Application Specification
114--8005
MULTILOCK*
040/070 and 070/250 Series
LOC B
1of 20
E2009 Tyco Electronics Corporation, Harrisburg, PA
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.
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.tycoelectronics.com
Hybrid Connectors 02 NOV 09 Rev A
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 MULTILOCK 040/070 and 070/250 Series Hybrid
Connectors. The 040/070 series I/O (input/output) connectors are available in wire--to--board configurations
incorporating mixed 040--series (signal) and 070--series (power). The 070/250 mixed series connectors are a
wire--to--wire configuration with 11, 13, and 15 positions. The 040/070 series plug connectors are available 10
through 26 positions and the cap connectors are available in 16 through 76 positions. The contacts are on
2.5 mm [.098 in.] centerlines. Plug connectors are available in either hinge lock or side lock features. The cap
assembly is available in a horizontal (right--angle) position with some positions available in a vertical position.
When corresponding with Tyco Electronics Representatives, use the terminology provided in this specification
to facilitate your inquiry for information. Basic terms and features of the connectors and contacts are provided
in Figure 1.
Figure 1
Printed Circuit (PC)
Board Female Cap
Assembly (Typ)
Receptacle Contact
(070 Series Shown)
Tab Contact
(070 Series Shown)
Male Plug
Housing
(Typ)
Contact Tine
Wire Barrel
Insulation Barrel
Wire Barrel
Double Lock Plate
NOTE
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114- 8005MULTILOCK 040/070 and 070/250 Series Hybrid Connectors
Rev A2 of 20 Tyco Electronics Corporation
2. REFERENCE MATERIALS
2.1. Revision Summary
SUpdated document to corporate requirements
SDeleted obsolete tooling part numbers and related documents
2.2. Customer Assistance
Reference Part Number 638211 and Product Code 0417 are representative numbers that identify the
MULTILOCK 040/070 and 070/250 Series Hybrid Connectors. These numbers are used in the network of
customer service to access tooling and product application information. This service is provided by your local
Tyco Electronics Representative or, after purchase, by calling the Product Information number at the bottom of
page 1.
2.3. Drawings
Customer Drawings for specific products are available from the responsible Tyco Electronics Engineering
Department via the service network. The information contained in the Customer Drawings takes priority if there
is a conflict with this specification or with any other technical documentation supplied by Tyco Electronics.
2.4. Specifications
The following Product Specifications (108--series) provide test and performance results, and Application
Specifications (114--series) provide related application information:
Specification Number Specification Title
108--5244 040 Series, MULTILOCK I/O Connector
108--5280 040/070 Hybrid I/O Connector for PC Board
108--5216 070 Series, MULTILOCK I/O Connector
108--5281 040 Series MULTILOCK I/O Connector MK II
108--5342 040 II/070 II Hybrid I/O Connector MK II for Wire--to--Board Termination
108--5352 040 Series MULTILOCK Connector Wire to Wire Type
114--5091 070 Series Receptacle Contact
114--5092 070 Series Tab Contact
114--5094 040 Series Receptacle Contact
114--5108 040 Series Tab Contact
114--5133 040 Series Receptacle Contact for CAVUS Wires
114--5134 070 Series Receptacle Contact for CAVUS Wires
114--5159 040 II Series Tab and Receptacle Contact
114--5160 070 II Series Tab and Receptacle Contact
114--5162 040 Receptacle Contact for CAVUS
2.5. Manuals
Manual 402--40 is available upon request and can be used as a guide in soldering. This manual provides
information on various flux types and characteristics along with the commercial designation and flux removal
procedures. A checklist is included in the manual as a guide for information on soldering problems.
2.6. Instructional Material
The following list includes available instruction sheets (408--and 411--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 provide setup, operation, and maintenance of machines.
Also included are Hand Books (410--series) which are written for operator training and reference material for
customers on various product lines and procedures.
Document Number Document Title
408--3295 Preparing Reel Of Contacts for Application Tooling
408--3326 Disengaging Double Lock Plate on .040/.070 Hybrid MULTILOCK Connector
408--7424 Checking Terminal Crimp Height or Gaging Die Closure
408--8024 Miniature Quick--Change Applicator (End--Feed Type)
408--8039 Heavy Duty Miniature Quick--Change Applicators (End--Feed Type)
114- 8005
MULTILOCK 040/070 and 070/250 Series Hybrid Connectors
Rev A 3 of 20Tyco Electronics Corporation
Document Number Document Title
408--8040 Heavy Duty Miniature Quick--Change Applicators (Side--Feed Type)
408--8053 Conversion Guide for Miniature Quick--Change Applicators
408--8547 CERTI--CRIMP* II Straight Action Hand Tools
408--9640 Crimp Quality Monitor Applicators for Side and End Feed Applications
408--9816 Handling Of Reeled Products
408--9853 PRO--CRIMPER* Hand Tool Assembly 90652--1 with Die Assembly 90652--2
408--9854 PRO--CRIMPER Hand Tool Assembly 90653--1 with Die Assembly 90653--2
408--9855 PRO--CRIMPER Hand Tool Assembly 90654--1 with Die Assembly 90654--2
408--9992 PRO--CRIMPER III Hand Tool Assembly 58521--1
408--9997 PRO--CRIMPER III Hand Tool Assembly 58528
409--5128 Basic AMP--O--LECTRIC* Model “K” Terminating Machine
409--5842 AMP--O--LECTRIC Model “G” Terminating Machine 354500--[ ]
409--5852 AMPOMATOR CLS III--G Lead--Making Machine
409--5855 AMP--O--MATIC* Side Feed Stripper--Crimper Model II Machine 854040--3, --4
409--5878 AMPOMATOR CLS IV+ Lead--Making Machine
409--10012 AMP--O--MATIC Side--Feed Stripper--Crimper III Machine 1320895--[ ]
410--5721 Setup and Operation Handbook for the Model II AMPOMATOR CLS Machine
410--5841 Customer Training Guide for AMP--O--LECTRIC Model “G” Terminator
411--5287 Extraction Tool 755430--2 for 070 Series Contacts
411--5288 Extraction Tool 755430--1 for 040 Series Contacts
411--5338 DAHT 755223--1 for 070 Series Contacts
411--5417 SAHT 911738--1, --2 for 040 Series Contacts
411--5480 SAHT 911788 --2 for 070 Series Contacts
411--5655 Double Action Tool 934192--1
411--5658 Double Action Tool 934195--1
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 and housings should remain in the shipping containers until ready for use to prevent
deformation to those components. The components 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 Ammonia Citrates Phosphates Citrates Sulfur Compounds
Amines Carbonates Nitrites Sulfides Nitrites Tartrates
Where the above environmental conditions exist, phosphor--bronze contacts are recommended instead of brass if
available.
3.2. Wire Selection and Preparation
A. Type
The wire size range for MULTILOCK 040/070 and 070/250 Series Hybrid Connectors is 24 to 12 AWG
stranded or solid copper wire. Refer to the specific application specifications or instructional material
supplied with the products or application tooling.
NOTE
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114- 8005MULTILOCK 040/070 and 070/250 Series Hybrid Connectors
Rev A4 of 20 Tyco Electronics Corporation
B. Preparation
The wire must be stripped to the dimensions provided in the specific application specifications or
instructional material supplied with the products or application tooling.
Do not nick, scrape, or cut the wire conductor during the stripping operation.
There are tool designs available to meet various application requirements. The developed crimp configuration 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.
3.3. Crimped Contact Requirements
Refer to Paragraphs 2.4 and 2.6 for related documentation which provide specific parameters for crimp
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.
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 contact as it should appear after crimping is shown in Figure 2.
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.
B. Crimp Length
For optimum crimp effectiveness, the crimp must be within the area shown 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
Figure 15.
C. Bellmouths
Front and rear bellmouths shall be evident and conform to the dimensions provided in the supplied
documentation.
D. Cutoff Tab
The cutoff tab shall be cut to the dimensions provided in the supplied documentation.
E. Burrs
The cutoff burr shall not exceed the dimensions provided in the supplied documentation.
F. Wire Barrel Flash
The wire barrel flash shall not exceed the dimensions provided in the supplied documentation.
G. Conductor Location
The conductor may extend beyond the wire barrel to the maximum dimensions provided in the supplied
documentation.
H. Wire Barrel Seam
The wire barrel seam must be closed with no evidence of loose wire strands visible in the seam.
CAUTION
!
NOTE
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CAUTION
!
114- 8005
MULTILOCK 040/070 and 070/250 Series Hybrid Connectors
Rev A 5 of 20Tyco Electronics Corporation
Figure 2
Max. Wire
Barrel Flash
Section X- X
Wire Barrel
Crimp Height
Wire Barrel
Crimp Width
Max.
Burr
Cutoff
Tab
View A
EndofWiretobeFlushto
Required Dimension from
EndofWireBarrel
Front Bellmouth Rear Bellmouth
See View A
X
X
No Missing or Nicked
Wire Strands
Crimp Length
Both Conductor and
Insulation Must Be Visible
No Insulation In Seam
No Wire Strands in
Wire Barrel Seam
NOTE: Receptacle Contact Shown, Requirements
the Same for Tab Contact
I. 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 3.
Figure 3
15_(Max)
Wire Barrel
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 limits as shown in Figure 4.
114- 8005MULTILOCK 040/070 and 070/250 Series Hybrid Connectors
Rev A6 of 20 Tyco Electronics Corporation
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 4.
2. Side to Side
The side--to--side bending of the contact may not exceed the limits provided in Figure 4.
Periodic inspections must be made to ensure crimped contact formation is consistent as shown.
Figure 4
NOTE: Angles are drawn for clarification only and are not to scale.
Datum Line
5_Max
5_Max
5_Max
Datum Line
5_Max
NOTE: Receptacle Contact Shown, Requirements
the Same for Tab Contact
3.4. Strain Relief
The MULTILOCK product family is designed so all wire crimped contacts float inside the circuit cavity. This float
helps the contact to find their centers during connector mating. In order to maintain proper contact float and
avoid excessive tension on wire crimps, the wire harness should not be taped, or otherwise secured within
30 mm [1.181 in.] of the connector assembly body. The individual wire leads between the connector and the
point of bundling must be able to move freely. Refer to Application Specification 114--5763, Figure 15.
If the installation is to be subject to bending forces, strain relief should be provided on the wire bundle approximately
25.4 mm [1.00 in.] from the back of the housing.
When bending or forming wires, hold the wire bundle at least 30 mm [1.181 in.] beyond the back of the housing
before bending in any direction.
Do not bend unsupported wires as this may cause strain on the contacts inside the housing.
3.5. Placement of Crimped Contact in Housing
The contact must be inserted in the back of the plug housing and snapped into place. When fully inserted, the
contact will engage the internal housing latch and prevent backing out during mating of the connector. After
inserting contact into housing, pull back lightly on the wire to ensure contact is fully seated. See Figure 5.
NOTE
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NOTE
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CAUTION
!
114- 8005
MULTILOCK 040/070 and 070/250 Series Hybrid Connectors
Rev A 7 of 20Tyco Electronics Corporation
Figure 5
Contact Fully Inserted
and Locked in Housing
Primary Lock
Double Lock Plate
NOTE: Secondary lock shown pre--staged before final engagement
3.6. Mating and Unmating
The design of the MULTILOCK Hybrid Connectors prevents mis--mating of connectors. The plug and cap
housing features an internal lock system to ensure positive retention. See Figure 6.
A. Mating
Make sure all contacts are locked in position, and the double lock plate is fully engaged in the locked
position. If the double lock plate is in the pre--staged position, it must be changed to the final locked
position. For plugs with hinge locks, rotate lock towards crimped wires, and press closed until it latches.
Insert the plug into the female cap assembly until you hear a click. This will ensure the plug connector has
bottomed. Pull back slightly on the plug connector to ensure the connectors can not be unmated.
B. Unmating
Grasp the female cap assembly by the ends. Release the hinge lock on the back of the plug connector, by
depressing the lever. Pull straight out from the female cap assembly.
Do NOT pull the plug assembly out from the female cap assembly by the wires. This could damage the connectors.
Figure 6
PC Board
Male Plug Assembly
Female Cap
Assembly
Internal Locking Feature Lever
CAUTION
!
114- 8005MULTILOCK 040/070 and 070/250 Series Hybrid Connectors
Rev A8 of 20 Tyco Electronics Corporation
3.7. PC Board
A. Material and Thickness
1. Board material will be glass epoxy (FR--4, G--10).
2. The female cap assembly connector can be installed on 1.57 mm [.062 in.] thick pc boards. Board
thickness may vary depending upon the application; however, contact tine length through the pc board
becomes important for wave soldering operations. A recommended minimum of 1.02 mm [.040 in.] of
the contact solder tine should protrude through the pc board.
Contact the Product Information Center or the Tooling Assistance Center number listed at the bottom of
page 1 for suitability of other board materials, thicknesses, specialized board designs or applications.
B. Tolerance
Maximum allowable bow of the pc board shall be 0.03 mm [.001 in.] over the length of the female cap
assembly.
C. PC Board Layout
The mounting and contact holes in the pc board must be precisely located to ensure proper placement and
optimum performance of the connector. See Figure 7. The connectors may be placed on the pc board
manually or by machine.
Figure 7 represents a typical pc board layout for this product. For dimensions and hole pattern layout for specific
product, obtain the appropriate customer drawing through your Tyco Electronics Representative or refer to the
telephone numbers at the bottom of page 1.
Figure 7
3.8. PC Board Contact Tine Holes
These connectors may be used with or without plated through holes. If plated, the drilled hole size, plating
types and plating thickness are dependent on customer application requirements. The finished hole size must
be as stated in Figure 8 to provide unrestricted insertion and ensure adequate application of the solder to the
connector solder tines.
NOTE
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114- 8005
MULTILOCK 040/070 and 070/250 Series Hybrid Connectors
Rev A 9 of 20Tyco Electronics Corporation
Figure 8
Pad Diameter
(As Required)
Copper Plating
(As Required)
(Maximum Hardness of
Copper to be 150 Knoop)
Tin/Lead Plated
(As Required)
Drilled Hole Diameter
(As Required)
See Specific Product
Customer Drawing for
Dia of Finished Hole
After Plating
Board Thickness
1.57 [.062]
3.9. PC Board Female Cap Assembly Placement
The female cap assembly should be handled only by the housing body to prevent deformation, contamination, or other
damage to the contact tines or boardlocks.
Determine the number one contact tine hole, then orient the connector so the number one solder tine is aligned
with the hole. Start all solder tines into the pc board. When the boardlocks (if applicable), start to engage the pc
board, press on the connector until it fully seats on the pc board.
After the connector is snapped into the pc board, the boardlocks (if applicable) are soldered with the connector
solder tines during the soldering process.
3.10. Methods of Attaching Female Cap Assembly to PC Board (See Figure 9)
These connectors have been designed to be used with 3 mm dia x 6 mm long [.118 in. dia x .236 in. long] pan
head class 2 self--tapping screws as specified in JIS B1115 and JIS B1122 or equivalent. Maximum tightening
torque is provided on the specific product customer drawings. In addition to boardlocks available from Tyco
Electronics, these connectors will also accept other types of commercially available mating hardware.
The connector may be affixed to the pc board by using commercially available hardware such as screws, lock
washers, nuts, rivets, or similar devices. Tyco Electronics applied boardlocks have shoulders that pass through
the pc board at the same time the connector solder tines are inserted through the pc board. The boardlocks
lock into position when the connector is seated on the pc board. The initial insertion and extraction forces are
41.15N [9.25 lb] maximum for insertion, and 6.68N [1.50 lb] minimum for extraction per connector with two
boardlocks.
Figure 9
PC Board
NOTE: Boardlocks are NOT designed to be a strain relief for the connector. And for maximum torque requirements on screws,
refer to the specific product customer drawings.
Self--Tapping
Screw
Boardlock
NOTE
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114- 8005MULTILOCK 040/070 and 070/250 Series Hybrid Connectors
Rev A10 of 20 Tyco Electronics Corporation
3.11. Soldering
A. Flux Selection
Contact solder tines must be fluxed prior to soldering with a mildly active, rosin base flux. Selection of the
flux will depend on the type of pc board and other components mounted on the board. Additionally, the flux
must be compatible with the wave solder line, manufacturing, health, and safety requirements. Call the
Product Information phone number at the bottom of page 1 for consideration of other types of flux. Some
fluxes that are compatible with these connectors are provided in Figure 10.
F
L
U
X
T
Y
P
E
A
C
T
I
V
I
T
Y
R
E
S
I
D
U
E
COMMERCIAL DESIGNATION
F
L
U
X
T
Y
P
E
A
C
T
I
V
I
T
Y
R
E
S
I
D
U
E
KESTER ALPHA
Type RMA (Mildly Activated) Mild Noncorrosive 186 611
Figure 10
B. Cleaning
After soldering, removal of fluxes, residues, and activators is necessary. Consult with the supplier of the
solder and flux for recommended cleaning solvents. The following is a listing of common cleaning solvents
that will not affect the connectors for the time and temperature specified. See Figure 11.
Consideration must be given to toxicity and other safety requirements recommended by the solvent manufacturer.
Refer to the manufacturer’s Material Safety Data Sheet (MSDS) for characteristics and handling of cleaners.
Trichloroethylene and Methylene Chloride can be used with no harmful affect to the connectors; however Tyco
Electronics does not recommend them because of the harmful occupational and environmental effects. Both are
carcinogenic (cancer--causing) and Trichloroethylene is harmful to the earth’s ozone layer.
If you have a particular solvent that is not listed, contact the Tooling Assistance Center or Product Information number
at the bottom of page 1.
CLEANER TIME
(
M
i
n
u
t
e
s
)
TEMPERATURES
(Maximum)
NAME TYPE (Minutes
)
CELSIUS FAHRENHEIT
ALPHA 2110 Aqueous 1132 270
BIOACT EC--7 Solvent 5100 212
Butyl CARBITOL Solvent 1Room Ambient
Isopropyl Alcohol Solvent 5100 212
KESTER 5778 Aqueous 5100 212
KESTER 5779 Aqueous 5100 212
LONCOTERGE 520 Aqueous 5100 212
LONCOTERGE 530 Aqueous 5100 212
Terpene Solvent Solvent 5100 212
Figure 11
C. Drying
When drying cleaned assemblies and printed circuit boards, make certain that temperature limitations are
not exceeded: --55_to 105_C[--67_to 221_F] for standard temperature products. Excessive temperatures
and dwell time may cause housing degradation.
D. Soldering Guidelines
MULTILOCK Hybrid Connectors can be soldered using wave, vapor phase (VPR), double sided
non--focused infrared reflow processes (IR) or equivalent soldering techniques. The temperatures and
exposure time shall be within the ranges specified in Figure 12. We recommend using SN60 or SN62
solder for these connectors.
Manual 402--40 provides some guidelines for establishing soldering practices. Refer to Paragraph 2.5, Manuals.
DANGER
NOTE
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NOTE
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114- 8005
MULTILOCK 040/070 and 070/250 Series Hybrid Connectors
Rev A11 of 20Tyco Electronics Corporation
SOLDERING
P
R
O
C
E
S
S
TEMPERATURE TIME
(
A
t
M
T
t
)
PROCESS CELSIUS FAHRENHEIT (At Max Temperature
)
WAVE SOLDERING 260s500s5 Seconds
VAPOR PHASE SOLDERING 215 419 5 Minutes
INFRARED REFLOW SOLDERING 230 446 5 Minutes
sWave Temperature
Figure 12
3.12. Checking Installed Connector
MULTILOCK Hybrid Connectors must be seated on the pc board to the dimensions shown in Figure 13.
Figure 13
Connector Must be
Flush Against PC Board
to 0.08 [.003] Max
PC Board
Connector
Solder Tine
Solder Must be
Evenly Distributed
and Not Cracked
3.13. Connector Spacing
Care must be used to avoid interference between adjacent connectors and/or other components. The
information provided in Figure 14 is to ensure proper mating.
The information provided is for manual placement of connectors. If robotic equipment is used, other space allowances
will be required for the grippers.
Figure 14
PC Board
Female Cap
Assembly
Dimension Variable Based
on Customers Requirements
3.14. Repair/Replacement
Use an extraction tool to remove individual contacts from male plug connectors for replacement or for
relocation to another housing cavity. Extraction Tool 755430--[ ] (Instruction Sheets 411--5287 or 411--5288) is
used to extract contacts from male plug connectors. Damaged or worn contacts may be replaced provided
there is sufficient slack, after restripping the wire, to insert the new contact into the connector. Damaged pc
board connectors may be removed from the pc board by standard de--soldering methods.
NOTE
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114- 8005MULTILOCK 040/070 and 070/250 Series Hybrid Connectors
Rev A12 of 20 Tyco Electronics Corporation
4. QUALIFICATIONS
MULTILOCK 040/070 and 070/250 Series Hybrid Connectors are not required to be agency evaluated.
5. TOOLING
This section provides a selection of tools for various application requirements. They include hand tools for
manual application of loose piece form contacts, and semi--automatic and automatic machines for power assist
application of strip form contacts. Modified designs and additional tooling concepts may be available to meet
other application requirements. For additional information, contact one of the service groups at the bottom of
page 1. A listing of tooling recommendations covering the full wire size range is provided in Figure 15.
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.
SApplicators
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.
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 at the bottom of page 1 for specific changes.
SPower 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.
The Model “K” AMP--O--LECTRIC Terminating Machine PN 565435--5 (409--5128) has been superseded by the Model
“G” Terminating Machine PN 354500--1 (409--5842) for new applications. For existing applications, the Model “K” is still
recommended because of the large number of installed machines.
SHand Crimping Tools
Hand crimping tools that accommodate the full wire size range are designed for prototype and
low--volume applications such as repair of damaged contacts.
SExtraction Tools
Extraction tools are designed to release the contacts inside the plug connector without damaging the
housing or contacts. Refer to Paragraph 3.14.
SPC Board Support
A pc board support must be used to prevent bowing of the pc board during insertion of the connector. It
should have a flat surface with holes or a channel large enough to receive the contact tines during
installation.
Figure 15 (cont’d)
Typical
PRO CRIMPER
Hand Tool
SAHT 911788--2,
91580--1
SAHT 911738--1, --2
Extraction Tool
755430--1, --2
Typical DAHT
NOTE
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NOTE
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NOTE
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114- 8005
MULTILOCK 040/070 and 070/250 Series Hybrid Connectors
Rev A13 of 20Tyco Electronics Corporation
Figure 15 (cont’d)
PC Board Support
(Customer Supplied)
Holes
(Ref)
Channel
(Ref)
Typical
Applicator
AMPOMATOR CLS III--G
Machine 22500--[ ]
114- 8005MULTILOCK 040/070 and 070/250 Series Hybrid Connectors
Rev A14 of 20 Tyco Electronics Corporation
Figure 15 (cont’d)
AMP--O--LECTRIC
Model “G” Terminating
Machine 354500--[ ]
AMP--O--LECTRIC
Model “K” Terminating Machine
565435--5, U--2 Assy 722460--1
AMPOMATOR CLS IV+
Lead--Making Machine
356500--[ ], 1213400--[ ]
AMP--O--MATIC Stripper
Crimper II 854040--[ ]
and Stripper Crimper III
1320895--[ ]
114- 8005
MULTILOCK 040/070 and 070/250 Series Hybrid Connectors
Rev A15 of 20Tyco Electronics Corporation
CONTACT
TYPE
SERIES
SIZE
WIRE
SIZE,
AWG
INSUL
DIA
RANGE
APPLICATOR
(DOCUMENT)
POWER
UNIT
(DOCUMENT)
HAND
TOOL
(DOCUMENT)
EXTRACTION
TOOL
(DOCUMENT)
122500--2 (409--5852)
122500--3 (409--5852)
567381--1 356500--1 (409--5878)
5
6
7
3
8
1
1
(408--8040) 356500--2 (409--5878)
1213400--1 (409--5878)
1213400--2 (409--5878)
567381--2 354500--1 (409--5842)
2
4
2
0
1.4--2.1
5
6
7
3
8
1
2
(408--8040) 565435--5 (409--5128) 58528--1 755430--1
24--20
1
.
4
2
.
1
[.055--.083] 567381--3
(408--8040) 354500--[ ] (409--5842)
5
8
5
2
8
1
(408--9997)
7
5
5
4
3
0
1
(411--5288)
122500--2 (409--5852)
567732--1 122500--3 (409--5852)
5
6
7
7
3
2
1
(408--8040) 356500--2 (409--5878)
1213400--2 (409--5878)
RECEPT 040
5
6
7
9
4
9
-
-
1
854040--3 (409--5855)
5
6
7
9
4
9
--
1
(409--5855) 1320895--1, --3
(409--10012)
2
2
-
-
2
0
1.0--1.4 9--482414--0 -- -- -- 911738--1
2
2
--
2
0
1
.
0
1
.
4
[.039--.055] 911924--2 -- -- --
9
1
1
7
3
8
1
(411--5417)
122500--2 (409--5852)
122500--3 (409--5852)
567442--1 356500--1 (409--5878)
7
5
5
4
3
0
1
5
6
7
4
4
2
1
(408--8040) 356500--2 (409--5878) 90652--1
755430--1
(411--5288)
22--18 1.1--1.8
[
0
4
3
0
7
1
]
1213400--1 (409--5878)
9
0
6
5
2
1
(408--9853)
or
(
)
2
2
1
8
[
.
0
4
3
-- .
0
7
1
]
1213400--2 (409--5878)
o
r
934192--1
(
4
1
1
--
5
6
5
5
)
567442--2 354500--1 (409--5842)
(
4
1
1
--
5
6
5
5
)
5
6
7
4
4
2
2
(408--8040) 565435--5 (409--5128)
567442--3
(408--8040) 354500--[ ] (409--5842)
Figure15(cont’d)
114- 8005MULTILOCK 040/070 and 070/250 Series Hybrid Connectors
Rev A16 of 20 Tyco Electronics Corporation
CONTACT
TYPE
SERIES
SIZE
WIRE
SIZE,
AWG
INSUL
DIA
RANGE
APPLICATOR
(DOCUMENT)
POWER
UNIT
(DOCUMENT)
HAND
TOOL
(DOCUMENT)
EXTRACTION
TOOL
(DOCUMENT)
122500--2 (409--5852)
122500--3 (409--5852)
567454--1 356500--1 (409--5878)
5
6
7
4
5
4
-
-
1
(408--8040) 356500--2 (409--5878)
1213400--1 (409--5878)
1213400--2 (409--5878)
567454--2 354500--1 (409--5842)
5
6
7
4
5
4
-
-
2
(408--8040) 565435--5 (409--5128)
567454--3
(408--8040) 354500--[ ] (409--5842) 58528--1
1
4
1
9
5
6
7
9
2
9
1
854040--3 (409--5855)
5
8
5
2
8
1
(408--9997)
or
24--22 1.4--1.9
[.055--.075]
567929--1
(409--5855) 1320895--1, --3
(409--10012)
o
r
91580--1
(408--8547)
o
r
122500--2 (409--5852)
o
r
755221--1
7
5
5
4
3
0
--
2
RECEPT 070 122500--3 (409--5852)
7
5
5
4
3
0
--
2
(411--5287)
680386--1 356500--1 (409--5878)
6
8
0
3
8
6
-
-
1
(408--8040) 356500--2 (409--5878)
1213400--1 (409--5878)
1213400--2 (409--5878)
680386--2 354500--1 (409--5842)
6
8
0
3
8
6
-
-
2
(408--8040) 565435--5 (409--5128)
680386--3
(408--8040) 354500--[ ] (409--5842)
22--20 1.0--1.4
[.039--.055] 913281--2 -- -- -- 90653--1
(408--9854)
2
2
1
8
1.1--1.8 567488--2 354500--1 (409--5842) 934195--1
22--18
1
.
1
-
-
1
.
8
[.043--.071]
5
6
7
4
8
8
-
-
2
(408--8040) 565435--5 (409--5128)
9
3
4
1
9
5
-
-
1
(411--5658)
2
0
1
6
1.2--1.9 567491--2 354500--1 (409--5842)
20--16
1
.
2
-
-
1
.
9
[.047--.075]
5
6
7
4
9
1
-
-
2
(408--8040) 565435--5 (409--5128) -- -- --
Figure15(cont’d)
114- 8005
MULTILOCK 040/070 and 070/250 Series Hybrid Connectors
Rev A17 of 20Tyco Electronics Corporation
CONTACT
TYPE
SERIES
SIZE
WIRE
SIZE,
AWG
INSUL
DIA
RANGE
APPLICATOR
(DOCUMENT)
POWER
UNIT
(DOCUMENT)
HAND
TOOL
(DOCUMENT)
EXTRACTION
TOOL
(DOCUMENT)
122500--2 (409--5852)
122500--3 (409--5852)
567441--1 356500--1 (409--5878)
1.8--2.5
5
6
7
4
4
1
-
-
1
(408--8040) 356500--2 (409--5878) 90654--1
1
.
8
-
-
2
.
5
[.071--.098] 1213400--1 (409--5878)
9
0
6
5
4
-
-
1
(408--9855)
1213400--2 (409--5878)
567441--2 354500--1 (409--5842)
5
6
7
4
4
1
-
-
2
(408--8040) 565435--5 (409--5128)
122500--2 (409--5852)
122500--3 (409--5852)
567375--1 356500--1 (409--5878)
5
6
7
3
7
5
-
-
1
(408--8040) 356500--2 (409--5878) 755430--2
070 20--16 1213400--1 (409--5878)
7
5
5
4
3
0
-
-
2
(411--5287)
1213400--2 (409--5878)
567375--2 354500--1 (409--5842) 58521--1
(
4
0
8
9
9
9
2
)
5
6
7
3
7
5
-
-
2
(408--8040) 565435--5 (409--5128) (408--9992)
or
RECEPT
2.0--2.6
[.079--.102] 567375--3
(408--8040) 354500--[ ] (409--5842)
o
r
755223--1
(411--5338)
o
r
567838--1
(409--5855)
8
5
4
0
4
0
4
(
4
0
9
5
8
5
5
)
o
r
911788--2
(411--5480)
567854--1
(409--5855)
854040--4
(
409--5855
)
or
1320895--2, --4
(
4
0
9
1
0
0
1
2
)
567855--1
(409--5855)
,
(409--10012)
5
6
7
9
0
8
1
854040--3 (409--5855)
567908--1
(409--5855) 1320895--1, --3
(409--10012)
2--541611--2
2--541611--6
9--541611--2 -- -- --
1
5
2
2
9--541611--6
-- -- --
250 22--20 1.5--2.2
[.059--.087] 722788--1
(408--8024)
-- -- -- -- -- --
722788--2
(408--8024) 722460--1
1--755816--1
(408--8024) -- -- --
Figure15(cont’d)
114- 8005MULTILOCK 040/070 and 070/250 Series Hybrid Connectors
Rev A18 of 20 Tyco Electronics Corporation
CONTACT
TYPE
SERIES
SIZE
WIRE
SIZE,
AWG
INSUL
DIA
RANGE
APPLICATOR
(DOCUMENT)
POWER
UNIT
(DOCUMENT)
HAND
TOOL
(DOCUMENT)
EXTRACTION
TOOL
(DOCUMENT)
122500--2 (409--5852)
122500--3 (409--5852)
466250--1 356500--1 (409--5878)
2
0
-
-
1
4
2.2--3.4
4
6
6
2
5
0
1
(408--8039) 356500--2 (409--5878)
2
0
--
1
4
2
.
2
3
.
4
[.087--.134] 1213400--1 (409--5878)
1213400--2 (409--5878)
466250--2 354500--1 (409--5842)
4
6
6
2
5
0
2
(408--8039) 565435--5 (409--5128)
RECEPT 250 122500--2 (409--5852) -- -- -- -- -- --
R
E
C
E
P
T
2
5
0
122500--3 (409--5852)
-
-
-
-
-
-
-
-
-
-
-
-
680086--1 356500--1 (409--5878)
6
8
0
0
8
6
1
(408--8039) 356500--2 (409--5878)
14--12 2.9--3.8
[
1
1
4
1
5
0
]
1213400--1 (409--5878)
1
4
-
-
1
2
[.114--.150] 1213400--2 (409--5878)
680086--2 354500--1 (409--5842)
6
8
0
0
8
6
2
(408--8039) 565435--5 (409--5128)
680086--3
(408--8039) 354500--[ ] (409--5842)
567478--2 354500--1 (409--5842)
5
6
7
4
7
8
2
(408--8040) 565435--5 (409--5128)
122500--2 (409--5852)
2
4
-
-
2
2
1.4--1.9 122500--3 (409--5852) 58528--1
2
4
--
2
2
1
.
4
1
.
9
[.055--.075] 567478--1 356500--1 (409--5878)
5
8
5
2
8
1
(408--9997)
TAB 070
5
6
7
4
7
8
1
(408--8040) 356500--2 (409--5878) 755430--2
(
4
1
1
--
5
2
8
7
)
1213400--1 (409--5878)
(
4
1
1
--
5
2
8
7
)
1213400--2 (409--5878)
22--20 1.19--2.49
[.047--.098] -- -- -- -- -- -- 90653--1
(408--9854)
22--18 1.1--2.2
[.043--.087] -- -- -- -- -- -- 934195--1
[411--5658]
Figure15(cont’d)
114- 8005
MULTILOCK 040/070 and 070/250 Series Hybrid Connectors
Rev A19 of 20Tyco Electronics Corporation
CONTACT
TYPE
SERIES
SIZE
WIRE
SIZE,
AWG
INSUL
DIA
RANGE
APPLICATOR
(DOCUMENT)
POWER
UNIT
(DOCUMENT)
HAND
TOOL
(DOCUMENT)
EXTRACTION
TOOL
(DOCUMENT)
2.0--2.6
[.079--.102]
567908--1
(409--5855) 854040--3 (409--5855) -- -- --
1.68--2.59
[.066--.102] -- -- -- -- -- -- 58521--1
(408--9992)
1.75--2.59
[.069--.102] -- -- -- -- -- -- 90654--1
(408--9855)
1
2
2
5
0
0
-
-
2
(
4
0
9
-
-
5
8
5
2
)
1
2
2
5
0
0
--
2
(
4
0
9
--
5
8
5
2
)
122500--3 (409--5852)
7
5
5
4
3
0
2
070 20--16 567375--1 356500--1 (409--5878) 755430--2
(411--5287)
2
0
-
-
2
6
5
6
7
3
7
5
1
(408--8040) 356500--2 (409--5878)
(
4
1
1
5
2
8
7
)
2
.
0
--
2
.
6
[.078--.102] 1213400--1 (409--5878) 755224--1
(
4
1
1
5
3
3
8
)
[
]
1213400--2 (409--5878)
(
4
1
1
--
5
3
3
8
)
567375--2 354500--1 (409--5842)
5
6
7
3
7
5
2
(408--8040) 565435--5 (409--5128)
T
A
B
567375--3
(408--8040) 354500--[ ] (409--5842)
T
A
B
2
2
-
-
2
0
1.5--2.2 680050--2 354500--1 (409--5842)
2
2
--
2
0
1
.
5
2
.
2
[.059--.087]
6
8
0
0
5
0
2
(408--8039) 565435--5 (409--5128)
2
0
-
-
1
4
2.1--3.4 567457--2 354500--1 (409--5842)
2
0
--
1
4
2
.
1
3
.
4
[.083--.134]
5
6
7
4
5
7
2
(408--8039) 565435--5 (409--5128)
122500--2 (409--5852)
122500--3 (409--5852)
5
6
7
4
6
2
1
356500--1 (409--5878)
250 567462--1
(
408--8039
)
356500--2 (409--5878) -- -- -- -- -- --
2
9
-
-
3
8
(
4
0
8
-
-
8
0
3
9
)
14--12
2
.
9
--
3
.
8
[.114--.150] 1213400--1 (409--5878)
[
]
1213400--2 (409--5878)
567462--2 354500--1 (409--5842)
5
6
7
4
6
2
2
(408--8039) 565435--5 (409--5128)
567462--3
(408--8039) 354500--1 (409--5842)
Figure 15 (end)
114- 8005MULTILOCK 040/070 and 070/250 Series Hybrid Connectors
Rev A20 of 20 Tyco Electronics Corporation
6. VISUAL AID
Figure 16 shows a typical application of MULTILOCK 040/070 and 070/250 Series Hybrid Connector. 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.
FIGURE 16. VISUAL AID
CONTACTS
MUST BE
LOCKED IN
PLACE
NO CONDUCTOR
WIRES SHOWING IN
WIRE BARREL SEAM
CONDUCTOR ENDS
MUST BE VISIBLE
WIRE CONDUCTORS
AND INSULATION BOTH
VISIBLE IN THIS AREA
HOUSINGS OR
CONTACTS MUST
NOTBEBENTOR
CRACKED
FEMALE CAP ASSEMBLY
MUST BE SEATED ON PC
BOARD
SOLDER FILLET
MUST BE FORMED
EVENLY AROUND
TINES AND
BOARDLOCK
FEMALE CAP
AND MALE PLUG
ASSEMBLY MUST
BE LATCHED
TOGETHER
HARDWARE MUST
BE SECURELY
TIGHTENED
