MCP 2.8 mm Contact System and Wre Seal for 1P Starter Motor Connectors Applcaton Specfcaton 114-13295 05 MAY 11 All numercal values are n metrc unts [wth U.S. customary unts n brackets]. Dmensons are n mllmeters. Unless otherwse specfed, dmensons have a tolerance of ±0.13 and angles have a tolerance of ±2. Fgures and llustratons are for dentfcaton only and are not drawn to scale. 1. INTRODUCTION Ths specfcaton covers the requrements for applcaton of 2.8 mm MCP termnal system for use n the automotve ndustry. The termnal system conssts of a receptacle termnal and wre seal. Each termnal features an nsulaton barrel, wre barrel, and matng end. The serratons nsde the wre barrel provde maxmum contact and tensle strength after crmpng. The termnal s held n the connector when the lockng lance mechansm of the termnal engages the lockng surface of the connector. The sealed termnals are desgned for severe envronmental condtons and hgh temperature applcatons. Applcaton s suted for class 4 temperatures (-40 to 155 C [-40 to 311 F]) and severe vbraton (mounted on engne). Platng system must be slver. Sealng s acheved by means of an ndvdual wre seal. The termnals are avalable n a carrer strp for termnatng wth sem-automatc machnes. When correspondng wth TE Connectvty Personnel, use the termnology provded n ths specfcaton to facltate your nqures for nformaton. Basc terms and features of ths product are provded n Fgure 1. Insulaton Barrel Serratons Wre Seal Lockng Lance Cutoff Tab Matng End Wre Barrel Receptacle Termnal 2. REFERENCE MATERIAL 2.1. Revson Summary Intal release of document Fgure 1 2011 Tyco Electroncs Corporaton, a TE Connectvty Ltd. Company All Rghts Reserved *Trademark TOOLING ASSISTANCE CENTER 1-800-722-1111 PRODUCT INFORMATION 1-800-522-6752 Ths controlled document s subject to change. For latest revson and Regonal Customer Servce, vst our webste at www.te.com TE Connectvty, TE connectvty (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of ther respectve owners. 1 of 7 LOC B
2.2. Customer Assstance 114-13295 Reference Part Number 968857 and Product Code 7715 are representatve of 2.8 mm MCP termnal system. Use of these numbers wll dentfy the product lne and expedte your nqures through a servce network establshed to help you obtan product and toolng nformaton. Such nformaton can be obtaned through a local TE Representatve or, after purchase, by callng PRODUCT INFORMATION at the number at the bottom of page 1. 2.3. Drawngs Customer Drawngs for product part numbers are avalable from the servce network. If there s a conflct between the nformaton contaned n the Customer Drawngs and ths specfcaton or wth any other techncal documentaton suppled, call PRODUCT INFORMATION at the number at the bottom of page 1. 2.4. Instructonal Materal Instructon Sheets (408-seres) provde product assembly nstructons or toolng setup and operaton procedures and Customer Manuals (409-seres) provde machne setup and operaton procedures. Documents avalable whch pertan to ths product are: 408-3295 Preparng Reel of Contacts for Applcaton Toolng 408-7424 Checkng Termnal Crmp Heght or Gagng De Closure 408-8322 Heavy Duty Industral (HD-I) Sde-Feed Type Applcator 408-8040 Heavy Duty Mnature Quck-Change Applcators (Sde-Feed Type) 408-8059 General Preventatve Mantenance for Applcators 408-9816 Handlng of Reeled Products 409-5842 AMP-O-LECTRIC* Model G Termnatng Machnes 354500-[ ] 409-10027 Strppng Module 1490502-[ ], 1490500-[ ], and 1725910-[ ] 409-10029 Strppng Module 1490503-[ ] and 1490501 409-10047 AMP 3K Termnatng Machnes 1725950 and AMP 5K Termnatng Machnes 1725900 411-18087 ERGOCRIMP Basc Crmp Hand Tool 539635-1 411-18177 ERGOCRIMP De 539727-2 3. REQUIREMENTS 3.1. Storage A. Shelf Lfe The termnals should reman n the shppng contaners untl ready for use to prevent deformaton. Termnals should be used on a frst n, frst out bass to avod storage contamnaton that could adversely affect sgnal transmssons. B. Ultravolet Lght Prolonged exposure to ultravolet lght may deterorate the chemcal composton used n the termnals. C. Reels Care must be taken to prevent stretchng, saggng, or other dstorton that would prevent smooth feedng of the tape through automatc machne feed mechansms. Store col wound reels horzontally and traverse wound reels vertcally. D. Chemcal Exposure Do not store termnals near any chemcals that may cause stress corroson crackng n the contacts. Where the above envronmental condtons exst, phosphor-bronze termnals are recommended nstead of brass. 3.2. Wre Selecton and Preparaton The sealed termnals accept stranded copper wre szes 2.5 mm 2 and 4.0 mm 2. Wre nsulaton dameter accordng to wre sze s gven n Fgure 2. Proper strp length s necessary to properly nsert the wre nto the termnal. Strp length s gven n Fgure 2. 2 of 7
CAUTION Reasonable care must be taken not to nck, scrape, or cut any strands durng the strppng operaton. The wre seal must be nserted onto the wre (pror to termnaton) and crmped n the nsulaton barrel of the termnal smultaneously wth the termnal. The approprate wre seal must be selected whch wll accommodate the nsulaton dameter of the wre (contact PRODUCT INFORMATION at the number at the bottom of page 1 for approprate wre seal part number). The wre seal must be nstalled onto the wre as shown n Fgure 2. CAUTION The wre seal must not be damaged when placng t over the wre. 1.0 Max Wre Insulaton Strp Length Wre Seal WIRE SIZE (mm 2 ) WIRE INSULATION DIAMETER RANGE STRIP LENGTH ±0.3 mm Fgure 2 3.3. Crmp Requrements A sealed and unsealed termnal as t should appear after crmpng s shown n Fgure 3. Perodc nspectons must be made to ensure crmped contact formaton s consstent as shown. A. Crmp Heght and Wdth 2.5 2.70-3.00 5.0 4.0 3.40-3.70 5.6 The crmp appled to the wre porton of the termnal s the most compressed area and s most crtcal n ensurng optmum electrcal and mechancal performance of the crmped termnal. The crmp heght and wdth must be wthn the dmensons provded n Fgure 3. The developed crmp confguratons result from usng the specfc toolng descrbed n Secton 5, TOOLING. 3 of 7
WIRE SIZE WIRE BARREL mm 2 HEIGHT ±0.05 WIDTH ±0.1 INSULATION BARREL WIDTH (REF) B. Wre Seal Fgure 3 The wre seal may not extend beyond the dmensons shown n Fgure 4. CAUTION The developed crmp confguratons result from usng the specfc toolng descrbed n Secton 5, TOOLING. C. Crmp Length 2.5 1.88 2.54 4.70 4.0 2.27 3.05 5.20 Effectve crmp length shall be defned as that porton of the wre barrel, excludng bellmouth(s), fully formed by the crmpng tool. For optmum crmp effectveness, the crmp must be wthn the area shown n Fgure 4. Wre Barrel Seam Closed wth No Strands Protrudng or Showng Wre Strands and Insulaton Must be Vsble n ths Area 0.1-0.7 0.9 Max Front Bellmouth Wre Strands Do Not Exceed Heght of Wre Barrel 0.6 ±0.3 Rear Bellmouth Y 0.5 Mn Seal Locaton X X Y See Vew A Fgure 4 4 of 7
D. Wre Barrel Seam The wre barrel seam must be closed wth no evdence of loose wre strands vsble n the seam as shown n Fgure 4. E. Bellmouths Front and rear bellmouths shall be evdent and conform to the dmensons gven n Fgure 4. F. Wre Locaton The wre conductor and nsulaton must be vsble n the transton area between the wre and nsulaton barrels. Refer to Fgure 4. G. Wre Barrel Flash The wre barrel flash shall not exceed the dmensons shown n Fgure 4. H. Conductor Locaton The conductor may extend beyond the wre barrel to the maxmum shown n Fgure 4. I. Cutoff Tab and Burr The cutoff tab and burr shall not exceed the dmensons shown n Fgure 4. 3.4. Twst and Roll There shall be no deformaton or other damage to the matng porton of the crmped contact that wll prevent proper matng. The twst and roll shall not exceed the lmt shown n Fgure 5. 5 Max Front of Termnal Wre Barrel Fgure 5 3.5. Tensle Crmped termnals should hold the wre frmly and have a pull-test tensle value meetng the requrements of DIN IEC 352, Part 2. 3.6. Straghtness The force appled durng crmpng may cause some bendng between the crmped wre barrel and the matng porton of the termnal. Such deformaton s acceptable wthn the followng lmts. 1. Up and Down The crmped termnal, ncludng cutoff tab and burr, shall not be bent above or below the datum lne more than the amount shown n Fgure 6. 2. Sde-to-Sde The sde-to-sde bendng of the termnal may not exceed the lmts provded n Fgure 6. 3.7. Repar and Replacement CAUTION These termnals are not reparable.damaged termnals must be removed from the connector and replaced wth new ones. Termnals MUST NOT be re-used by removng the wre. 5 of 7
Sde-to-Sde Up and Down Datum Lne 4. QUALIFICATIONS Fgure 6 Termnals n the 2.8 mm MCP termnal system are not requred to be agency approved. 5. TOOLING Sem-automatc machnes for power asssted applcaton of tape-mounted termnals are avalable to cover the full wre sze range. Modfed desgns and addtonal toolng concepts may be avalable to meet applcaton requrements. Toolng part numbers are shown n Fgure 7. 5.1. Applcators The applcator s desgned to crmp tape-mounted termnals onto pre-strpped wre, and provdes for hgh volume, heavy duty producton requrements. The applcator must be nstalled onto a power unt. 5.2. Power Unts Each applcator s shpped wth a metal dentfcaton tag attached. DO NOT remove ths tag or dsregard the nformaton on t. Also, a packet of assocated paperwork s ncluded n each applcator shpment. Ths nformaton should be read before usng the applcator; then t should be stored n a clean, dry area near the applcator for future reference. Some changes may have to be made to the applcators to run n all related power unts. Contact the Toolng Assstance Center number located at the bottom of page 1 for specfc changes. The power unt provdes the force requred to drve the applcator for crmpng tape-mounted termnals. These power unts are desgned to be bench mounted. 5.3. Hand Tools Hand crmpng tools that accommodate the full wre sze range are desgned for prototype and low-volume applcatons such as repar of damaged contacts. 5.4. Extracton Tools Extracton Tools are desgned to release the lockng lance nsde the connector housng wthout damagng the housng or contacts. TERMINAL SEAL WIRE SIZE (mm 2 ) HAND TOOL FRAME TOOLING DIE SET APPLICATOR POWER UNIT EXTRACTION TOOL 1-968857-3 368941-1 2.5 539635-1 539727-2 1-968859-3 368940-1 4.0 1426348-2 1385432-3 354500-1 1490501-1 1725900-[ ] 1725910-[ ] 1725950-[ ] 1-1579007-2 GM J38125-557 Fgure 7 6 of 7
6. VISUAL AID 114-13295 Fgure 8 shows a typcal applcaton of 2.8 mm MCP termnal. Ths llustraton should be used by producton personnel to ensure a correctly appled product. Applcatons whch DO NOT appear correct should be nspected usng the nformaton n the precedng pages of ths specfcaton and n the nstructonal materal shpped wth the product or toolng. WIRE SEAL AND WIRE MUST BE VISIBLE BETWEEN WIRE BARREL AND INSULATION BARREL FRONT BELLMOUTH AND REAR BELLMOUTH MUST BE VISIBLE WIRE CONDUCTOR MUST PROTRUDE SLIGHTLY FROM FRONT OF WIRE BAREL Fgure 8 (VISUAL AID) 7 of 7