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114-2025
2. REFERENCE MATERIAL
2.1. Revision Summary
Revisions to this application specification include:
•
Added text to Paragraph 3.4,B and illustration to Figure 2
2.2. Customer Assistance
Reference Product Base Part Number 480003 and Product Code 1108 are representative of .110, .187, .250,
.312, and .375 Series FASTIN-FASTON housings and 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
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 page 1.
2.3. Drawings
Customer Drawings for product part numbers are available from the service network. 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. Specifications
Product Specification 108-2002 provides product performance and test results for .187 Series FASTIN-FASTON
connectors.
2.5. Instructional Material
Instruction Sheets (408-series) provide product assembly instructions or tooling setup and operation procedures
and Customer Manuals (409-series) provide machine setup and operating procedures. Documents available
that pertain to this product are:
408-3295
408-4138
408-7424
408-7432
408-8039
408-8053
408-9580
408-9816
409-5866
409-5870
409-5842
Preparing Reel of Contacts for Application Tooling
Double Action Hand Tool 189508-1
Checking Terminal Crimp Height or Gaging Die Closure
Force Gage 92-100505 for Testing Terminals
Heavy Duty Quick Change Applicators (End Feed Type)
Conversion guide for Miniature Quick-Change Applicators
Extraction Tip 465665-1 for Use with Universal Handle Assembly 465629-1
Handling of Reeled Products
AMPOMATOR* CLS IV Lead-Making Machine
Crimp Quality Monitors for AMPOMATOR CLS IV Lead-Making Machines
AMP-O-LECTRIC*
Model “G”
Terminating Machines 354500-[ ]
3. REQUIREMENTS
3.1. Temperature
The temperature rating of these housings is up to 125°C [256°F] to permit use in applications of relatively high
temperatures.
3.2. Storage
A. Ultraviolet Light
Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the housing material.
B. Reel Storage
When using reeled contacts, store coil wound reels horizontally and traverse wound reels vertically.
C. Shelf Life
The contacts should remain in the shipping containers until ready for use to prevent deformation to the
contact. The contacts should be used on a first in, first out basis to avoid storage contamination that could
adversely affect signal transmissions.
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114-2025
D. Chemical Exposure
Do not store contacts near any chemicals listed below as they may cause stress corrosion cracking in the
contacts.
Alkalies
Amines
Ammonia
Carbonates
Citrates
Nitrites
Phosphates Citrates
Sulfur Nitrites
Sulfur Compounds
Tartrates
i
NOTE
Where the above environmental conditions exist, phosphor-bronze contacts are recommended instead of brass.
3.3. Wire Selection and Preparation
The contacts accept stranded wire size range of 26 through 8 AWG. The acceptable insulation diameter of each
contact is given in the applicator sheet.
Proper strip length is necessary to properly insert the wire into the contact. An illustration of this is shown in
Figure 2. The strip length of the wire is given in the applicator sheet. A list of applicators is given in Figure 8.
!
!
CAUTION
The wire conductor must not be nicked, scraped, or cut during the stripping operation.
3.4. Crimp Requirements
CAUTION
Wire insulation shall NOT be cut or broken during the crimping operation. Reasonable care should be taken by tooling
operators to provide undamaged wire terminations.
A. Wire Barrel Crimp
The crimp applied to the wire barrel of the contact is the most compressed area and is most critical in
ensuring optimum electrical and mechanical performance of the contact. The crimp height and width must
be within the dimensions provided in the applicator sheet.
B. Insulation Barrel Crimp
The crimp applied to the insulation barrel of the contact must result in either an “F” crimp where the
insulation barrel forms a closed seam with no evidence of wire insulation in the seam or an overlap crimp
where the tips of the insulation barrel wraps overlap each other and wrap firmly around the wire insulation
without cutting into the wire insulation. Alternatively, for wires having a reduced insulation thickness, a scroll
crimp is acceptable where each tip of the insulation barrel wraps inward to form a curl that touches the wire
insulation. The wire must be centered within the crimped insulation barrel. Refer to Figure 2.
C. Crimp Length
Effective crimp length is defined as that portion of the wire barrel, excluding the bellmouths, fully formed by
the crimping tool. Refer to Figure 2 and the applicator sheet.
D. Bellmouths
Front and rear bellmouths shall be evident and conform to the dimensions given in Figure 2. Both front and
rear bellmouths dimension is required to be 0.5mm to 0.76mm for special terminal 160928-* crimping.
E. Cutoff Tab and Burr
The cutoff tab shall be cut to and the cutoff burr shall not exceed the dimensions given in Figure 2.
F. Wire Barrel Flash
The wire barrel flash shall not exceed the dimension given in Figure 2.
G. Wire Location
The wire conductors and insulation must be visible in the transition area (the area between the wire barrel
and insulation barrel). The conductors may extend beyond the wire barrel to the maximum dimension given
in Figure 2.
H. Wire Barrel Seam
The wire barrel seam must be closed with no evidence of loose wire strands visible in the seam.
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Note:
Not to Scale
Wire Strip Length
(Ref)
Insulation
Note:
Receptacle contact shown, same
requirements apply to tab contact.
Conductors
0.76 [.030] Max
Conductor Extends
Wire Conductors and Insulation
Both Visible in Transition Area
No Damage to
Mating End
Wire Barrel Seam Closed
with No Loose Strands
Section X-X
Wire Barrel
Crimp Width
(Ref)
Wire Barrel
Crimp Height
(Ref)
0.00-0.38 [.000-.015]
Front Bellmouth
X
Insulation Barrel Seam Closed
with No Wire Insulation in Seam
(“F” Crimp Shown, Refer to
Table)
0.38-0.76 [.015-.030]
Rear Bellmouth
Insulation Barrel
Crimp Width (Ref)
Detail A
0.13 [.005]
Max Burr
X
0.25 [.010] Max
Wire Barrel Flash
Effective Crimp Length
(Ref)
See Detail A
0.00-0.38 [.000-.015]
Cutoff Tab
INSULATION BARREL CRIMP
TYPE
QUALITY
CORRECT
TOO LOOSE
TOO TIGHT
“F”
Overlap
Scroll
Figure 2
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I. Twist and Roll
There shall be no deformation or other damage to the crimped wire barrel or mating portion of the crimped
contact that will prevent proper mating. Twist and roll is permissible to the limit given in Figure 3.
Mating End of Contact
15° Max Twist and Roll
Crimped Wire Barrel
Datum Line
Figure 3
J. 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 following limits.
Up and down
—
the crimped contact, including cutoff tab and burr, shall not be bent beyond the limitations
given in Figure 4.
Side-to-side
—
side-to-side bending of the contact may not exceed the limits provided in Figure 4.
NOTE
Periodic inspections must be made to ensure crimped contact formation is consistent.
Up and Down Alignment
3° Max
i
Datum Line
3° Max
Side-to-Side Alignment
3° Max
Datum Line
3° Max
Figure 4
3.5. Tensile Inspection
Crimped contacts should hold the wire firmly and have a pull-test tensile value meeting the values given in Figure 5.
NOTE
The head travel of the tensile testing machine must be adjusted to 25.4 [1.0] per minute. Force must be directly and gradually
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