Product Specification
040III HIGH DENSITY CONNECTOR
72POS/86POS/94POS/108POS/122POS/125POS
108-5673
Rev C2
27JUN06
タイコ エレクトロニクス アンプ株式会社 （〒213-8535 川崎市高津区久本 3-5-8）
1 of 10
Tyco Electronics AMP K.K. (3-5-8 Hisamoto Takatsu-ku Kawasaki, 213-8535)
この文書の改版の確認は本社、支店へお問い合わせください。 This document is subject to change. Call local AMP for the latest revision.
© Copyright 2002 by Tyco Electronics AMP K.K. All rights reserved.
* : 商標 Trademark
1. Scope:
1.1 Contents
This specification covers the requirements for product performance, test methods and quality
assurance provisions of 040Ⅲ HIGH DENSITY CONNECTOR
72pos/86Pos/94Pos/108Pos/122Pos/125Pos for Wire-to-Board Termination.
Applicable product description and part numbers are as shown in Appendix 1.
2. Applicable Documents:
The following documents form a part of this specification to the extent specified herein. In the event of
conflict between the requirements of this specification and the product drawing, the product drawing
shall take precedence. In the event of conflict between the requirements of this specification and the
referenced documents, this specification shall take precedence.
2.1 AMP Specifications:
A. 109-5000 ：Test Specification, General Requirements for Test Methods
B. 114-5217 : Crimping 040 Ⅲ Series Receptacle Contact
C. 501-5487 : Qualification Test Report
2.2 Commercial Standards and Specifications.
A. JASO D605 : Multi-pole Connector for Automobiles
B. JASO D7101 : Test Methods for Plastic Molded Parts
C. JIS C3406 : Low Voltage Wires and Cables for Automobiles
D. JIS D0203 : Method of Moisture, Rain and Spray Test for Automobile Parts
E. JIS D0204 : Method of High and Low Temperature Test for Automobile Parts
F. JIS D1601 : Vibration Testing Method for Automobile Parts
G. JIS R5210 : Portland Cement
H. MIL-STD-202 : Testing Method 208 : Method of Soldering
040III HIGH DENSITY CONNECTOR
72POS/86POS/94POS/108POS/122POS/122POS/125POS
108-5673
Rev. C2 2 of 10
3. Requirements:
3.1 Design and Construction:
Product shall be of the design, construction and physical dimensions specified on the applicable product
drawing.
3.2 Material :
A. Contact :
a. Receptacle Contact : Pre-tinned Phosphor bronze
b. Tab Contact : Pre-tinned Copper alloy
B. Housing：PBT resin
3.3 Ratings:
A. Temperature Rating：-30℃ to 105℃
3.4 Performance Requirements and Test Descriptions:
The product shall be designed to meet the electrical, mechanical and environmental performance
requirements specified in Fig.2. All tests shall be performed in the room temperature, unless otherwise
specified.
040III HIGH DENSITY CONNECTOR
72POS/86POS/94POS/108POS/122POS/122POS/125POS
108-5673
Rev. C2 3 of 10
3.5 Test Requirements and Procedures Summary:
Para.
Test Items Requirements Procedures
3.5.1
Confirmation of
Product
Product shall be conforming to the
requirements of applicable product
drawing and Application
Specification.No.114-5217
Visually, dimensionally and functionally
inspected per applicable quality inspection
plan.
Electrical Requirements
3.5.2
Termination
Resistance
（Low Level）
10mΩMax.（Initial）
20mΩMax.（Final）
Subject mated contacts assembled in housing
to closed circuit current of 10mA Max. at
open circuit voltage of 20mV Max. Fig.3
AMP Spec.109-5311-1
3.5.3
Termination
Resistance
（Specified
Current）
10mΩMax.（Initial）
20mΩMax.（Final）
Measure initial mill volt drop of contact test
circuit in mated connectors.
Fig.3
AMP Spec.109-5311-2
3.5.5
Insulation
Resistance 100MΩMin.
Impressed voltage 500V DC.
Test between adjacent circuits of mated
connectors. Fig.4
AMP Spec. 109-5302
3.5.4
Dielectric
Strength
No creeping discharge nor
flashover shall occur.
1kVAC for 1 minute.
Test between adjacent circuits of mated
connectors. Fig.4
AMP Spec. 109-5301
3.5.6
Temperature
Rising
Represent inter relative characters
betwe
en temperature rising of
energized contact crimp vs.
current
intensity in graph.
No abnormal temperature rising
shall take place.
Measure temperature rising by engaged
current.(Measure until the temperature
rising reaches 80℃)
AMP Spec. 109-5310
3.5.7
Current
Leakage 1mA Max 12V DC impressed 1min. Fig.5
AMP Spec. 109-5312
Physical Requirements
3.5.8
Handling
Ergonomics
No abnormalities allowed in
Manualmating/unmating
handling.
Manually operated
3.5.9
Contact
Mating Force 4.9N Max
Operation Speed : 100mm/min.
Measure the force required to mate contacts.
AMP Spec.109-5206
3.5.10
Contact
Unmating Force
0.98N Min.
Operation Speed : 100mm/min.
Measure the force required to unmate
contacts.
AMP Spec.109-5206
Fig.1 (To be continued)
040III HIGH DENSITY CONNECTOR
72POS/86POS/94POS/108POS/122POS/122POS/125POS
108-5673
Rev. C2 4 of 10
Para.
Test Items Requirements Procedures
3.5.11
Insertion Force
of Housing Unit
29.4N Max.
Operation Speed : 100mm/min.
Measure the force required to mate Housing
Unit.
AMP Spec.109-5206
3.5.12
Housing Locking
Strength 98N Min.
Measure housing locking strength.
Operation Speed:100mm/min.
AMP Spec. 109-5210
3.5.13
Connector
Mating Force
17Pos.147N Max.
22Pos.147N Max.
24Pos.147N Max.
31Pos.147N Max.
Operation Speed : 100mm/min.
Measure the force required to mate
connectors.
AMP Spec.109-5206
3.5.14
Connector
Unmating Force
17Pos.147N Max.
22Pos.147N Max.
24Pos.147N Max.
31Pos.147N Max.
Operation Speed:100mm/min.
Measure the force required to unmate
connectors.
AMP Spec. 109-5206
3.5.15
Contact
Insertion Force
9.8N Max. par contact.
Measure the force required to insert contacts
into housing.
AMP Spec. 109-5211
3.5.16
Contact
Retention Force
(Pre-Lock)
39.2N Min.
Apply an axial pull-off load to crimped wire.
Operation Speed: 100mm/min.
AMP Spec. 109-5212
3.5.17
Connector
Retention Force
58.8N Min.
Operation Speed:100mm/min.
Measure the force required to pull off the
housing from the connector or to break the
locking.
3.5.18
Reverse
Insertion of
Housing
Shall not be inserted the other
way.
Attempt to mate in the direction other than
normal mating .
3.5.19
Reverse
Insertion of
Terminal
Shall not be inserted the other
way.
attempt to load the contact in the direction
other than normal way.
3.5.20
Releasing Force
of Lock 49.0N Max. Measure releasing force of lock.
Wire size Crimp
tensile(Min)
mm
2
(AWG)
N
0.3 22 58
0.5 20 88
0.85 18 127
3.5.21
Crimp Tensile
Strength
1.25 16 177
Apply an axial pull-
off load to crimped wire of
contact secured on the tester.
Operation Speed:100mm/min.
AMP Spec. 109-5205
Fig.1 (To be continued)
040III HIGH DENSITY CONNECTOR
72POS/86POS/94POS/108POS/122POS/122POS/125POS
108-5673
Rev. C2 5 of 10
Para.
Test Items Requirements Procedures
3.5.22
Contact
Retention Force
(Secondary-Lock)
78N Min.
Apply an axial pull-
off load to crimped
wire.
Operation Speed: 100mm/min.
3.5.23
Fitting Force of
Double Lock
Plate
59N Max.
Operation Speed:100mm/min.
Measure the fitting force of double lock
plate.
3.5.24
Solderability Wet Solder Coverage: 95%Min.
Solder Temperature :230±5℃
Immersion Duration :3±0.5seconds
Flux: Alpha 100
AMP Spec. 109-5203
Environmental Requirement
3.5.25
Temperature
Life
（Heat Aging）
（Low level）:
20mΩMax.（Final）
Contact Retention Force:
0.98N Min.
120℃,Duration:120hours
AMP Spec. 109-5104
3.5.26
Resistance to
Cold
（Low level）:
20mΩMax.（Final）
-40±2℃, 120hours
AMP Spec. 109-5108
3.5.27
Thermal Shock
（Low level）:
20mΩMax.（Final）
Satisfied 3.5.21 Crimp Tensile
Strength
-30℃/120min.,80℃/120min.
Making this a cycle, repeat 5cycles.
AMP Spec. 109-5103
3.5.28
Humidity,
Steady State
（Low level）:
20mΩMax.（Final）
Insulation resistance:
100MΩMin.（Final）
1kVAC for１minute：No creeping
discharge nor flashover shall occur.
Contact Retention Force:
0.98N Min.
Connector Retention Force：
58.8N Min.
Current Leakage：1mA Max.
Mated connector,
90～95％R.H.,60℃
96hours
AMP Spec. 109-5105
3.5.29
Current Cycling
（Low level）:
20mΩMax.（Final）
No ignition is allowed during the test.
Temperature rise in the terminal
press point area shall be 20℃Max.
45minutes”ON”,15minutes”OFF”,
1000cycles.
Current intensity shall cause temperature
rising up to 40℃.
AMP Spec.109-5308
3.5.30
Durability
(Repeated
Mate/Unmating)
（Specified Current）：
20mΩMax.（Final）
Operation Speed: 100mm/min.
No. of Cycles:20 Cycles.
AMP Spec.109-5213
Fig.1 (To be continued)
040III HIGH DENSITY CONNECTOR
72POS/86POS/94POS/108POS/122POS/122POS/125POS
108-5673
Rev. C2 6 of 10
Para.
Test Items Requirements Procedures
3.5.31
Resistance
to ”Kojiri”
（Specified Current）：
20mΩMax.（Final）
Secure one of the connectors on the
table, and with the half mated
condition, apply the bending force of
98N in front-rear and right-left
directions two times. Making this a
cycle, repeat 10 cycles.
3.5.32
Vibration
(High
Frequency)
No electrical discontinuity greater
than 1μsec. shall occur.
（Specified Current）：
20mΩMax.（Final）
Vibration Frequency:
20～400Hz/6min.
Accelerated Velocity: 44.1m/s
2
Vibration Direction：Up and Down,
Back and Force, Right and Left
Directions：Each 3hours
Open circuit voltage：13V
Closed circuit current：1±0.1A
3.5.33
Resistance Oil
（Specified Current）：
20mΩMax.（Final）
Immerse the connector in the
engine-oil mixture of SAE 10W or
equivalent and kerosene conforming
to JIS K 2203(Kerosene)K No.2 in
equal quantity kept at 50±℃ for 20
hours.
3.5.34
Dust
Bombardment
（Specified Current）：
20mΩMax.（Final）
Subject JIS R 5210 cement blow of
1.5Kg per 10 seconds in 15 minutes
intervals for 8 cycles, which
Unmate/Re-mating per 2 cycles.
AMP Spec. 109-5110
3.5.35
Industrial Gas
（SO
2
）
（Low level）:
20mΩMax.（Final）
SO
2
Gas：10ppm, 90~95％R.H.
40℃, 24hours
AMP Spec. 109-5107
3.5.36
Resistance to
Ammonia
Satisfied 3.5.21 Crimp Tensile
Strength
The ammoniacal water solution
100ml(concentration:1%) in the sealed
glass container(20~25l),which
pedestal the samples leave 96hours.
Fig.1 （End）
040III HIGH DENSITY CONNECTOR
72POS/86POS/94POS/108POS/122POS/122POS/125POS
108-5673
Rev. C2 7 of 10
3.6 Product Qualification Test Sequence
Test Group
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Para.
Test Items
Test Sequence (a)
3.5.1
Confirmation of
Product
1
1
1
1
1
1
1
1
1
1
1
1 1 1
1
1
3.5.2
Termination Resistance
（Low Level）
2
2,4
2,4
2,4,
7,9
6
3.5.3
Termination Resistance
（Specified Current）
3
4,68
2,4
6
2,4
3.5.4
Insulation Resistance
4
10
3.5.5
Dielectric Strength 5
11
3.5.6
Temperature Rising 7
3.5.7
Current Leakage 6
12
3.5.8
Handling Ergonomics
2
3.5.9
Contact Mating Force
2
3.5.10
Contact Unmating
Force
3
5
3.5.11
Insertion Force of
Housing Unit
2
3.5.12
Housing Locking
Strength
3
3.5.13
Connector Mating Force
2
3.5.14
Connector Unmating
Force
3
3.5.15
Contact Insertion Force
2
3.5.16
Contact Retention
Force(Pre-Lock)
2
3.5.17
Connector Retention
Force
3
13
3.5.18
Reverse Insertion of
Housing
3
3.5.19
Reverse Insertion of
Terminal
4
3.5.20
Releasing Force of Lock
2
3.5.21
Crimp Tensile Strength
5
5
3
3.5.22
Contact Retention
Force(Secondary Lock)
4
Fig.2（To be continued）
040III HIGH DENSITY CONNECTOR
72POS/86POS/94POS/108POS/122POS/122POS/125POS
108-5673
Rev. C2 8 of 10
Test Group
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Para.
Test Items
Test Sequence (a)
3.5.23
Double Lock Plate
Locking Strength
2
3.5.24
Solderability 2
3.5.25
Temperature Life
（Heat Aging）
3
3.5.26
Resistance to Cold 6
3.5.27
Thermal Shock 3
3.5.28
Humidity,
Steady State
8
3.5.29
Current Cycling 3
3.5.30
Durability(Repeated
Mate/Unmating)
5
3.5.31
Resistance to ”Kojiri” 3
3.5.32
Vibration
(High Frequency)
5
3.5.33
Resistance to Oil 7
3.5.34
Dust Bombardment 3
3.5.35
Industrial Gas (SO
2
) 5
3.5.36
Resistance to Ammonia
2
(a) Numbers indicate sequence in which tests are performed.
Fig.2（End）
040III HIGH DENSITY CONNECTOR
72POS/86POS/94POS/108POS/122POS/122POS/125POS
108-5673
Rev. C2 9 of 10
1mm Max.
Y L
X Y'
Soldering
PCB
Deduct resistance of Y-Y'(wire"L")from X-Y'
Fig.3
Measuring Apparatus
Adjacent Contacts
Contacts-Housing
Wrap metallic-
foil to cover the
connector surface
Fig.4
108
-
5673
040III HIGH DEHSITY CONNECTOR
72POS/86POS/94POS/108POS/122POS/125POS
Rev. C2 10 of 10
The applicable product descriptions and part numbers are as shown in Appendix 1.
Appendix １
Prod.P/N Description
353027-□ 17 Position Plug-housing Assembly
353028-□ 22 Position Plug-housing Assembly
353029-□ 24 Position Plug-housing Assembly
353826-□ 31 Position Plug-housing Assembly B Type
1318682-□ 31 Position Plug-housing Assembly C Type
353015-3 122 Position Cap-housing Assembly
1318612-1 125 Position Cap-housing Assembly
1318613-1 108 Position Cap-housing Assembly
1318614-1 86 Position Cap-housing Assembly
1123038-2 72 Position Cap-housing Assembly
1123042-3 72 Position Cap-housing Assembly without several contacts
316836-1 040Ⅲ ”S” Receptacle Contact （Tin-plate）
1123653-1 040Ⅲ”MS” Receptacle Contact （Tin-plate）
316838-1 040Ⅲ”M” Receptacle Contact （Tin-plate）
1473181-1 94 Position Cap-housing Assembly B Type
Fig.5
