MCON-1.2 mm Interconnection System · Industry Truck Industry Other Industry Safety Systems Chassis...

MCON-1.2 mm

Interconnection

System

G L O B A L A U TO M OT I V E D I V I S I O N

RoHSReady

MCON 1.2 Umschlag.qxd 19.04.2006 12:13 Uhr Seite 1

Driver Information

Safety Systems

Body

T Y C O E L E C T R O N I C S G L O B A L A U T O M O T I V E D I V I S I O N


T H E 7 A P P L I C A T I O N A R E A S

1

Convenience

PowertrainSystems

ChassisSystems

Security

MCON 1.2 Inhalt.qxd 19.04.2006 11:14 Uhr Seite 1

2

T E R M I N A L S & C O N N E C T O R S

Tyco Electronics offers a broad range of high quality terminals and

connectors. Our electrical and electronic interconnection products and

solutions are used to electrically and mechanically join wires and cables,

printed circuit boards, integrated circuit packages and batteries.

Our growing capabilities include new copper and fiber-optic connectors,

wires, cables and cable management systems that are designed to meet

automotive industry demands. The AMP brand encompasses the broadest

range of connectors in the world, including high-density, high-speed designs for

leading-edge communications equipment.

LITERATURE NO. 1308092-1

I N N O V A T I V E T E C H N O L O G I E S

Tyco Electronics is one of the major business units of Tyco International Ltd.

Headquartered in Harrisburg, Pennsylvania, USA. Tyco Electronics is the

world’s largest passive electronic components manufacturer and a world

leader in cutting-edge wireless technologies. The company has facilities

located in over 50 countries, serving customers in the aerospace, automotive,

computer, communications, consumer electronics, industrial and power

industries. The global automotive division follows the globalization goals of

our customers, speeds up the integration of new technologies and enables our

customers access to our vast product portfolio and services.

M E C H A T R O N I C S

A variety of technical products is designed today by integrating mechanical

components and electronic hardware into one packaging unit thus creating

true mechatronic solutions. Mechatronic applications offer amazing and

versatile potentials related to functionality, cost, space requirements and

quality. Tyco Electronics contributes to those applications with its wide range

of innovative and cost-effective product and process technologies.

Advanced stamping, injection molding and assembly techniques are applied along with

highly selective surface plating methods.




3

C L O C K S P R I N G S Y S T E M S

Automotive technology and integrated systems continue to develop

at a rapid pace with electric and electronic systems playing an important

role in traffic safety and travel comfort.

The Safety Systems (SAS) subdivision of Tyco Electronics’ Global Automotive

Division offers a wide range of engineering “know-how“ and production

facilities concerning electrical transfer units (“clocksprings”) for steering

wheel airbag devices. Tyco Electronics has a remarkable combination of

competencies in development, production, application support and related technologies

to ensure a competitive edge for business growth worldwide.


S E N S O R T E C H N O L O G Y

Tyco Electronics offers non-contact sensors for a variety of applications.

As sensor manufacturer and processing partner, we also provide project

planning support for new sensor applications, assistance in the

selection of the appropriate sensor technology for the respective application,

and assistance with defining the corresponding mechanical, electrical and

magnetic interface. Tyco Electronics has a broad electromechanical portfolio

that includes robust housing technologies, connector systems, and

temperature stable designs based on foil and cable networks. This combination of

technologies and experience ensures that reliable and cost effective sensor solutions are

available for all application types.


R E L AY S A N D S W I T C H I N G M O D U L E S

Automotive technology and integrated systems continue to develop at

a rapid pace with electric and electronic systems playing an important role

in traffic safety and travel comfort. Tyco Electronics is the world’s number

one supplier for automotive relays and switching modules (AR & SM),

offering a wide range of vital components for safety systems.

Tyco Electronics has a remarkable combination of competencies in

development, production, application support and related technologies to

ensure a competitive edge for business growth worldwide.



4

P O W E R D I S T R I B U T I O N S Y S T E M S

The extensive net of electrical and electronic loads in vehicle environments

requires the next evolution of complex powernet structures such as

intelligent control and distribution systems. Tyco Electronics offers modules

with intelligent technology for power distribution units with integrated

switching and protection functions. Our power distribution systems offer

maximum flexibility and modularity at the highest package density that can

be customized based on customer requirements.


I N D U C T I V E S Y S T E M S

Tyco Electronics, Global Automotive Division, is your source for interconnec-

tion and wireless technologies for automotive, truck and off-highway OEMs

and Tier 1 suppliers

Tyco Electronics has inductive system components that are suitable for any

LF-application in the vehicle environment. Tyco Electronics offers a vast

Inductive Systems product portfolio which includes antennas, actuators and

integrated modules. Applications are developed using cost-effective engineering and are

focused on customized designs based on customer requirements.


H Y B R I D S Y S T E M S

Tyco Electronics is a leader in next-generation transportation technologies

and products for hybrid and electric vehicles. The Global Automotive Division

is your source for high voltage power distribution, high current contacts, high

voltage connectors and cables, high voltage relays, sensors and temperature

protection devices for hybrid and other alternative powered vehicles.




5

H I G H S P E E D C O M M U N I C A T I O N

With the introduction of the D2B Optical Networking System in 1997,

the way was set for the automotive world to start reaping the benefits for

optical data transmission.

The advantages of Optical Networking were attracting the attention of many

other car OEM’s and in 1998 with the foundation of the MOST® Cooperation

the first steps were taken to build on the work of the D2B technology and

spread the benefits of the Optical Networking technology throughout the automotive world.

The MOST Cooperation focused on developing an optical network specification defining all

key interface points which would enable the automotive supplier market to develop

components when based on the MOST Specification to be compatible and interoperable.

M O S T ® I S A R E G I S T E R E D T R A D E M A R K O F O A S I S


A V I T A L P A R T O F Y O U R W O R L D

Tyco businesses operate in thousands of different areas of industry. The products and services we

deliver all have one thing in common: They are vital to everyday living. Individuals and companies

worldwide have critical needs, and every minute of every day, Tyco is satisfying those needs.

W I R E L E S S T E C H N O L O G I E SR A D A R S E N S O R S & A N T E N N A S F O R T E L E M A T I C S

Tyco Electronics offers wireless sensors for automotive and off-highway

applications for just about any location in the vehicle. We are first to market

in-radar based sensors for truck collision warning systems, autonomous

cruise control systems and short-range sensor systems.

Tyco Electronics also offers quad band antennas which use Satellite Radio

(SDARS), GPS and two cellular bands that comply with current vehicle

navigation and safety system antenna requirements.



■ Connector Systems / Electromechanical Components

■ Relays

■ Wireless

■ Antennas, GPS Antennas

■ Sensors

■ Fiber Optic (Passive)

■ Heat Shrink Tubing

■ Wire & Cable

■ Printed Circuit Board Technologies

■ Circuit Protection Devices

■ Touchscreens / Interactive Displays

■ Application Tooling

■ Battery Assemblies

■ Power Systems / Electronic Modules

■ Magnetics

■ Resistors and Inductors

■ Heat Sinks / Thermal Management

■ Switches

■ Identification & Labeling Products

■ Racks and Panels

■ Smart Cards / Leadframes

■ Clock Springs

■ Small Motors (20–1,500 W)

T Y C O E L E C T R O N I C S “ T E C H N O L O G Y P O R T F O L I O ”

6


7

Internet Homepage www.tycoelectronics.comwww.tycoelectronics.com/automotive

Electronic Internet Catalog www.catalog.tycoelectronics.com

Tyco Electronics Online

The Tyco Electronics website is an innovative and

interactive source for application information,

product updates and technical solutions.

Our step-by-step software makes our website

intuitive and user-friendly to better serve you !

Please contact us at :

www.tycoelectronics.com/automotive

Product Information Center

(PIC)

You can rely on Tyco Electronics PIC Team to

provide you support for answers to your general

information or technical questions in an efficient

and effective manner. To reach our PIC staff,

please contact your local Tyco Electronics

organization.

Product and Machine Literature

Tyco Electronics offers a variety of product specific catalogs, brochures

and high impact flyers to help better serve you !

For more information on literature for Tyco Electronics’ Global Automotive

Division, please contact your local Tyco Electronics Organization or go to

www.tycoelectronics.com/automotive

T Y C O E L E C T R O N I C S “ A T Y O U R S E R V I C E ”


T Y C O E L E C T R O N I C S G L O B A L A U T O M O T I V E D I V I S I O N

Powertrain SystemsPage

Safety Systems

Chassis Systems

Security

8

MCON-1.2 mm Interconnection System

Contact System

Housings and Connectors

Application Tooling

Introduction 11 ● ● ● ●


Receptacle Contacts – Clean Body (CB) 14 ● ● ● ●

Receptacle Contacts – Locking Lance (LL) 15 ● ● ● ●

Tab Contacts – Locking Lance (LL) 16 ● ● ● ●

Single Wire Seals and Cavity Plugs 17 ● ● ● ●


Sealed 1.2 Receptacle Housingsfor Locking Lance Contacts

20 ● ● ● ●

Sealed 1.2 Receptacle Housingsfor Clean Body Contacts

27 ● ● ● ●


Wire Preparation Equipment 32 ● ● ● ●

Hand Tools 33 ● ● ● ●

Applicators 34 ● ● ● ●

Bench Top Presses 35 ● ● ● ●

Lead Makers 36 ● ● ● ●

Service 37 ● ● ● ●


T H E P R O D U C T S

Driver Information

Body Convenience Car Industry

Truck Industry

Other Industry

9

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All specifications subject to change. Consult Tyco Electronics for latest specifications.

Engineering Notes

MCON-1.2 mm Interconnection System Catalog 1308070-1Issued 04-06.

10



Introduction


11

Car Industry

Truck Industry

Other Industry

Safety Systems

Chassis Systems

Security Body Driver Information

ConveniencePowertrain Systems

The New Generation MCON-1.2 mm Connector System isdesigned for electronic and electrical applications inmotor vehicles.

It fullfils all requirements for a connector system for use inautomobiles and covers awide range of applications.

MCON-1.2 mm Contact System

■ Base material with high current capacity

■ 8 defined contact points for increased reliability

■ Improved vibration resistance

■ Good guiding inside thecavity

■ Protected contact springdue to the closed box

■ Overstress protection of thecontact springs

■ Box with polarization andsecondary locking feature

■ Protected locking lance

MCON-1.2 mm Connectors

■ High reliability status sup-ported for long term use

■ High vibration level sup-ported

■ Perfect design to avoid quality problems, reducemanufacturing and servicecost

■ Integrated secondary locking device delivered inpre-locked position

■ Wire-to-wire sealed and unsealed connectors (SWS)

■ Wire-to-board sealed andunsealed connectors (SWS)

■ Polarisation, several keyings ■ Locking mechanism for

smaller connectors/matingaid for higher numbers ofways



Engineering Notes


12



Introduction

MCON-1.2 mm Interconnection System Contact System

Catalog 1308070-1Issued 04-06.

13

■ Protection of the contactsprings

■ No over elongation of thecontact springs possibleunder normal circum-stances

■ No possibility to connectfrom the rear side

■ Protection against mechanical damage

■ Good guiding in the cavity

■ Secondary locking possible(from 4 directions)

■ Assembly into housing fully-automatically

In addition there are usuallytwo lances on the steel tospring. These serve to lockthe contact securely in thehousing.

The MCON-1.2 mm NewGeneration Contact System ismainly used in the automotiveindustry. Each contact con-sists of a flat receptacle,which mates with a flat tab.Every contact has got a steelspring and a copper alloybody.

The two-piece contact designmeans that the electrical andmechanical properties areseparated. One end of thecontact body is crimped towire and the other end mateswith the matching tab. Theclosed spring has got severalfunctions and also differentadvantages for the completecontact system.

The main advantages of theNew Generation 1.2 mmSystem are :

■ Base material with highcurrent capacity

■ 8 defined contact points for increased reliability

■ Improved vibration resistance

■ Good guiding inside thecavity

■ Protected contact springdue to the closed box

■ Overstress protection of thecontact springs

■ Box with polarization andsecondary locking feature

■ Protected locking lance

Tabs and receptacles can beapplied in both sealed and unsealed connectors.

MCON-1.2 mm contacts can be fast and economicallyarranged to the lead usingTyco Electronics AMP application tooling.

Car Industry

Truck Industry

Other Industry

Safety Systems

Chassis Systems





Receptacle Contacts – Clean Body (CB)



14

Insulation Diameter(mm)

FLK FLR

✱) Material and Finish: xxx-1 = CuNiSi, pre-tin/silver plated xxx-2 = CuNiSi, selective gold plated xxx-3 = CuNiSi, selective silver plated

Material and Finish ✱

Part Numbers

Strip Package Loose- Package Hand Tool

Form Quantity Piece Quantity◆ Applicator ◆ 539635-1

with Die Set

Standard Receptacle Contacts (SRC)

Wire Size Range(mm2)

0.14–0.22 – 1.05–1.20 -1 / -2 / -3 1452500 10,000 1452501 500 x-1528146-x 3-1579001-6

0.25–0.35 – 1.10–1.75 -1 / -2 / -3 1534594 10,000 1534595 500 x-1528147-x 3-1579001-6

0.50–0.75 – 1.4–1.9 -1 / -2 / -3 1394897 8,000 1534063 500 x-1528148-x 3-1579001-5

1.0–1.5 – 1.9–2.4 -1 / -2 / -3 1452503 8,000 1452504 500 x-1528150-x 1-1579001-3

Note: All part numbers are RoHS and ELV compliant.

Technical Features

Contact Material: CuSn0.15 Insert Spring: CuNiSi

Contact Finish: Tin-silver plated, selective silverplated, selective gold plated

Wire Size Range: 0.14–0.22 mm2

0.25–0.35 mm2

0.50–0.75 mm2

1.00–1.50 mm2

Current Carrying Capacity: up to 14 Ampere (at 20 °C ambient temperature)

Temperature Range: –40 °C ... +140 °C (tin-silver plated) –40 °C ... +140 °C (silver plated) –40 °C ... +150 °C (gold plated)

Contact Resistance: New State ≤2 mΩ

Mating Cycles: up to 20 cycles (tin-silver plated) up to 50 cycles (silver plated) up to 100 cycles (gold plated)

Dimension of Male Contacts: (1.2 ±0.1 x 0.6 ±0.03 mm)

Extraction Tool: Part No. 1579007-8

Mating Force: Max. 5 N

Unmating Force: Max. 2.5 N

Product Group Drawing: 1534326

Product Specification: 108-18782

Application Specification: 114-18464

Modular Dimensions (Centerline): max. 0.75 mm2 2.5 x 2.5 mm max. 1.0 mm2 2.5 x 3.0 mm sealed 4.0 x 4.0 mm

sealed staggered 3.5 x 4.0 mm cavity 3.55 mm Dia.

max. 1.5 mm2 2.5 x 3.5 mm sealed 4.5 x 4.5 mm 3.0 x 3.5 mm sealed staggered 4.0 x 4.5 mm

cavity 3.95 mm Dia.


FLK FLR


Part Numbers



with Die Set

Receptacle Contacts Single Wire Sealing System (SWS)


0.14–0.22 – 1.05–1.20 -1 / -2 / -3 1418841 6,500 1418842 500 x-1528151-x 4-1579001-0

0.25–0.35 – 1.10–1.75 -1 / -2 / -3 1418844 6,500 1418845 500 x-1528152-x 3-1579001-9

0.50–0.75 – 1.4–1.9 -1 / -2 / -3 1418847 6,500 1418848 500 x-1528153-x 3-1579001-8

1.0–1.5 – 1.9–2.4 -1 / -2 / -3 1418850 6,500 1418851 500 x-1528154-x 3-1579001-7


2.4 1.83

1.83

7.25

0.22

15.0–16.5

◆) The pre- and suffix for the applicators depends on the applied termination equipment.



Receptacle Contacts – Locking Lance (LL)



15


FLK FLR



Part Numbers



with Die Set

Standard Receptacle Contacts (SRC)



FLK FLR


Part Numbers



with Die Set

Receptacle Contacts Single Wire Sealing System (SWS)



Technical Features

Contact Material: CuSn0.15 Insert Spring: CuNiSi



0.25–0.35 mm2

0.50–0.75 mm2

1.00–1.50 mm2

Current Carrying Capacity: up to 14 Ampere (at 20 °C ambient temperature)

Temperature Range: –40 °C ... +140 °C (tin-silver plated) –40 °C ... +140 °C (silver plated) –40 °C ... +150 °C (gold plated)

Contact Resistance: New State ≤2 mΩ

Mating Cycles: up to 20 cycles (tin-silver plated) up to 50 cycles (silver plated) up to 100 cycles (gold plated)

Dimension of Male Contacts: (1.2 ±0.1 x 0.6 ±0.03 mm)

Extraction Tool: Part No. 5-1579007-3

Mating Force: Max. 5 N

Unmating Force: Max. 2.5 N







cavity 3.95 mm Dia.

2.4 1.83

1.83

7.25

0.2

15.0–16.5

0.14–0.22 – 1.05–1.20 -1 / -2 / -3 1452650 10,000 1452651 500 x-1528155-x 4-1579001-4

0.25–0.35 – 1.10–1.75 -1 / -2 / -3 1452653 10,000 1452654 500 x-1528156-x 4-1579001-3

0.50–0.75 – 1.4–1.9 -1 / -2 / -3 1452656 8,000 1452657 500 x-1528157-x 4-1579001-2

1.0–1.5 – 1.9–2.4 -1 / -2 / -3 1452659 8,000 1452660 500 x-1528159-x 4-1579001-1


0.14–0.22 – 1.05–1.20 -1 / -2 / -3 1452662 6,500 1452663 500 x-1528160-x 4-1579001-8

0.25–0.35 – 1.10–1.75 -1 / -2 / -3 1452665 6,500 1452666 500 x-1528161-x 4-1579001-7

0.50–0.75 – 1.4–1.9 -1 / -2 / -3 1452668 6,500 1452669 500 x-1528162-x 4-1579001-6

1.0–1.5 – 1.9–2.4 -1 / -2 / -3 1452671 6,500 1452672 500 x-1528163-x 4-1579001-5




Tab Contacts – Locking Lance (LL)



16




cavity 3.95 mm Dia.

1.83

1.2 1.83

0.632.4

7.5

0.2

16.39.2


FLK FLR



Part Numbers



with Die Set

Standard Tab Contacts



FLK FLR


Part Numbers



with Die Set

Tab Contacts Single Wire Sealing System (SWS)



Technical Features

Contact Material: CuNiSi Insert Tab: CuSn 0.15



0.25–0.35 mm2

0.50–0.75 mm2

1.00–1.50 mm2

Extraction Tool: Part No. 5-1579007-3




0.14–0.22 – 1.05–1.20 -1 / -2 / -3 1418756 9,000 1418757 500 x-1528427-x 4-1579001-4

0.25–0.35 – 1.10–1.75 -1 / -2 / -3 1418758 9,000 1418759 500 x-1528428-x 4-1579001-3

0.50–0.75 – 1.4–1.9 -1 / -2 / -3 1418760 8,000 1418761 500 x-1528506-x 4-1579001-2

1.0–1.5 – 1.9–2.4 -1 / -2 / -3 1418762 7,000 1418763 500 x-1528507-x 4-1579001-1


0.14–0.22 – 1.05–1.20 -1 / -2 / -3 1718756 6,500 1718757 500 x-1528508-x 4-1579001-8

0.25–0.35 – 1.10–1.75 -1 / -2 / -3 1718758 6,500 1718759 500 x-1528509-x 4-1579001-7

0.50–0.75 – 1.4–1.9 -1 / -2 / -3 1718760 6,000 1718761 500 x-1528510-x 4-1579001-6

1.0–1.5 – 1.9–2.4 -1 / -2 / -3 1718762 6,000 1718763 500 x-1528511-x 4-1579001-5




Single Wire Seals and Cavity Plugs



17

Single Wire Seals and Cavity Plugs for MCON-1.2 Contact System (Cavity Diameter 3.55 mmand 3.95 mm)

3.1 4.12.6

0.8

8.5

3.1 4.72.6

0.8

8.6

Color Part Number Package Quantity

– 0.9–1.4 Yellow 967067-2 20,000

– 1.4–2.1 Green 967067-1 20,000

Cavity Plug Blue 967056-1 5,000

Insulation Diameter

FLK FLR(mm) (mm)

Cavity Diameter 3.55 mm

Color Part Number Package Quantity

– 0.9–1.9 Grey 963142-2 20,000

– 1.9–2.4 Green 967067-1 20,000

Cavity Plug White 963143-1 20,000

Insulation Diameter

FLK FLR(mm) (mm)

Cavity Diameter 3.95 mm



Engineering Notes


18



Introduction

MCON-1.2 mm Interconnection System Housings and Connectors


19

Car Industry

Truck Industry

Other Industry

Safety Systems

Chassis Systems



The New Generation MCON-1.2 mm Connector Systemoffers receptacle and tabhousings with capability forwaterproofing and resistanceto conditions of extremevibration.

The system is designed forelectronic and electrical appli-cations in motor vehicles,where vibrations and mecha-nical stress, in the long term,can affect the quality on thecontact system.

Features

■ High reliability status supported for long term use

■ High vibration level supported

■ Perfect design to avoid quality problems, reducemanufacturing and servicecost

■ Integrated secondary locking device delivered inpre-locked position

■ Wire-to-Wire sealed and unsealed connectors (SWS)

■ Wire-to-Board sealed andunsealed connectors (SWS)

■ Polarisation,several keyings

■ Locking mechanism forsmaller connectors/matingaid for higher numbers ofways



Sealed 1.2 Receptacle Housings for Locking Lance Contacts



20

Technical Features

Number of Positions: 2 Positions

Housing Material: PA66 GF15

Wire Size Range: 1.0 mm2


Application Specification: ––

26.5

14.9

15.0

4.0

HousingColour

Number ofPositions

KeyingOptions

Part Numbers

Receptacle Cover Locking Mating Pin Mating PCB HeaderHousing Device Housing Right Angle Vertical

Sealed 1.2 Receptacle Housings

2 A Black 1-1718643-1 – – – – –






21

Technical Features






26.5

11.0

18.8

4.0

HousingColour

Number ofPositions

KeyingOptions

Part Numbers



2 A Black 1-1718811-1 – – – – –






22

Technical Features






26.5

11.0

19.0

4.0

HousingColour

Number ofPositions

KeyingOptions

Part Numbers



3 A Black 1-1718644-1 – – – – –






23

Technical Features






26.5

11.0

22.8

4.0

HousingColour

Number ofPositions

KeyingOptions

Part Numbers



3 A Black 1-1718812-2 – – – – –






24

Technical Features






26.5

16.5

24.7

4.0

HousingColour

Number ofPositions

KeyingOptions

Part Numbers



4 A Black 1-1718645-1 – – – – –






25

Technical Features






26.5

16.5

28.7

4.0

HousingColour

Number ofPositions

KeyingOptions

Part Numbers



5 A Black 1-1718806-1 – – – – –






26

Technical Features






26.5

16.5

32.7

4.0

HousingColour

Number ofPositions

KeyingOptions

Part Numbers



6 A Black 1-1718646-1 – – – – –



Sealed 1.2 Receptacle Housings for Clean Body Contacts



27

Technical Features




Product Specification: ––


● For use with Clean BodyContacts Numbers 1418841,1418844, 1418847 and1418850.

● Can be used with or withoutCPA.

● Blocked circuits versions areavailable (see customerdrawing for released options).

26.5

15.6

19.0

4.0

HousingColour

Number ofPositions

KeyingOptions

Part Numbers


Sealed 1.2 Receptacle Housings Top Latch Version

3 A Black 1488991-1 – – – – –

3 B Natural 1488991-2 – – – – –

3 C Blue 1488991-3 – – – – –

3 D Grey 1488991-4 – – – – –



Sealed 1.2 Receptacle Housings for Clean Body Contacts



28

Technical Features




Product Specification: ––


● For use with Clean BodyContacts Numbers 1418841,1418844, 1418847 and1418850.

● Can be used with or withoutCPA.

● Blocked circuits versions areavailable (see customerdrawing for released options).

26.5

11.0

23.8

4.0

HousingColour

Number ofPositions

KeyingOptions

Part Numbers


Sealed 1.2 Receptacle Housings Side Latch Version

3 A Black 1488992-1 – – – – –

3 B Natural 1488992-2 – – – – –

3 C Blue 1488992-3 – – – – –

3 D Grey 1488992-4 – – – – –



Introduction

Application Tooling Catalog 1308070-1Issued 04-06.

29

Application Tooling from Tyco Electronics is designed toperform perfect terminations,time after time. Beyond that, theresult is productivity gains,yielding more terminations forless money at the time of appli-cation, and in service. It is thiscombination of superior qualityat a lower installed final coststhat distinguishes the TycoElectronics system solution.

Because production require-ments vary, GATD – Global Application Tooling Division – can provide various levels of tooling to meet the full spectrumof output requirements.

The continuous support by ourfield service completes the TycoElectronics system. Our fieldservice engineers ensure theapplication equipment fulfil allrequirements at any given time.

Car Industry

Truck Industry

Other Industry

Safety Systems

Chassis Systems



Find the latest Tooling and Equipment options for your application at: www.tooling.tycoelectronics.com



Introduction


30

Introduction


Visit our Application Tooling Website at: www.tooling.tycoelectronics.com/europe Save it as one of your favourites.

Helping Yourself!

If you are new to referencing our Terminals / Contacts to tooling and equipment, we strongly recommendthat you read our guide to selecting the right tool before continuing.

First, select the category you are looking for from the left-hand menu bar i.e: Hand Tool, Applicator, Lead Maker etc.

Generally there will be a brochure that will show top-level information on the range of equipment available for the category selected. Also, flyers that give more detailed information for each type ofequipment listed in the brochure.

On the Applicator and Hand Tool pages – you can search on Terminal Part Numbers for tooling options or by Tool Part Number for more equipment information.

If you regularly need Hand Tool information, there is an online Hand Tool Cataloge that is available toview or print, but can also be printed and sent to you if more convenient. This cataloge is updated regularly, so please ensure that your version is kept up to date.

Requesting Assistance

If you can’t find what you are looking for, it does not necessarily mean that there is nothing available foryour application:

For cross-referencing information – contact one of our Product Information Centers (PIC), listed whenmaking a selection from the left-hand menu box.

For more complex equipment and technical help – find your country contact by selecting from the left-hand menu box. Local contact information is available for most countries in a one page pdf file.

Find Equipment:

● For Wire Processing

● For PCB Processing

● By Product Type

● By Industry

● How to Purchase

● Documentation

● Product InformationCenter

● Service and Repair

● Trade Shows

● Country Contacts

● European Tooling Home



Introduction


31

Loose-Piece For a Terminal to be suitable for use in a hand tool it must be cut from the carrier strip it is manufacturedon, and more importantly pre-formed. We call this loose-piece (LP) version – this may have the same / different base PN and / or dash number thanthe strip version. Pre-forming allows the short stroke of a hand tool to work and helps stabilise the terminal within the tooland form correctly during crimping.

Terminal Types Terminal type descriptions are very general and can be misleading if solely used to identify suitable tooling. It is strongly recommended that when searching for a tool for your application, you establish anduse specific loose-piece PN.

Terminal Wire Range Each Terminal will have a specific wire range, this may be different for different dash numbers of the samebase PN. This will determine which wire / tool combinations that can be used with the terminal.

What you need to know about Hand Tools The procedures in the relevant Instruction Sheet must be followed to achieve optimum crimp results.

Tool Grade A prime consideration when choosing the appropriate tool for an application. Our hand tools are categorised into three levels; Service, Commercial and Premium, each level requiringless operator skill and care respectively to ensure a quality crimp. A Service tool relies completely on the operator’s skill to ensure that the terminal and wire are correctlypositioned together within the tool, and that the relevant specification crimp height is achieved every time. A Commercial tool relies more on the operator’s skill to ensure that the terminal and wire are correctlypositioned together within the tool, but also has a ratchet or CERTI-CRIMP mechanism to ensure that therelevant specification crimp height is achieved every time. A Premium tool has terminal and wire positioning aids built in, along with a ratchet or CERTI-CRIMP mechanism to ensure that all of the relevant specification parameters are met every time.

Wire Range The overall wire range is also a prime consideration when choosing the appropriate tool for an application.Often there will be several tools reference to the same product but having different wire ranges.

Tool Type Choosing a tool type maybe driven by several factors; simply by type preference, or by the applicationneeds itself i.e: a heavy duty crimp, industry specification requirements etc.

Choosing the Right Tool 1. Check the db for the LP PN of your terminal(s) if not already known – if not available contact your nearest

PIC (Product Information Center).2. Establish the wire sizes that you want to use within the terminal(s) wire range.3. Check the db for the tool options available for your LP PN – if not available contact your nearest PIC.4. Choose a tool based on; tool type, wire range and tool grade i.e: the standards that your application

demands.


Wire Processing

Note:

Tyco Electronics recommends thathand powered tools are used only for repair or very low volume production use.

Care must be taken not to use these types of tools continuously for prolonged periods as RSI (repetitivestrain injury) may result.

Tyco Electronics provides a widerange of powered equipment options where medium to high volumes are anticipated.



Wire Preparation Equipment

Application ToolingWire Processing


32

We supply a comprehensive range of Hand Tools and Semi-Automatic Wire PreparationEquipment suitable for wires and cables used in all industries, small to very large, discreteand multi-core.




Hand Tools



33

Hand Tools – SDE Equipment

SDE stands for Standard Die Envelope, an innovation from Tyco Electronics that providescost effective flexibility, through a common die outline – SDE dies can be used in severalapplication platforms, including powered.

Hand Tools – General

Tyco Electronics has a large range of Hand Tool types, each with different features and characteristics for use in a wide range of applications.

Hand Tools – Contractor Tools

A broad range of equipment that meets your everyday cutting, stripping, terminating andtesting needs, used in networking, residential cabling, security and Telecommunications.

Hand Tool – Kits

We have a range of standard kits available, some examples are shown below. But we mayalso be able to provide kits to your own specifications where volumes are sufficient. Pleaselet us provide a quotation if you have such a requirement.




Applicators



34

Our applicators are designed to crimp Tyco Electronics products as well as products comingfrom other manufacturers. Based on a flexible concept Tyco Electronics applicators provide asolution to almost all current crimping requirements. Professional consulting will be given byour sales engineers and by our order processing department.




Bench Top Presses



35

Tyco Electronics offers field-proven bench top presses with a wide range of optionalequipment for wire termination.

So your specific application requirements can be fully met.

Simple maintenance, high level of accuracy, quick product change-over and tailor-madesolutions characterize our terminator product range.




Lead Makers



36

Tyco Electronics supplies the complete range of komax equipment, along with spare partsand a comprehensive array of service options.

Komax Lead Makers offer all of the well know processes such as Twisting & Tinning, Crimping and Seal Application and much much more; block-loading, IDC applications, head to head, and butt-splicing by ultrasonic welding, daisy-chain configurations and processes for many other complex connector applications.




Service


37

Field Service

Tyco Electronics provides Field Service support across Europe andbeyond. In most cases we can provide 48-hour cover in extremelyremote areas and at very competitive rates.

In addition to installation, warranty and repair we can help you with;equipment choice, operator & maintenance, training and trouble-shooting. We can offer Standard Service Contracts, MaintenanceContracts, Hand Tool Contracts and Custom made contracts to coverall your needs.

Preventative maintenance makes sense!

For more information please contact your local Tyco Electronics representative or visit our web-site.

Training

New manufacturing processes and termination technologies, increased customer expectations and the competitive pressure of themarket place all add to the demands on your staff.

Tyco Electronics Training Programs prepare your personnel and armthem with the latest technical know-how to optimize the use of yourequipment and control systems.

Our standard training courses cover our common Application Toolinglike hand tools and applicators up to training on Lead-Makers andCrimp Technology.

We can also offer custom made courses in your own plant or at a Tyco Electronics site near you.

Hand Tool Repair and Calibration

Premium tools and Commercial tools can be economically servicedand repaired. Our tooling Service Centers hold spares for all commonly used tools along with the specialist equipment and skillsrequired to re-calibrate after repair.

Servicing hand tools on a regular basis will keep the tool in goodshape and is therefore cost effective.

Preventative maintenance makes sense!




Numerical Index


38

Part Number Page

963142-2 17963143-1 17967056-1 17967067-1 17967067-2 17

1394897-1 141394897-2 141394897-3 141418756-1 161418756-2 161418756-3 161418757-1 161418757-2 161418757-3 161418758-1 161418758-2 161418758-3 161418759-1 161418759-2 161418759-3 161418760-1 161418760-2 161418760-3 161418761-1 161418761-2 161418761-3 161418762-1 161418762-2 161418762-3 161418763-1 161418763-2 161418763-3 161418841-0 27, 281418841-1 141418841-2 141418841-3 141418842-1 141418842-2 141418842-3 141418844-0 27, 281418844-1 141418844-2 141418844-3 141418845-1 141418845-2 141418845-3 141418847-0 27, 281418847-1 141418847-2 141418847-3 141418848-1 141418848-2 141418848-3 14

Part Number Page

1418850-0 27, 281418850-1 141418850-2 141418850-3 141418851-1 141418851-2 141418851-3 141452500-1 141452500-2 141452500-3 141452501-1 141452501-2 141452501-3 141452503-1 141452503-2 141452503-3 141452504-1 141452504-2 141452504-3 141452650-1 151452650-2 151452650-3 151452651-1 151452651-2 151452651-3 151452653-1 151452653-2 151452653-3 151452654-1 151452654-2 151452654-3 151452656-1 151452656-2 151452656-3 151452657-1 151452657-2 151452657-3 151452659-1 151452659-2 151452659-3 151452660-1 151452660-2 151452660-3 151452662-1 151452662-2 151452662-3 151452663-1 151452663-2 151452663-3 151452665-1 151452665-2 151452665-3 151452666-1 15

Part Number Page

1452666-2 151452666-3 151452668-1 151452668-2 151452668-3 151452669-1 151452669-2 151452669-3 151452671-1 151452671-2 151452671-3 151452672-1 151452672-2 151452672-3 151488991-1 271488991-2 271488991-3 271488991-4 271488992-1 281488992-2 281488992-3 281488992-4 281528146-0 141528147-0 141528148-0 141528150-0 141528151-0 141528152-0 141528153-0 141528154-0 141528155-0 151528156-0 151528157-0 151528159-0 151528160-0 151528161-0 151528162-0 151528163-0 151528427-0 161528428-0 161528506-0 161528507-0 161528508-0 161528509-0 161528510-0 161528511-0 161534063-1 141534063-2 141534063-3 141534594-1 141534594-2 141534594-3 141534595-1 14




39

Numerical Index

Part Number Page

1534595-2 141534595-3 141579001-5 141579001-6 14

1-1579001-3 143-1579001-6 143-1579001-7 143-1579001-8 143-1579001-9 144-1579001-0 144-1579001-1 15, 164-1579001-2 15, 164-1579001-3 15, 164-1579001-4 15, 164-1579001-5 15, 164-1579001-6 15, 164-1579001-7 15, 16

Part Number Page

4-1579001-8 15, 161579007-8 14

5-1579007-3 15, 161-1718643-1 201-1718644-1 221-1718645-1 241-1718646-1 26

1718756-1 161718756-2 161718756-3 161718757-1 161718757-2 161718757-3 161718758-1 161718758-2 161718758-3 161718759-1 16

Part Number Page

1718759-2 161718759-3 161718760-1 161718760-2 161718760-3 161718761-1 161718761-2 161718761-3 161718762-1 161718762-2 161718762-3 161718763-1 161718763-2 161718763-3 16

1-1718806-1 251-1718811-1 211-1718812-2 23



Engineering Notes


40


Global Contacts

AMP und TYCO sind eingetragene Warenzeichen. http://www.tycoelectronics.com

Americas

Asia/Pacific

Argentina – Buenos Aires Phone: +54-1-733-2000 Fax: +54-1-717-0988

Brasil – São PauloPhone: +55-11-2103-6000 Fax: +55-11-2103-6200

Canada – TorontoPhone: +905-475-6222Fax: +905-474-5520

Chile – Santiago Phone: +56-2-739-1230 Fax: +56-2-739-1227

Colombia – Bogota Phone: +57-1-231-9398 Fax: +57-1-240-3769

Mexico – Mexico CityPhone: +52-5-729-0400Fax: +52-5-361-8545

United StatesHarrisburg, PA Phone: +1-717-564-0100 Fax: +1-717-986-7575

Troy, MIPhone: +1-248-273-3359 Fax: +1-248-273-3322

Customer Service: Phone: +1-800-522-6752

Australia – Sydney Phone: +61-2-9554-2600 Fax: +61-2-9502-2556

India – Bangalore Phone: +91-80-2854-0800 Fax: +91-80-2854-0820

Indonesia – Jakarta Phone: +62-21-526-7852 Fax: +62-21-526-7856

Japan – Kawasaki, KanagawaPhone: +81-44-844-8111Fax: +81-44-812-3207

Korea – Seoul Phone: +82-2-3415-4500 Fax: +82-2-3486-3810

Malaysia – Selangor Phone: +60-3-7805-3055 Fax: +60-3-7805-3066

New Zealand – Auckland Phone: +64-9-634-4580 Fax: +64-9-634-4586

Philippines – Makati City Phone: +632-867-8641 Fax: +632-867-8661

People’s Republic of ChinaHong Kong Phone: +852-2735-1628 Fax: +852-2735-0243

Shanghai Phone: +86-21-6485-7333 Fax: +86-21-6485-6222

Singapore – Singapore Phone: +65-480-4525 Fax: +65-482-1012

Taiwan – Taipei Phone: +886-2-2664-9977 Fax: +886-2-2664-9900

Thailand – Bangkok Phone: +66-2-955-0500Fax: +66-2-955-0505

Vietnam – Ho Chi Minh CityPhone: +84-8-930-4547Fax: +84-8-930-3443

Venezuela – Caracas Phone: +58-2-986-7774 Fax: +58-2-986-9739

For Latin/South American Countries not shownPhone: +54-11-4733-2015Fax: +54-11-4733-2083

Europe/Middle East/Africa

Austria – Vienna Phone: +43-1-905-60-0 Fax: +43-1-905-60-1333 Product Information Center: Phone: +43-1-905-60-1249 Fax: +43-1-905-60-1251

Belgium – Kessel-Lo Phone: +32-16-352-300 Fax: +32-16-352-352

Bulgaria – Sofia Phone: +359-2-971-2152 Fax: +359-2-971-2153

Czech Republic – Kurim Phone: +420-5-41-162-111 Fax: +420-5-41-162-223 Product Information Center: Phone: +420-5-41-162-113 Fax: +420-5-41-162-132

Denmark – Glostrup Phone: +45-43-480-452 Fax: +45-43-441-414

Egypt – Cairo Phone: +20-2-417-76-47 Fax: +20-2-419-23-34

Finland – Helsinki Phone: +358-95-12-34-20 Fax: +358-95-12-34-250

France – Cergy-Pontoise Cedex Phone: +33-1-3420-8888 Fax: +33-1-3420-8600 Product Information Center: Phone: +33-1-3420-8686 Fax: +33-1-3420-8623

France Export Divisions – Cergy-Pontoise Cedex Phone: +33-1-3420-8866 Fax: +33-1-3420-8300

Germany – Bensheim Tyco Electronics AMP GmbH Phone: +49-6251-133-0 Fax: +49-6251-133-1600 Product Information Center: Phone: +49-6251-133-1999 Fax: +49-6251-133-1988

Germany – Niefern Tyco Electronics pretemaGmbH & Co. KGPhone: +49-7233-69-0 Fax: +49-7233-69-100

Germany – Ottobrunn Tyco Electronics Raychem GmbH Phone: +49-89-6089-0 Fax: +49-89-6096-345

Great Britain – Stanmore Middlesex Phone: +44-8706-080-208 Fax: +44-1793-572-109 Product Information Center: Freephone GB: 0800-267-666 Phone: +44-208-420-8341

+44-208-420-8343 Fax: +44-208-420-8081

Greece – Athens Phone: +30-210-9370-396/397 Fax: +30-210-9370-655

Hungary – Budapest Phone: +36-1-289-1000 Fax: +36-1-289-1010 Product Information Center: Phone: +36-1-289-1016 Fax: +36-1-289-1017

Ireland – Dublin Phone: +353-1-820-3000 Fax: +353-1-820-9790

Israel – Yokneam Phone: +972-4-959-0508 Fax: +972-4-959-0506

Italy – Collegno (Torino) Phone: +39-011-4012-111 Fax: +39-011-4031116Product Information Center: Phone: +39-011-4012-360 Fax: +39-011-40287360

Lithuania – Vilnius Phone: +370-5-2131-402 Fax: +370-5-2131-403

Netherlands – ’s-Hertogenbosch Phone: +31-73-6246-246 Fax: +31-73-6212-365 Product Information Center: Phone: +31-73-6246-999 Fax: +31-73-6246-998

Norway – Nesbru Phone: +47-66-77-88-86 Fax: +47-66-77-88-55

Poland – Warsaw Phone: +48-22-4576-700 Fax: +48-22-4576-720 Product Information Center: Phone: +48-22-4576-704 Fax: +48-22-4576-720

Romania – Bucharest Phone: +40-21-311-3479 + 3596 Fax: +40-21-312-0574

Russia – Moscow Phone: +7-495-926-55-06…09 Fax: +7-495-926-55-05

Russia – St. Petersburg Phone: +7-812-718-8192 Fax: +7-812-718-8193

Slovenia – Ljubljana Phone: +386-1561-3270 Fax: +386-1561-3240

South Africa – Port Elizabeth Phone: +2741-503-4500 Fax: +2741-581-0440

Spain – Barcelona Phone: +34-93-291-0330 Fax: +34-93-201-7879

Sweden – Upplands Väsby Phone: +46-8-50-72-50-00 Fax: +46-8-50-72-50-01

Switzerland – Steinach Phone: +41-71-447-0447 Fax: +41-71-447-0444

Turkey – Istanbul Phone: +90-212-281-8181…3

+90-212-282-5130/5430 Fax: +90-212-281-8184

Ukraine – Kiev Phone: +380-44-206-2265 Fax: +380-44-206-2264


Tyco Electronics AMP GmbH AMPèrestr. 12–14 • 64625 Bensheim Phone: +49- (0)6251-133-0 Fax: +49- (0)6251-133-1600 www.tycoelectronics.com

AMP and TYCO are trademarks.

© 2006 Tyco International 1308070-1 Issued 04-2006 4M ST(Z)


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