conductor(s)
Failure
treatment
of
5
stripping ( too longer). △
wire
D
Not completely inserted wire insulator
into “Insulation Barrel.”
(Dimension “D” over 0.3mm.)
4
Over inserted( Dimension “E”) the
conductor(s) into Box.
(Dimension “E” over 0.7mm from the
conductor barrel end.)
Incompletely inserted of wire insulation
E
Over inserted of conductor
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No.
JAHL-1594-E
Table3-4 Defective Items for Crimping Work
Defective Item
Example
No.
Inclined Insulator Barrel
5
Page 6/13
X
The incline over 0.3mm at any side.
Bended( On axis)
6
P
The angle “P” over 3 degrees, between
crimping parts axis.
Twisted
7
R
The angle of center of conductor
barrel to insulator barrel center has
over 2.5 degrees.
Burr after cut off
the carrier
8
The burr after the cut off is over
0.2mm.
Burr
Without Bell-mouth
9
Failure of crimpling, “Bell-mouth” is
not formed.
No “Bell-mouth”
Deformed of
Insulator Barrel
10
K
The deformation has the gap between
insulator barrel over 0.3mm.
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JAHL-1594-E
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Table3-4 Defective Items for Crimping Work
Defective Item
Example
Bend up/ down
Y1
No.
No.
“Bend up(or down)” is based on the
crimp barrel area.
a. Bend-up(Pin contact)
Y2
Failure case is dimension Y1 (or Y2)
is over C1( or C2).
Y1( or Y2): Pin contact’s Bend up (or down)
C1( or C2): Socket contact’s Bend up( or down)
b. Bend-down(Pin contact)
Fig. Pin contact
-----------------------------------------------------------------------------
C1
11
C2
a. Bend-up(Socket contact)
b. Bend-down(Socket contact)
Fig. Socket contact
H2
Pin Contact
F3
F1～4 >0.05mm
H1～4 >0.15mm
F4
12
F1
If you find a contact deformation
(H1～4) of following, as shown in right
figures, never use such as a crimped
contact.
Check and adjust( or repair) a
crimpling machine( or a device.)
In the case of a deformation is
within
0.15mm
but
having
dimensions F1～4 over 0.05 on a side,
the crimping work is failed.
H1
F2
End-face deformation
H4
Socket Contact
Deformation of contact rear end
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4. Contact/ Dummy Plug Insertion △△
2 3
4.1 Contact Insertion
1. Visual inspection, the connector has no breakage, deformation, discoloration, and/or damage etc.
2. Aligned the axis and direction between a contact and a cavity.
3. Handling the wire of the near position of contact for not to be occurred bending.
4. Contact insertion is completely done until the terminal locking part sounded.
(Check the terminal insertion by pulling the wire with little force.)
NOTE: If the contact insertion is tight or incapable, DON’T force to insert, check the direction of contact.
Tight( or incapable) insertion will cause a contact deformation, crack and/or disconnection.
Socket housing
Pin Housing
Socket Terminal
Pin contact
Right way
Wrong way
Fig.4-1 Contact insertion
Deformation
Fig.4-2 Example, contact deformation by wrong contact insertion.
DCF-C-091C(97.10)
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4.2 Dummy Plug Insertion △
4
1. Check by visual inspection, the connector has no breakage, deformation, discoloration, and/or damage
etc.
2. Aligned the axis between a dummy plug and a cavity.
3. Inserting a dummy plug into cavity, insertion is the end-face of dummy-plug by connector's.
Acceptance Criteria: Base on the housing end-face, Dummy plug’s end-face is within 0 +0.5/-0.5mm.
NOTE: DON’T apply unnecessary force to on inserting dummy plug.
Dummy Plug
Housing’s end-face
+0.5
-0.5
±0
Fig.4-3 Dummy Plug insertion
a. Absence insertion
b. over insertion
Fig.4-4 Failure dummy plug insertion
DCF-C-091C(97.10)
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5. Contact withdraw
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JAHL-1594-E
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2
△
1. Visual inspection, the connector has no breakage, deformation, discoloration, and/or damage etc.
2. Pushing lightly the wire with crimpling contact and keeping.
3. Inserting a “Withdrawing Tool” into a tool cavity, as following Fig.6-2 and Fig.6-3.
4. When the toe of withdrawing tool met the molding lance, release contact locking. And keeping.
5. Withdrawing the wire on straight axis.
Withdrawing Tool
Pin Housing
Molding Lance
Tool Cavity
Withdrawing Tool
Pin Contact
Fig.5-1 Pin Contact Withdraw
Socket Housing
Molding Lance
Withdrawing Tool
Tool Cavity
Socket Contact
Withdrawing Tool
Fig.5-2 Socket Contact Withdraw
NOTE: Suitable dimension for withdrawing tool( JAE’s withdrawing tool is “ET-MX19.”)
16(MIN)
1.3 ±0.03
0.75 ±0.03
NOTE: DON’T snag a contact on grommet by forcedly withdrawing.
NOTE: The limitation frequency for withdrawing at one cavity is 3 times. If you find any damage and
deformation, DON’T use it, change to the new one.
NOTE: DON’T apply unnecessary force on withdrawing.
NOTE: Withdrawing tool insertion is only a “tool cavity,” never inserting the contact cavity.
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6. How to engage connector
6.1 Engaging
1. Check the contact insertion.
2. Check by visual inspection, the connector has no breakage, deformation, discoloration, and/or damage
etc. in contacts and housing.
3. Aligned the direction with the engagement aperture.
4. Insert the connector into the housing until the lock parts sounded.
NOTE: DON’T apply unnecessary force to connector on inserting/separating connector.
NOTE: If housings insertion is tight or incapable, DON’T force to insert, check the direction of contact.
Tight( or incapable) insertion will cause a connector deformation, crack and/or disconnection.
Locking Part
Lock Lever
Fig.6-1 Connector insertion
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6.2 Connector Separation Method
Hold a Socket Housing, and pull out the connector straightly;
1: Depressing the lock arm of socket housing.
2: Releasing the engagement lock.
NOTE: On separating the connector, DON’T pulling only wires and prying the connector.
NOTE: In case of incapable of separation, DON’T force it to pull out.
Check the engagement lock is released.
NOTE: DON’T apply unnecessary force to connector on inserting/separating connector.
Lock Lever
Fig.6-2 Connector separation
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7. Cautionary Statements
！
△
Caution
Comply strictly with the following matters because of possibility of physical
damage and/or connector failures.
● Perform the engagement of connector straightly until the "click" sound.
● Be careful not to slide and/or pinch your fingers accidentally because some force
may be applied to your fingers at the time of connector insertion/withdrawal.
Moreover, DON’T pull a cable at the time of withdrawal.
● DON’T touch the contact area, or adhere any foreign materials on.
● When withdrawing a contact from the connector, be sure to use an exclusive tool.
● Exercise care to avoid injuring at the time of cable treatment, pre-mounting,
soldering and using other tools.
● Care must be taken to prevent excessive current (over load) as this might be cause
overheating and fire.
● DON’T disassemble each component of housing.
● DON’T insert anything other than the specified contacts to housing.
● For handling on connectors and contacts, comply with the provisions in this
document. Unreasonable handling is not permissible.
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