Application Specification 114-- 2025 FASTIN- FASTON* Tabs, Receptacles, and Housings NOTE i 13 AUG 09 Rev C 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 the application of FASTIN--FASTON Tabs, Receptacles, and Housings. The connectors are designed to accept a wire size range of 26--8 AWG. These contacts are used in housings to make simultaneous and quick matings of up to eleven separate circuits. Some housings offer a panel mount option, see Paragraph 3.6. Application may be done by hand for replacement loose piece contacts and/or machine reel--mounted contacts. When corresponding with Tyco Electronics Personnel, use the terminology provided on this specification to help facilitate your inquiry for information. Basic terms and features of components are provided in Figure 1. Tab Receptacle Polarization Feature Receptacle Housing (Six Circuit) Typical Tab Housing (Six Circuit) Typical Figure 1 2. REFERENCE MATERIAL 2.1. Revision Summary This paragraph is reserved for a revision summary of the most recent additions and changes made to this specification which include the following: S Updated document to corporate requirements S Changed UL file listing in Section 4, QUALIFICATIONS 2.2. Customer Assistance Reference Part Number 480003 and Product Code 1108 are representative numbers of FASTIN--FASTON Tabs, Receptacles, and Housings. 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 Tyco Electronics Representative or, after purchase, by calling the Tooling Assistance Center or the Product Information Center number at the bottom of this page. 2.3. Drawings Customer Drawings for specific products are available from the service network. The information contained in Customer Drawings takes priority if there is a conflict with this specification or with any technical documentation supplied by Tyco Electronics. TOOLING ASSISTANCE CENTER 1-- 800-- 722-- 1111 E2009 Tyco Electronics Corporation, Harrisburg, PA PRODUCT INFORMATION 1-- 800-- 522-- 6752 All International Rights Reserved TE logo and Tyco Electronics are trademarks. *Trademark. Other products, logos, and company names used are the property of their respective owners. This controlled document is subject to change. For latest revision and Regional Customer Service, visit our website at www.tycoelectronics.com 1 of 13 LOC B FASTIN- FASTON Tabs, Receptacles, and Housings 114- 2025 2.4. Product Specifications Product Specification 108--2002 provides test and performance requirements for 4.75 mm [.187 in.] FASTIN--FASTON Series Modular Connectors. 2.5. Instructional Material The following list includes available instruction sheets (408--series) that provide assembly procedures for product, operation, maintenance and repair of tooling, as well as setup and operation procedures of applicators; and customer manuals (409--series) that provides setup, operation, and maintenance of machines. Document Number Document Title 408--3295 408--4138 408--7424 408--7432 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 FASTON*, FASTIN--FASTON, PIDG*, and Ultra--Fast 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 Machine 354500--[ ] 408--8039 408--8053 408--9580 408--9816 409--5866 409--5870 409--5842 3. REQUIREMENTS 3.1. 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. D. Chemical Exposure Do not store contacts near any chemicals listed below as they may cause stress corrosion cracking in the contacts. Alkalies Amines NOTE Ammonia Carbonates Citrates Nitrites Phosphates Citrates Sulfides Nitrites Sulfur Compounds Tartrates Where the above environmental conditions exist, phosphor--bronze contacts are recommended instead of brass. i 3.2. Special Characteristics FASTIN--FASTON Connectors are the multiple circuit connector version of the FASTON* Connector product. They are used primarily as harness connectors. This specification only provides information on housings and contact receptacles accepting tab widths of 9.52 mm [.375 in.], 7.92 mm [.312 in.], 6.35 mm [.250 in.], 4.75 mm [.187 in.], and 2.79 mm [.110 in.]. See Figure 2. 2 of 13 Tyco Electronics Corporation Rev C FASTIN- FASTON Tabs, Receptacles, and Housings 114- 2025 Series Designator Dimension FASTIN-- FASTON Housings Figure 2 3.3. Wire Selection and Preparation A. Type The wire size range for FASTIN--FASTON Tabs and Receptacles is 26 through 8 AWG. B. Preparation The wire must be stripped to the dimension provided in Figure 3. CAUTION Do not nick, scrape, or cut the wire conductor during the stripping operation. ! The table in Figure 3 also provides insulation strip lengths as determined by the size contact used. Also listed are acceptable wire insulation outside diameters for the contacts. Strip Length Wire Insulation WIRE SIZE AWG INSULATION DIAMETER NOTE: Not to Scale STRIP LENGTH WIRE BARREL CRIMP WIDTH CRIMP HEIGHT INSUL BARREL CRIMP WIDTH 9.52 [.375] SERIES 12 10 8 3.81--5.08 [.150--.200] 6.35--6.86 [.250--.270] 4.52--4.62 [.178--.182] 2.34--2.44 [.092--.096] 5.54--5.64 [.218--.222] 3.81--5.08 [.150--.200] 6.35--6.86 [.250--.270] 4.52--4.62 [.178--.182] 2.59--2.69 [.102--.106] 5.54--5.64 [.218--.222] 5.08--6.98 [.200--.275] 6.35--6.86 [.250--.270] 6.3--6.4 [.248--.252] 2.31--2.41 [.091--.095] 8.08--8.18 [.318--.322] 5.08--6.98 [.200--.275] 6.35--6.86 [.250--.270] 6.3--6.4 [.248--.252] 2.72--2.82 [.107--.111] 8.08--8.18 [.318--.322] Figure 3 (cont'd) Rev C Tyco Electronics Corporation 3 of 13 FASTIN- FASTON Tabs, Receptacles, and Housings WIRE SIZE AWG INSULATION DIAMETER STRIP LENGTH 16 4.06 [.160] Max. 4.06 [.160] Max. 4.06 [.160] Max. 4.06 [.160] Max. 5.21--5.72 [.205--.225] 5.21--5.72 [.205--.225] 5.72--6.22 [.225--.245] 5.21--5.72 [.205--.245] 1.52--3.18 [.060--.125] 1.52--3.18 [.060--.125] 4.83--5.33 [.190--.210] 4.83--5.33 [.190--.210] 1.52--3.18 [.060--.125] 4.83--5.33 [.190--.210] 1.52--2.54 [.060--.100] (2) 16 14 or (16 & 18) 12 26 24 22 20 18 114- 2025 WIRE BARREL CRIMP HEIGHT INSUL BARREL CRIMP WIDTH 1.7--1.8 [.067--.071] 2.08--2.18 [.082--.086] 1.93--2.03 [.076--.080] 2.29--2.39 [.090--.094] 6.3--6.4 [.248--.252] 6.3--6.4 [.248--.252] 6.3--6.4 [.248--.252] 6.3--6.4 [.248--.252] 0.81--0.91 [.032--.036] 0.86--0.97 [.034--.038] 3.51--3.56 [.138--.140] 3.51--3.56 [.138--.140] 1.35--1.45 [.053--.057] 0.94--1.04 [.037--.041] 3.51--3.56 [.138--.140] 5.82--6.07 [.229--.239] 2.24--2.34 [.088--.092] 1.17--1.27 [.046--.050] 3.5--3.61 [.138--.142] 1.52--2.54 [.060--.100] 5.44--5.69 [.214--.224] 2.24--2.34 [.088--.092] 1.02--1.12 [.040--.044] 2.49--2.59 [.098--.102] 2.16--3.18 [.085--.125] 5.82--6.07 [.229--.239] 2.24--2.34 [.088--.092] 1.17--1.27 [.046--.050] 3.5--3.61 [.138--.142] 2.16--3.18 [.085--.125] 5.41--5.66 [.213--.223] 2.24--2.34 [.088--.092] 1.02--1.12 [.040--.044] 3.5--3.61 [.138--.142] 1.52--2.54 [.060--.100] 6.22--6.48 [.245--.255] 2.24--2.34 [.088--.092] 1.22--1.32 [.048--.052] 2.49--2.59 [.098--.102] 1.52--2.54 [.060--.100] 5.82--6.07 [.229--.239] 2.24--2.34 [.088--.092] 1.07--1.17 [.042--.046] 2.49--2.59 [.098--.102] 2.16--3.18 [.085--.125] 6.22--6.48 [.245--.255] 2.24--2.34 [.088--.092] 1.22--1.32 [.048--.052] 3.5--3.61 [.138--.142] 2.16--3.18 [.085--.125] 5.82--6.07 [.229--.239] 2.24--2.34 [.088--.092] 1.07--1.17 [.042--.046] 3.5--3.61 [.138--.142] 3.05--4.32 [.120--.170] 3.05--4.06 [.120--.160] 6.23--6.48 [.245--.255] 5.41--5.66 [.213--.223] 2.74--2.84 [.108--.112] 2.74--2.84 [.108--.112] 1.5--1.6 [.059--.063] 1.5--1.6 [.059--.063] 4.01--4.11 [.158--.162] 4.01--4.11 [.158--.162] 3.05--3.68 [.120--.145] 5.41--5.66 [.213--.223] 2.74--2.84 [.108--.112] 1.5--1.6 [.059--.063] 4.01--4.11 [.158--.162] 2.54--4.42 [.100--.170] 5.41--5.66 [.213--.223] 2.74--2.84 [.108--.112] 1.37--1.42 [.054--.058] 4.52--4.62 [.178--.182] 2.54--4.42 [.100--.170] 5.41--5.66 [.213--.223] 2.74--2.84 [.108--.112] 1.47--1.57 [.058--.062] 4.01--4.11 [.158--.162] 2.16--3.18 [.085--.125] 6.22--6.48 [.245--.255] 2.24--2.34 [.088--.092] 1.35--1.45 [.053--.057] 3.5--3.61 [.138--.142] 2.16--3.18 [.085--.125] 5.82--6.07 [.229--.239] 2.24--2.34 [.088--.092] 1.17--1.27 [.046--.050] 3.5--3.61 [.138--.142] 1.52--2.54 [.060--.100] 6.22--6.48 [.245--.255] 2.24--2.34 [.088--.092] 1.35--1.45 [.053--.057] 2.49--2.59 [.098--.102] 1.52--2.54 [.060--.100] 5.82--6.07 [.229--.239] 2.24--2.34 [.088--.092] 1.17--1.27 [.046--.050] 2.49--2.59 [.098--.102] 2.2--4.44 [.090--.175] 5.1--6.1 [.200--.240] 2.74--2.84 [.108--.112] 1.42--1.52 [.056--.060] 4.52--4.62 [.178--.182] CRIMP WIDTH 7.92 [.312] SERIES 2.74--2.84 [.108--.112] 2.74--2.84 [.108--.112] 2.74--2.84 [.108--.112] 2.74--2.84 [.108--.112] 6.35 [.250] SERIES 1.35--1.45 [.053--.057] 1.35--1.45 [.053--.057] Figure 3 (cont'd) 4 of 13 Tyco Electronics Corporation Rev C FASTIN- FASTON Tabs, Receptacles, and Housings WIRE SIZE RANGE RANGE, AWG INSULATION DIAMETER STRIP LENGTH 114- 2025 WIRE BARREL CRIMP WIDTH CRIMP HEIGHT INSULATION BARREL CRIMP WIDTH 6.35 [.250] SERIES 16 14 12 10 4.06--5.33 [.160--.210] 5.82--6.07 [.229--.239] 3.0--3.1 [.118--.122] 1.5--1.83 [.059--.072] 6.3--6.4 [.248--.252] 3.81--4.83 [.150--.190] 5.82--6.07 [.229--.239] 3.0--3.1 [.118--.122] 1.73--1.83 [.068--.072] 5.28--5.38 [.208--.212] 3.3 [.130] Max. (2 Wires) 5.82--6.07 [.229--.239] 3.0--3.1 [.118--.122] 1.85--2.18 [.073--.086] 6.3--6.4 [.248--.252] 3.05--4.32 [.120--.170] 6.22--6.48 [.245--.255] 2.74--2.84 [.108--.112] 1.65--1.75 [.065--.069] 4.01--4.11 [.158--.162] 3.05--4.06 [.120--.160] 5.41--5.66 [.213--.223] 2.74--2.84 [.108--.112] 1.65--1.75 [.065--.069] 4.01--4.11 [.158--.162] 3.05--3.68 [.120--.145] 5.41--5.66 [.213--.223] 2.74--2.84 [.108--.112] 1.65--1.75 [.065--.069] 4.01--4.11 [.158--.162] 2.54--4.32 [.100--.170] 5.41--5.66 [.213--.223] 2.74--2.84 [.108--.112] 1.32--1.42 [.052--.056] 4.52--4.62 [.178--.182] 2.54--4.32 [.100--.170] 5.41--5.66 [.213--.223] 2.74--2.84 [.108--.112] 1.6--1.7 [.063--.067] 4.01--4.11 [.158--.162] 2.2--4.44 [.090--.175] 5.1--6.1 [.200--.240] 2.74--2.84 [.108--.112] 1.57--1.68 [.062--.066] 4.52--4.62 [.178--.182] 4.06--5.33 [.160--.210] 6.22--6.48 [.245--.255] 3.0--3.1 [.118--.122] 1.7--2.03 [.067--.080] 6.3--6.4 [.248--.252] 3.81--4.83 [.150--.190] 6.22--6.48 [.245--.255] 3.0--3.1 [.118--.122] 1.93--2.03 [.076--.080] 5.28--5.38 [.208--.212] 3.05--4.32 [.120--.170] 7.01--7.26 [.276--.286] 2.74--2.84 [.108--.112] 1.88--1.98 [.074--.078] 4.01--4.11 [.158--.162] 3.05--4.32 [.120--.170] 6.60--6.86 [.260--.270] 3.25--3.35 [.128--.132] 1.78--1.88 [.070--.074] 4.52--4.62 [.178--.182] 3.05--4.06 [.120--.160] 5.82--6.07 [.229--.239] 2.74--2.84 [.108--.112] 1.88--1.98 [.074--.078] 4.01--4.62 [.158--.182] 3.05--3.68 [.120--.145] 5.82--6.07 [.229--.239] 2.74--2.84 [.108--.112] 1.88--1.98 [.074--.078] 4.01--4.11 [.158--.162] 2.54--4.32 [.100--.170] 5.82--6.07 [.229--.239] 2.74--2.84 [.108--.112] 1.55--1.65 [.061--.065] 4.52--4.62 [.178--.182] 2.54--4.32 [.100--.170] 5.82--6.07 [.229--.239] 2.74--2.84 [.108--.112] 1.83--1.93 [.072--.076] 4.01--4.11 [.158--.162] 2.2--4.44 [.090--.175] 5.1--6.1 [.020--.240] 2.74--2.84 [.108--.112] 1.8--1.9 [.071--.075] 4.52--4.62 [.178--.182] 4.06--5.33 [.160--.210] 6.22--6.48 [.245--.255] 3.0--3.1 [.118--.122] 2.03--2.36 [.080--.093] 6.3--6.4 [.248--.252] 3.81--4.83 [.150--.190] 6.22--6.48 [.245--.255] 3.0--3.1 [.118--.122] 2.26--2.36 [.089--.093] 5.28--5.38 [.208--.212] 3.05--4.32 [.120--.170] 6.6--6.86 [.260--.270] 3.25--3.35 [.128--.132] 2.08--2.18 [.082--.086] 4.52--4.62 [.178--.182] 3.05--4.32 [.120--.170] 6.6--6.86 [.260--.270] 3.25--3.35 [.128--.132] 2.57--2.67 [.101--.105] 4.52--4.62 [.178--.182] Figure 3 (cont'd) Rev C Tyco Electronics Corporation 5 of 13 FASTIN- FASTON Tabs, Receptacles, and Housings WIRE SIZE RANGE RANGE, AWG INSULATION DIAMETER STRIP LENGTH 114- 2025 CRIMP HEIGHT INSULATION BARREL CRIMP WIDTH WIRE BARREL CRIMP WIDTH 4.75 [.187] SERIES 22 20 18 16 2.29--3.3 [.090--.130] 3.81--4.32 [.150--.170] 2.24--2.34 [.088--.092] 1.12--1.22 [.044--.048] 3.51--3.61 [.138--.142] 2.29--3.3 [.090--.130] 3.81--4.32 [.150--.170] 2.24--2.34 [.088--.092] 1.19--1.3 [.047--.051] 3.51--3.61 [.138--.142] 2.29--3.3 [.090--.130] 5.33--6.1 [.210--.240] 1.98--2.08 [.078--.082] 1.14--1.45 [.045--.057] 4.52--4.62 [.178--.182] 2.79 [.110] Max. (2 Wires) 5.33--6.1 [.210--.240] 1.98--2.08 [.078--.082] 1.14--1.68 [.045--.066] 4.52--4.62 [.178--.182] 2.29--3.3 [.090--.130] 3.81--4.32 [.150--.170] 2.24--2.34 [.088--.092] 1.3--1.4 [.051--.055] 3.51--3.61 [.138--.142] 2.29--3.3 [.090--.130] 5.33--6.1 [.210--.240] 1.98--2.08 [.078--.082] 1.27--1.57 [.050--.062] 4.52--4.62 [.178--.182] 2.29--3.3 [.090--.130] 3.81--4.32 [.150--.170] 2.24--2.34 [.088--.092] 1.47--1.57 [.058--.062] 3.51--3.61 [.138--.142] 2.29--3.3 [.090--.130] 5.33--6.1 [.210--.240] 1.98--2.08 [.078--.082] 1.47--1.8 [.058--.071] 4.52--4.62 [.178--.182] 0.89--0.99 [.035--.039] 3.51--3.61 [.138--.142] 0.91--1.07 0.91-1.07 [.036--.040] 3.51--3.61 3.51-3.61 [.138--.142] 1.02--1.19 1.02-1.19 [.040--.047] 3.51--3.61 3.51-3.61 [.138--.142] 1.19--1.3 [.047--.051] 3.51--3.61 [.138--.142] 2.79 [.110] SERIES 22 2.03--3.05 [.080--.120] 3.81--4.32 [.150--.170] 20 2.03--3.05 [.080--.120] 3.81--4.32 [.150--.170] 18 2.03--3.05 [.080--.120] 3.81--4.32 [.150--.170] 16 2.03--3.05 [.080--.120] 3.81--4.32 [.150--.170] 1.73--1.83 [.068--.072] 1.73--1.83 [.068--.072] 2.24--2.35 [.088--.092] 1.73--1.83 [.068--.072] 2.24--2.35 [.088--.092] 2.24--2.35 [.088--.092] Figure 3 (end) 3.4. Crimped Contact Requirements Locate the contact to be crimped in the appropriate tooling according to the instructions packaged with that tooling. Detailed instructions covering the placement of contacts in the tooling and the use of such tooling is packaged with each tool. Terminate the contact according to the directions shipped with the appropriate tooling. See Section 5, TOOLING. CAUTION ! Wire insulation shall NOT be 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. A typical receptacle contact as it should appear after crimping is shown in Figure 4. These requirements apply equally to the tab contact. A. Crimp Height 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 crimp height must be within the dimensions provided in Figure 3. 6 of 13 Tyco Electronics Corporation Rev C FASTIN- FASTON Tabs, Receptacles, and Housings 114- 2025 Wire Conductors and Insulation Both Visible in this Area Insulation Barrel Crimp Width Visible to 0.76 [.030] Max. Conductor Location Crimp Length 0.00-- 0.38 [.000-- .015] Front Bellmouth X X 0.38-- 0.76 [.015-- .030] Rear Bellmouth See View A 0.13 [.005] Max. Burr Wire Barrel Crimp Height Wire Barrel Crimp Width 0.25 [.010] Max. Wire Barrel Flash View A 0.00 - 0.38 [.000 - .015] Cutoff Tab Section X- X Figure 4 B. 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 Figure 10. C. Bellmouths Front and rear bellmouths shall be evident and conform to the dimensions given in Figure 4. D. Cutoff Tab The cutoff tab shall be cut to the dimensions shown in Figure 4. E. Burrs The cutoff burr shall not exceed the dimensions shown in Figure 4. F. Wire Barrel Flash The wire barrel flash shall not exceed the dimensions shown in Figure 4 in Section X--X. G. Wire Location After crimping, the wire conductor and insulation must be visible in the transition area between the wire and insulation barrels. Rev C Tyco Electronics Corporation 7 of 13 FASTIN- FASTON Tabs, Receptacles, and Housings 114- 2025 H. Conductor Location The conductor may extend beyond the wire barrel to the maximum shown in Figure 4. I. Wire Barrel Seam The wire barrel seam must be closed with no evidence of loose wire strands visible in the seam. J. Twist and Roll There shall be no twist, roll, deformation or other damage to the mating portion of the crimped contact that will prevent proper mating. See Figure 5. 15_ (Max) Wire Barrel Front of Contact (Pin or Socket) Figure 5 K. 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. 1. Up and Down The crimped contact, including cutoff tab and burr, shall not be bent above or below the datum line more than the amount shown in Figure 6. 2. Side to Side The side--to--side bending of the contact may not exceed the limits provided in Figure 6. NOTE Periodic inspections must be made to ensure crimped contact formation is consistent as shown. i 3_ (Max) 3_ (Max) Datum Line 3_ (Max) 3_ (Max) NOTE: Angles are drawn for clarification only and are not to scale. Figure 6 8 of 13 Tyco Electronics Corporation Rev C FASTIN- FASTON Tabs, Receptacles, and Housings 114- 2025 3.5. Tensile Inspection Crimped contacts should hold the wire firmly and have a pull--test tensile value meeting that specified in the chart in Figure 7. NOTE i Adjust tensile testing machine for head travel of 25.4mm [1 inch] per minute. Directly and gradually apply force for 1 minute. CRIMP PULL-- OUT TEST Wire Size [AWG] Minimum Force Newtons Pounds 26 17.8 4 24 26.7 6 22 35.6 8 20 57.8 13 18 89.0 20 16 133.4 30 14 222.4 50 12 311.4 70 10 355.9 80 8 400.3 90 Figure 7 3.6. Housings Housings are available in 1, 2, 3, 4, 6, 8, 10, and 11 circuit positions for your production requirements. Figure 8 shows some typical housings. For specific housing requirements, contact the Product Information number at the bottom of page 1 for more information. The temperature range of these housings is rated at up to 125_C [256_F] to permit use in areas of relatively high temperatures. 6-- Position Housings 1-- Position Housings 8-- Position Housings Circuit Position Figure 8 Some 6.35 mm [.250 in.] and 4.75 mm [.187 in.] housings have optional panel mounts. See Figure 9 for panel mounting dimensions. Rev C Tyco Electronics Corporation 9 of 13 FASTIN- FASTON Tabs, Receptacles, and Housings 114- 2025 Alternative Mounting C 1.4 [.055] Max B G H A Ref. 1.4 [.055] Max Hole to accept No. 6 Hardware D 4.37 [.172] E F J 6.35 [.250] Series Panel Cutout A Size B C D E ------ 29.77 [1.172] 15.88 [.625] F G H J 25.15 [.990] 6.73 [.265] 28.58 [1.125] 6.35 [.250] 4 2.31 [.091] 6 3.43 [.135] 3.56 [.140] 35.86 [1.412] 14.22 [.560] 15.88 [.625] 29.01 [1.142] 4.7 [.185] 34.42 [1.355] 3.96 [.156] 8 4.39 [.173] 6.1 [.240] 16.76 [.660] 18.42 [.725] 38.74 [1.525] 6.6 [.260] 46.23 [1.820] 6.35 [.250] 47.52 [1.871] ------ 4.75 [.187] Series Panel Cutout Number of Modules 1 5.59 [.220] L Circuits K L 3 8.51 [.335] 2 6 16.64 [.655] 8.13 [.320] 3 9 24.76 [.975] 16.26 [.640] 4 12 32.89 [1.295] 24.38 [.960] 5 15 41.02 [1.615] 32.51 [1.280] 33.66 [1.325] ------ 3.96 [.156] Dia. 4.44 [.175] 19.43 [.765] K Figure 9 3.7. Repair Damaged crimped contacts or housings must be removed, discarded, and replaced with new components. CAUTION ! If a damaged contact is apparent before the contacts are inserted into the housing, cut the wire in back of the contact and reterminate the wire end. If contacts or housing are damaged after insertion, the wire must be cut directly in back of the housing and reterminated with new contacts and housing. See Section 5, TOOLING. 4. QUALIFICATION FASTIN--FASTON Connectors are Recognized under the Component Program of Underwriters Laboratories, Inc. (UL) in File Number E28476 and Certified by CSA International in File Number LR7189. 5. TOOLING Figure 10 provides tool part numbers and instructional material related to wire size. 10 of 13 Tyco Electronics Corporation Rev C FASTIN- FASTON Tabs, Receptacles, and Housings NOTE i 114- 2025 Tyco Electronics Tool Engineers have designed machines for a variety of application requirements. For assistance in setting up prototype and production line equipment, contact Tyco Electronics Tool Engineering through your local Tyco Electronics Representative or call the Tooling Assistance Center number at the bottom of page 1. S Hand Crimping Tool Hand crimping tools that accommodate the full wire size range are designed for prototype and low--volume applications such as repair of damaged contacts. S Applicator 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. NOTE i Each applicator is shipped with a metal identification tag attached. DO NOT remove this tag or disregard the information on it. Also, a packet of associated paperwork is included in each applicator shipment. This information should be read before using the applicator; then it should be stored in a clean, dry area near the applicator for future reference. Some changes may have to be made to the applicators to run in all related power units. Contact the Tooling Assistance Center number located at the bottom of page 1 for specific changes. S 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. S Extraction Tools Extraction Tools are designed to release the locking lance inside the connector housing without damaging the housing or contacts. WIRE SIZE, AWG INSULATION DIAMETER HAND TOOL (DOCUMENT) APPLICATOR (408-- 8039) POWER UNIT (DOCUMENT) (2) 28 1.52--3.18 [.060--.125] ------ 567487--2D 354500--1 (409--5842) 26--24 1.52--3.18 [.060--.125] ------ 567487--2 354500--1 (409--5842) 1.52 2.54 1.52--2.54 [.060--.100] ------ 687979--3D 687979--1 354500--1 (409--5842) 217500--1, --2 (409--5866) 2.16--3.18 2.16 3.18 [.085--.125] ------ 687981 1 687981--1 2.03--3.05 2.03 3.05 [.080--.120] ------ 2.29--3.3 2.29 3.3 [.090--.130] ------ 2.03--3.05 2.03 3.05 [.080--.120] ------ ------ ------ 2.2--3.1 [.090--.120] 189508--1 (408--4138) 22 18 22--18 22 16 22--16 20 16 20--16 18 14 18--14 3.05 4.06 3.05--4.06 [.120--.160] 567135--1 567135--2D 466683--1 466683--2D 466737--1 466737--3 567326--1 354500--1 (409--5842) 217500--1, --2 (409--5866) 217500--1 --2 (409--5866) 354500--1 (409--5842) 217500--1, --2 (409--5866) 354500--1 (409--5842) 217500--1, --2 (409--5866) 354500--1 (409--5842) 567326--2D 217500--1, --2 (409--5866) 354500--1 (409--5842) ------ ------ 687839 1 687839--1 354500--1 (409--5842) 217500--1, --2 (409--5866) 687932 1 687932--1 354500--1 (409--5842) 217500--1, --2 (409--5866) ------ D Applicator will require minor modification for "G" Terminating Machine 354500--1. See Instruction Sheet 408--8053. Figure 10 (cont'd) Rev C Tyco Electronics Corporation 11 of 13 FASTIN- FASTON Tabs, Receptacles, and Housings 114- 2025 WIRE SIZE, AWG INSULATION DIAMETER HAND TOOL (DOCUMENT) APPLICATOR (408-- 8039) POWER UNIT (DOCUMENT) 18 14 or (2) 18 18--14 3.05 4.32 3.05--4.32 [.120--.170] ------ 687940 1 687940--1 217500--1, --2 (409--5866) 354500--1 (409--5842) 16 12 16--12 4.06--5.59 [[.160--.220] 160 220] or (2) 3.3 [.130] Max. ------ 466057--4 354500--1 (409--5842) 466057--1 217500--1, --2 (409--5866) 16 12 or (2) 16 16--12 4.06--5.33 [[.160--.210] 160 210] or (2) 3.3 [.130] Max. ------ 466058--1 217500--1, --2 (409--5866) 466058--2D 354500--1 (409--5842) 16--12 16 12 or (2) 16 or 14 or (16 & 18) 4.06 [.160] Max. ------ 687944 1 687944--1 14 10 14--10 3.05--4.32 3.05 4.32 [.120--.170] ------ 466092--1 466092--4 3.43--5.08 3.43 5.08 [.135--.200] ------ 466331 1 466331--1 3.81--5.08 [.150--.200] ------ 466848--2D 354500--1 (409--5842) 10 5.08--6.98 [.200--.275] ------ 466875--2D 354500--1 (409--5842) 8 5.08--6.98 [.200--.275] ------ 466875--2 354500--1 (409--5842) 12--10 217500--1, --2 (409--5866) 354500--1 (409--5842) 217500--1, --2 (409--5866) 354500--1 (409--5842) 354500--1 (409--5842) 217500--1, --2 (409--5866) DApplicator will require minor modification for "G" Terminating Machine 354500--1. See Instruction Sheet 408--8053. Hand Tool 189508--1 Applicator (Typ) Extraction Tool 465629--1 with Extraction Tip 465665--1 AMPOMATOR CLS IV Lead--Making Machine 217500--[ ] AMP--O--LECTRIC Model "G" Terminating Machine 354500--1 Figure 10 (end) 12 of 13 Tyco Electronics Corporation Rev C FASTIN- FASTON Tabs, Receptacles, and Housings 114- 2025 6. VISUAL AID Figure 11 shows a typical application of FASTIN--FASTON Tab and Receptacle Contacts and Housings. 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. NO CONDUCTOR WIRES SHOWING IN WIRE BARREL SEAM WIRE CONDUCTORS AND INSULATION BOTH VISIBLE IN THIS AREA CUTOFF TAB MUST BE VISIBLE CONDUCTOR ENDS MUST BE VISIBLE CONTACTS MUST BE LOCKED IN PLACE HOUSINGS OR CONTACTS MUST NOT BE BENT OR CRACKED FIGURE 11. Rev C VISUAL AID Tyco Electronics Corporation 13 of 13