Tyco Electronics 16Pos.Plug Housing Guida di riferimento

Customer Manual

412-5666-1

19AUG08 Rev.D2

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 13

Tyco Electronics AMP K.K. (3-5-8 Hisamoto Takatsu-ku Kawasaki, 2 3-8535)

この書は当社により変更管理されており、必要に応じ変更されます。

最新の改定については当社本支店にお問い合わせ下さい。

* : 商標 Trademark

16POS DIAGNOSTIC CONNECTOR

CONTENTS

Page

1. Product Name and Part Number ............................................................................. 2

1.1 Contact ...................................................................................................................... 2

1.2 Housing ..................................................................................................................... 2

1.3 Part Number .............................................................................................................. 3

2. Inspect on of Contact and Hous ng ........................................................................ 3

2.1 TE’s Shipping Inspection............................................................................................ 3

2.2 Customer’s Receiving Inspection...............................................................................

3. Cr mp ng

Operat on ................................................................................................ 5

3.1 Control of Storage and Transfer ................................................................................. 5

3.2 Control of Crimping Operation.................................................................................... 6

3.3 Control of Crimped In-Process Products .................................................................... 9

4. Manufactur ng Harness Assembl es....................................................................... 10

Mating Contact into Housing and Complete of Doublelock........................................ 10

.2 Extract of Contact ..................................................................................................... 12

.3 Dealing with Harness Products ................................................................................. 13

5. Assembl ng on Veh cles.......................................................................................... 1

5.1

Receiving Inspection................................................................................................. 1

5.2 Points of Mating Operation........................................................................................ 1

5.3 Caution ..................................................................................................................... 1

Customer Manual

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Rev. D2 2 of 14

1 Product Name and Part Number

This product is called 16position Diagnostic Connector and composed of following parts.

1.1 Contact

1.2 Hous ng

Double Lock Plate

Plug Housing

Cap Lock

Touching Area (inside box)

Stabilizer

Insulation Barrel

1.5mm Female Contact

ire Barrel

Customer Manual

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Rev. D2 3 of 14

1.3 Part Number

1.3.1

Contact

Applicable Wire

Name TE Number

Wire Type 0.3 0.5 0.85

CAVUS ○ ○ ○

CAVS/AVSS ○ ○ ○

1.5mm Female

Contact 776001

AVS ○ ○ ○

1.3.2

Hous ng

Pos. Name Number

16 16Pos.Plug Housing 179631

Inspect on of Contact and Hous ng

2.1

TE’s Sh pp ng Inspect on

Prior to shipping, products are thoroughly inspected by TE in accordance with the self-specified quality

control procedures and regulations to cover all the data of manufactures by each lot production. Date of

manufacturing is shown on the wrapping so that the process of manufacturing can be traced referring to

the records of inspection, manufacturing and machinery control.

Date of manufacturing is shown like follows.

95 40 2

shows the day. Monday

ordered week of the year. 0th week.

shows A.D.1995(H.7)

Customer Manual

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Rev. D2 4 of 14

2.2

Customer’s Rece v ng Inspect on

Also, it is desirable that products are at least inspected referring to the applied customer drawing as

receiving inspection. Please follow the method below.

〈Contact〉

Item Inspection Regulation and Method Tools for

Measurement

1）Shape Visual

2）Plate Finishing Visual

Appearance

Inspection

3）Condition of Strip Terminals Visual

1）Width and Height of Wire Barrel Callipers

Size Inspection 2）Width and Height of Insulation

Barrel Callipers

In receiving, whole reels must be cut apart by Date Code as Reeling unit, visually inspected on II

(MIL-STD-105) standard and AQL %, also inspect the five edge points of the reels. When the all five

reels meet the standard, the lot is supposed to have passed the inspection.

〈Housing〉

Item Inspection Regulation and Method Tools for

Measurement

1）Burrs, Discoloration and Deformation Visual

Appearance

Inspection 2）Cracking, Breakage and Tip-Off of Housing Visual

Functional

Inspection

1) Mating and Unmating Function of Contacts; Check to see

if the housing is normally mated and unmated, and locked

when mated. Unmating must be easily done by pressing

unlocking leg and pulling it out.

Manual

Set one wrapped as box one unit, classify the boxes by Date Code, inspect their appearance in

accordance with II (MIL-STD-105) standard and AQL %, then give a functional inspection to five of

them. When the all housings meet these standards, the lot is supposed to have passed the inspection.

Customer Manual

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Rev. D2 5 of 14

3. Cr mp ng Operat on

Crimping of Contacts must be done with TE specified application tools following the specified

procedure. Also, it is recommended to record the part number and date code (see already specified

example; 95 02) for future reference.

3.1

Storage and Transfer of Reeled Products

1）Avoid Carrying or leaving terminal reel in an open area without wrapping it with proper material.

2）Do not lift up or carry the terminal reel by gripping only one flange of the reel lest it should cause the

damage of the reel and become unable to be used on crimping machine.

3) Avoid leaving terminal reels in a damped area. Store them at where relatively dry and clean room

without direct sunlight with the appropriate temperature 5～35℃ and the humidity 5～85％.

) When the terminal reel is not in use for a long time, discharge it from the machine, and fasten the

end of terminal strip on the edge of reel with the proper string or wire as shown in the figure below.

CORRECT

Make a not on the edge

Do not hold only one side rim of the reel

Customer Manual

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Rev. D2 6 of 14

3.2

Control of Cr mp ng Operat on

It is required to prepare the Instruction Manual following the Application Specification 11 -2136.

Important points are listed below.

（1）Wires must not be damaged or severed

（2）Wire end pre-treatment before Crimping

appropriate length: the length of wire barrel of used contact +0.5～1.0mm

（3）Cross-section of Wire Barrel Crimp

cut severed cut

defected

normal

length of the strip

±0.05mm difference

Crimp Height

ire Barrel

Micrometer

ires

Customer Manual

412-5666-1

Rev. D2 of 14

（）Modified Micrometer for Measurement of Crimp Height

3.2.1 Cr mp ng Cond t on of Contact

Number: 4001

(J980A2-2)

Bend-Up 3°MAX

Wire Barrel Seam

(No stand looses out of the seam)

Deformation after Crimpin

Twist

±5°

Bend-Down 3°MAX Insulation Strippin Len th

Front Bell mouth (0.25mm)

Wire End Protrusion Len th (1.27mm MAX)

Insulation End

Wire Barrel Crimp Hei ht

Cut-off Tab Len th(0.13～0.38mm)

Insulation Barrel Crimp Hei ht

Rear bell mouth (0.2mm)

Customer Manual

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Rev. D2 8 of 14

3.2.2 Cr mp ng Data （

（（

（1.5mm Ser es）

））

）

Applicator No. to crimp contacts and the sizes are follows. Please have a check before the operation.

Wire Barrel Crimp Inspection Items

Contact

No. Applicator No. Wire Size Width

（mm）

Height

（mm）

Width

（mm）

Height

（mm）

0.3 1.07

0.5 1.15

776001 567 67-2

0.85

1.78

1.2

2.3 2. 6max

*: Applicable wires are Automotive Low Voltage ones. AVS/AVSS/CAVUS 0.3～0.85

Customer Manual

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Rev. D2 9 of 14

3.3

Control of Cr mped In-Process Products

3.3.1

Inspect on of Products

Inspection of crimped in-process products must be conducted by the lot unit, which means the

group of products manufactured under the same set-up adjustment of the crimping machine or that of

products manufactured during whole one day. The inspection must be conducted under the same

condition.

Refer to the list below the details.

Type of Inspection Timing Inspection Items

Inspection on Products made

under initial set-up condition

of applicator

When the first applicator is

set up on the wire

Visual Inspection and Dimensional

Inspection of all items listed below

Beginning of the operation

everyday Same as above

Lot Inspection

During the continuous

production run

Visual Inspection on all the items

listed below, and Dimensional

Inspection only on the Item No.3 in

following chart

Type of

Inspection

Checking Points and Methods Tools for

Measurement

1.Loose-out of wire conductors outside the wire barrel crimp, and

cut-off of conductor(s) Visual

2.Defective crimped form of contact (forming up of bellmouth, and

wire end protrusion length) Visual

3.Defective wire barrel at the bottom(burrs appearing, inclusive) Visual

.Misgripping of insulation barrel crimp on wire insulation Visual

Visual

Inspection

5.Deformation of contacting area of contact Visual

1.The length of Cut-Off Tab 0.13～0.38mm Callipers

2.Deformation of Contact (bend-up, rolling, and twisting) Magnifying

Glass

3.Crimp Height Micrometer

Size

Inspection

.Front and rear of bellmouth forming

Front bellmouth:0.2mm max

Rear bellmouth: 0.5mm max

Callipers

*Note: Callipers are defined as vernier callipers or equivalent measuring tools, having the identical

precise measurement level.

Customer Manual

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Rev. D2 10 of 14

3.2.2

Storage

a） Products must be kept in the clean, dry area. Exposing in the open air until the following day is

strictly forbidden for the prevention from contamination by dust and particle.

b） Maximum 100 of in-process crimped leads to bundle.

c） Avoid stacking and piling up of the in-process products in large volume, lest it should result in

catching each other and entangling on the projecting parts of the leads. This will cause damage

and breakage of the products. Deformation of the contact will result in malfunction of contacting

parts electrically.

d） Beware in separating bundles not to get contacts entangled.

e） Do not leave uncrimped contacts in the damp place. Contacts must be kept in suitably dry

sunshined clean room with the appropriate temperature (5～35℃)and the humidity( 5～85％)

f） Beware in string or transferring bundles of crimped contacts lest they should be entangled of

deformed. Maximum 100 of contacts to bundle.

Manufactur ng Harness Assembl es

4.1

Mat ng Contact nto Hous ng and Complete of Doublelock

4.1.1

Load ng Contact

Direction of Contact

Direction of Contact is distinguished from that of stabilizer.

Place the housing with its cap locking side up (without shorter side of trapezoid up), stabilizer of

upper contact side up, and that of lower down. Load the contact following the instructions below.

(1) Please make certain of direction of contact and insert contact into housing until it clicks and does not

go further . Also pull the wire lightly and make sure the contact does not come out.

(2) In case contact must be taken out, beware of the deformation.

(3) After the completion of loading contact, doublelock it as soon as possible.

Stabilizer (down)

Plug Housing

Contact (down)

Contact (u )

Doublelock Plate

Stabilizer (u )

Ca Locking

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