Application Specification
Type III+ (Size 16) Contacts
18 MAR 15
Rev M
114-10004
NOTE
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 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 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.
Insulation Grip Contacts
Wire Barrel
Insulation Barrel
Color Dot
(Loose Piece Only)
Socket
Pin
Wire Barrel
Insulation Barrel
Locking Lance
Posted Socket
Solder Tab Pin
Solder Type Socket
Figure 1
2. REFERENCE MATERIAL
2.1. Revision Summary
Updated document to corporate requirements
Changed information in Paragraph 2.6, and tables in Figures 2 and 6
2.2. Customer Assistance
Reference Product Base Part Number 66098 and Product Code 5022 are representative of the Type III+
(Size 16) 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.
© 2015 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.
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TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners.
114-10004
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. Manuals
Manual
402-40
can be used as a guide to soldering. This manual provides information on various flux types
and characteristics 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 and test results.
2.6. Instructional Material
Instruction sheets (408-series) provide product assembly instructions or tool setup and operation procedures.
Instruction sheets available that pertain to this product are:
Document Number
408-1216
408-1379
408-3295
408-7347
408-7424
408-8039
408-8040
408-8059
408-8547
408-9640
408-9816
408-10389
409-5870
409-10012
409-32034
409-32035
Document Title
Extraction Tools 305183-[ ]
Selection Charts for Multimate Pin and Socket Contacts
Preparing Reel of Contacts for Application Tooling
Insertion Tools 91002-[ ]
Checking Terminal Crimp Height or Gaging Die Closure
Heavy Duty Miniature Quick-Change Applicators (End-Feed Type)
Heavy Duty Miniature Quick-Change Applicators (Side-Feed Type)
General Preventive Maintenance for Applicators
CERTI-CRIMP* II Straight action Hand Tools
Crimp Quality Monitor Applicators for Side-Feed and End-Feed Applications
Handling of Reeled Products
Ocean Side-Feed Applicators
Crimp Quality Monitors (CQM) for AMPOMATOR* CLS IV Lead-Making Machines
AMP-O-MATIC* Side Feed Stripper-Crimper III Machine 1320895-[ ]
AMP 3K* Terminating Machine 1725950-[ ] and AMP 5K Terminating Machine
1725900-[
AMP-O-LECTRIC Model G II Terminator 2217000-[ ]
3. REQUIREMENTS
3.1. Storage
A. Ultraviolet Light
Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the product
material.
B. 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.
C. Reel Storage
When using reeled contacts, store coil wound reels horizontally and traverse wound reels vertically.
Rev
M
2
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114-10004
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
NOTE
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.
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.
CAUTION
DO NOT nick, scrape, or cut the wire conductor during the stripping operation.
Strip Length
4.34-3.58
[.171-.141]
Conductor
WIRE SIZE
(AWG)
30-26
26
INSULATION
DIAMETER
0.36-0.76 [.014-.030]
1.02-1.52 [.040-.060]
0.89-1.40 [.035-.055]
2.03-2.54 [.080-.100]
24
1.52-3.43 [.060-.135]
1.02-2.03 [.040-.080]
0.89-1.40 [.035-.055]
2 (24)
1.52-3.43 [.060-.135]
1.02-2.03 [.040-.080]
1.02-2.03 [.040-.080]
22
1.52-3.43 [.060-.135]
1.02-2.03 [.040-.080]
Insulation
WIRE BARREL CRIMP
HEIGHT
1.05-0.89 [.0415-.035]
1.05-0.89 [.0415-.035]
0.84-0.74 [.033-.029]
1.04-0.86 [.041-.034]
0.97-0.76 [.038-.030]
1.05-0.86 [.0415-.034]
0.89-0.74 [.035-.029]
1.07-0.86 [.042-.034]
1.07-0.97 [.042-.038]
1.04-0.91 [.041-.036]
1.02-0.81 [.040-.032]
1.05-0.91 [.0415-.036]
Figure 2 (cont’d)
WIDTH
1.75-1.57 [.069-.062]
1.75-1.57 [.069-.062]
1.57-1.40 [.062-.055]
1.75-1.57 [.069-.062]
1.75-1.57 [.069-.062]
1.75-1.57 [.069-.062]
1.57-1.40 [.062-.055]
1.75-1.57 [.069-.062]
1.75-1.57 [.069-.062]
1.75-1.57 [.069-.062]
1.75-1.57 [.069-.062]
1.75-1.57 [.069-.062]
INSULATION BARREL
CRIMP WIDTH
1.60-1.20 [.063-.047]
1.98-1.58 [.078-.062]
1.98-1.58 [.078-.062]
3.25-2.85 [.128-.112]
3.25-2.85 [.128-.112]
2.49-2.09 [.098-.082]
1.98-1.58 [.078-.062]
3.25-2.84 [.128-.112]
2.49-2.09 [.098-.082]
3.25-2.85 [.128-.112]
3.25-2.84 [.128-.112]
2.49-2.09 [.098-.082]
Rev
M
3
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114-10004
WIRE SIZE
(AWG)
INSULATION
DIAMETER
2.03-2.54 [.080-.100]
20
1.52-3.43 [.060-.135]
1.02-2.03 [.040-.080]
18
16
14
1 mm
2
0.75 mm
2
2.79-3.81 [.110-.150]
2.03-2.54 [.080-.100]
2.79-3.81 [.110-.150]
2.03-2.54 [.080-.100]
2.79-3.81 [.110-.150]
2.03-2.54 [.080-.100]
1.45-1.80 [.057-.071]
1.35-1.65 [.053-.065]
WIRE BARREL CRIMP
HEIGHT
1.12-0.94 [.044-.037]
1.12-0.91 [.044-.036]
1.12-0.95 [.044-.0375]
1.37-1.24 [.054-.049]
1.35-1.24 [.053-.049]
1.55-1.24 [.061-.049]
1.47-1.24 [.058-.049]
1.78-1.68 [.070-.066]
1.78-1.68 [.070-.066]
1.35-1.24 [.053-.049]
1.27-1.17 [.050-.046]
Figure 2 (end)
WIDTH
1.75-1.57 [.069-.062]
1.75-1.57 [.069-.062]
1.75-1.57 [.069-.062]
2.46-2.29 [.097-.090]
2.20-2.03 [.087-.080]
2.46-2.29 [.097-.090]
2.20-2.03 [.087-.080]
2.46-2.29 [.097-.090]
2.46-2.29 [.097-.090]
2.20-2.03 [.087-.080]
2.20-2.03 [.087-.080]
INSULATION BARREL
CRIMP WIDTH
3.25-2.85 [.128-.112]
3.25-2.84 [.128-.112]
2.49-2.09 [.098-.082]
4.16-3.76 [.163-.147]
3.25-2.85 [.128-.112]
4.16-3.76 [.163-.147]
3.25-2.85 [.128-.112]
4.16-3.76 [.163-.147]
3.25-2.85 [.128-.112]
3.25-2.85 [.128-.112]
3.25-2.85 [.128-.112]
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.
CAUTION
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.
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Rev
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114-10004
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.
J. Wire Barrel Seam
The wire barrel seam must be closed with no evidence of loose wire strands visible in the seam.
NOTE
Periodic inspections must be made to ensure crimped contact formation is consistent as referenced.
Wire Conductors and
Insulation Must Both be
Visible in This Area
0.81 [.032] Max
Conductor Location
Insulation Barrel
Crimp Width
Wire Barrel Seam Closed
with No Conductor
Strands Showing
Locking Lance Undamaged
Crimp Length
0.20-0.64 [.008-.025]
Rear Bellmouth
X
0.51 [.020] Max Front Bellmouth
X
0.25 [.010]
Max Wire
Barrel Flash
Cutoff Tab
0.25 [.010]
Max
Wire Barrel
Crimp Width
Wire Barrel
Crimp Height
0.08 [.003]
Max Burr
Figure 3
Section X-X
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.
Rev
M
5
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