66261-5 TEC

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i Application Specification © 2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company All Rights Reserved *Trademark 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 8TOOLING 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 LOC B 114-10005 Type XII Contacts 11 JUL 11 Rev L 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 XII Male and Female Contacts. These contacts have a wire size range of 10 through 16 AWG with an insulation diameter range of 3.43 to 5.59 mm [.135 to .220 in.]. Type XII Contacts are terminated with hand held tooling or automatic machines, and are used in various types of connector housings designed with power circuit cavities. When corresponding with company personnel, use the terminolog y provided in this specification to facilitate your inquiries for information. Basic terms and features of this product are provided in Figure 1. Female Male Cutoff TabSerrated  Wire Barrel Contact Assist  Spring Contact  Body Insulation Barrel Cutoff Tab Contact  Latch Serrated  Wire Barrel Insulation Barrel Contact  Body Contact  Latch Figure 1 2. REFERENCE MATERIAL 2.1. Revision Summary Since the revious release of this document, the new company logo was applied. 2.2. Customer Assistance Reference Part Number 66741 and Product Code 5016 are representative numbers of Type XII Contacts. Use of these numbers will identify the product line and expedite your inquiries through a service network established to help you obtain product and tooling information. Such information can be obtained through a local company representative or, after purchase, by calling the TOOLING ASSISTANCE CENTER or PRODUCT INFORMATION number at the bottom of this page. 2.3. Drawings Customer Drawings for specific products are available from this service network. The information contained in customer drawings takes priority if there is a conflict with this specification or with any other technical documentation supplied by the company.

2.4. Product Specifications Product Specification 108-10037 provides product performance requirements and test information. 2.5. Instructional Specifications The following list includes available instruction sheets (408-series secifications) that provide assembly  procedures for operation, maintena nce and repair of tooling; and customer manuals (409-series  specifications) that provide setup, op eration, and maintenance of machines. A variety of documents for  Type XII Contacts are available. Call the PRODUCT INFORMA TION number or TOOLING ASSISTANCE CENTER number at the bottom of page 1. 408-2095 Hand Crimping Tool 69710-1 408-3295 Preparing Reel of Contacts for Applicator Tooling 408-4190 C-Head Pneumatic Adapter 318161-[ ] 408-4321 Pneumatic CERTI-CRIMP* Tool Holder 356304-1 408-7175 Crimping Die Assemblies 90140-1, 90140-2, 90145-1, and 90145-2 408-7276 Extraction Tool 91019-3 for Type XII Contacts 408-7424 Checking Contact Crimp Height 408-8040 Heavy Duty Miniature Quick-Change Applicators (Side-Feed Type) 408-8053 Miniature (Mini) and Quick-Change Applicators 408-8059 General Preventative Maintenance for Applicators 408-9816 Handling of Reeled Products 409-5128 AMP-O-LECTRIC* Model "K" Terminating Machine 1-471273-3 409-5862 626 Pneumatic Tooling Assemblies 189721-[ ] and 189722-[ ] 3. REQUIREMENTS 3.1. Storage The contacts should remain in the shipping containers until ready for use to prevent deformation of the contact. The contacts should be used on a first in, first out basis to avoid storage contamination that could adversely affect current transmission. These contacts have a shelf life of two years from date of manufacture. CAUTION Extra protection should be given to silver plated contacts to minimize tarnishing when exposed to the environment. When loose piece or reeled silver plated contacts are not in use, they should be stored in a plastic bag or other sealed container. 3.2. Wire Selection and Preparation A. Wire Type The contacts will accept copper fused-stranded or stranded conductor wire within the range of 10 through  16 AWG. B. Preparation The wire must be stripped to the dimension provided in Figure 2. WIRE SIZE (AWG) STRIP LENGTH ±0.79 [±.031] 10 8.33 [.328] 16-12 7.14 [.28] Strip Length Conductors Insulation Note: Not to Scale Figure 2

Do not nick, scrape, or cut the wire conductor during the stripping operation. 3.3. Chemical Exposure Do not store contacts near any chemicals listed below as they may cause stress corrosion cracking in the contacts. Alkalies Ammonia Citrates Phosphates Citrates Sulfur Compounds  Amines Carbonates Nitrites Sulfur Nitrites Tartrates 3.4. Cutoff Tab Cutoff tabs are the remaining portion of the carrier strip after the contact is cut from the strip. The following dimensional requirements will ensure proper application for these contacts. 1. The cutoff tab must not exceed the dimension shown in Figure 3. 2. The burr resulting from the cutoff tab shearing must not exceed the dimension shown in Figure 3. 3.5. Terminating Select the contact to be crimped for the wire size being used. Crimp the contact according to the instructions packaged with that tooling (refer to Section 5, TOOLING). 3.6. Crimped Contact Requirements A. 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 the table in Figure 2. Effective crimp length is defin ed as that portion of the wire barrel, excluding bellmouth(s), fully formed by the crim ping tool. Instructions for adjusting, repairing, and inspecting tools are packaged with the tools. CAUTION Each crimp dimension represents the functional range of a wire/contact combination. There are tool designs available to meet various application requirements. The developed crimp conf iguration is unique for each tool design and is acceptable provided the crimp height is within the functional range. For crimp dimensions of a specific tool, refer to instruction sheet packaged with manual tools and applicator log packaged with power tools. B. Wire Conductor Location After crimping, the end of the wire conductor must be flush with or extend 1.27 mm [.050 in.] from the front end of the contact wire barrel. Both the insulation and the conductor must be visible between the insulation barrel and wire barrel. Care must be taken not to allow the wire insulation to be crimped in the wire barrel. Refer to Figure 3. C. Contact Assist Spring The contact assist spring on female contacts must be straight and not deformed. D. Wire Barrel Seam The seam between the two sides of the wire barrel must be completely closed and there must be no evi - dence of loose wire strands or wire strands visible in the seam. E. Wire Barrel Flash Wire barrel flash is the formation that may appear on both sides of the wire barrel as the result of the crimp- ing process. It must not exceed the dimension provided in Figure 3. F. Wire Barrel and Insulation Barrel Crimp NOTE i The crimp applied to the wire barrel and insulation barrel of the contact is the most compressed area and is most critical in ensuring optimum electrical and mechanical performan ce of the crimped contact. The contact wire barrel and insulation barrel height and width must be within the dimensions provided in Figure 3.

G. Bellmouths Crimped Female Contact Contact Assist Spring Insulation Barrel Wire Barrel Seam Both Wire and Insulation Must Be Visible in Transition Area Wire Conductor  Location 1.27 [.050] (Max) Effective Crimp Length Rear Bellmouth Front Bellmouth 0.51 [.020] (Max) Burr Area 0.25 [.010] Crimp Width  (See Table) Wire Barrel Flash 0.25 [.010] (Max) Cutoff Tab 0.63 [.025] (Max) Front Bellmouth Crimped Male Contact Crimp Width  (See Table) Crimp Width  (See Table) Rear Bellmouth Figure 3 WIRE CONTACT SIZ E (AWG) INSULATION DIAMETER WIRE BARREL CRIM INSULATION BARREL CRIMP (Ref) HEIGHT WIDTH WIDTH

Assembly (See Table) Handle Assembly 69710-1 Power Unit Manual -- 189721-2 Foot Actuated -- 189722-2 Tool Holder Assembly Without Ratchet -- 189928-1 With Ratchet -- 356304-1 C-Head Adapter 318161-1 Miniature Quick Change Applicator 722762-2 AMP-O-LECTRIC Power Unit 1-471273-3

626 Pneumatic Tool System

(AWG) TOOLING (DOCUMENT) CRIMPING DIE ASSEMBLY (408-7175) HAND TOOL FRAME (408-2095) APPLICATOR (408-8040) POWER UNIT (409-5128)

626 PNEUMATIC

(408-7276) 10 90140-1 90140-2 69710-1 722762-2 1-471273-3 See Above 91019-316-14 90145-2 14-12 90145-1