Instruction Sheet 132 / 104 / 60 POS
Contents
1. NOI The contact performs higher insertion force than non sealed type connector cause of using family seal device The contact especially requires careful insertion operation specified by above mentioned 2 and 3 Rev B2 9 of 20 Instruction Sheet TE connectivity 411 78121 5 2 Retainer Final Lock Secondary Lock 1 After all cavities are filled by inserted Contacts or Cavity Plugs properly insert Retainers Into Housindg to deep end and complete Final Lock condition Before Retainer Insertion Push Pre Lock Position 4 Retainer Final Lock Position Fig 102. In case It inserts until it make a clicking sound And please check that retainer it has run dOwnward as Shown in a figure 2 Fig 10 When Retainers can not be inserted do not operate with force and must find half insertion contact Refer Fig 10 The half insertion contact prevents the retainers from inserting Rev B2 10 of 20 Instruction Sheet TE connectivity 411 78121 5 3 Retainer Release Procedure In case of Female Contact insertion or extraction Retainer is extracted to Pre Lock condition see Fig 10 It is impossible to insert or extract the contacts with Retainer final lock condition 1
3. 3 Normal mating operation may not be made if the operation is started under Incomplete pre lock operation The operation must be returned to 3 Rev B2 18 of 20 Instruction Sheet TE 411 78121 5 Make connector be mated Operate rotate Lever to the final lock position completely At this operation do not handle Lever only but also pressing female housing to male housing Connector Pre Ilock position Lever at mating complete position Fig 17 In case Of any unexDected feeling such as double action or unsmooth insertion durin th e Operation Lever must be adiusted to at initial condition Opera
4. Wire end must be stripped without cut or damage of wire strands Nick Cut off Damaged Defective Defective Defective Intact and Normal Acceptable Fig 7 The wire must be using smooth insulation surface Do not use the one that there is a wound and deformation in the wire insulation surface when the contact crimping here is fear that the waterproof performance decreases 4 2 Operation of Crimping Machine See following Customer Manual for each contact Clean Body 025 040 Clean Body 0257040 Contact a Rev B2 6 of 20 Instruction Sheet TE connectivity 411 78121 4 3 Storage and Handling of Crimping Products 1 Store the products in a clean dry area cover with proper sheet or paper when pla
5. Push the retainer by finger or a tool then move rt to Pre Lock condition And please be careful not to damage the rubber then Pre Lock Working Push Push Detail Fig 11 Rev B2 11 of 20 Instruction Sheet TE connectivity 411 78121 5 4 Female Contact Extraction 1 Fig 10 Confirm Retainers are in Pre Lock condition In case of Final Lock condition it IS necessary to move it to Pre Lock condition see Fig 10 Iis impossible to extract the contacts under Final Lock condition 2 P N 1729919 1 Extract contact with pulling the crimped wire while pressing latch slightly with extraction jig P N 1729919 1 It makes easier the operation that push the contacts to bottom end of the cavities onc
6. 2 1 Avoid receiving or carrying the contact reel in an open area without wrapping It in proper material 2 Do not lift up and carry the contact reel by gripping one the side of the reel this may result in damage to the reel and contacts before use Do not lift up laterally A holding one side only cceptable 3 5 35 C 45 85 RH Avoid storing the contact reel in a moist or dusty place Stock the reel in a comparatively dry and clean place 5 35 C 45 85 RH away from direct sunlight Rev B2 4 of 20 a Instruction Sheet TE 411 78121 4 When removing the contact reel from the machine fasten the end of the contact strip onto the edge Of the reel with use of proper string or wire Fig 6
7. Fig 16 Tyco ships the product with Lever at mating complete position Change it to initial position as shown Fig 16 Lever at initial position 4 F F MI J Lever at mating complete position Fig 16 Fig 15 Connector Pre lock Operation Insert female housing straight in male housing with specified direction by Fig 15 It is at connector pre Iock condition when the female housing can not be inserted further more NOTE At the insertion operation no Kojiri apply force except insertion direction must be made INI Must not apply too much force against harness or female housind
8. Use applicable mating connector or equivalent for conductivity check jig 2 Check probe pin must not be inserted inside of female contact INI E Contact must be replaced in case of the prove pin insertion 3 Contact Tyco if the check jig IS reduired 5 7 4 Storage Store the product dry and clean area In addition do not leave the product with exposed condition 5 7 5 Shipping and Carrying Use Droper Dackage which can prevent Droduct from dust rain and etc And handle carefully Rev B2 16 of 20 Instruction Sheet TE connectivity 411 78121 6 Connector mating and unmating operation Mate after confirm
9. Fig 8 Check Retainer is in pre lock condition See Fig 8 The contact cannot be inserted in case of the final lock condition Pre lock Condition Retainer Final Lock Condition Fig 9 Rev B2 8 of 20 Instruction Sheet TE connectivity 411 78121 2 Fig 9 Insert the contacts into the housing with same direction as shown in Fig 9 The insertion finished when you hear click sound and contact stops Please check the position of Retainer without pushing in by force when it is hard to insert gt 040 Contact dd 025 Contact Pa 4 lt SC iz IN SS Fig 9 3 20N In addition to above action confirm no extraction is made by puling wires with 20N max for contact
10. A 34Pos Plug Assembly A 44 V 44Pos Wire Cover V Type 132 132Pos Cap Assembly 44 A 44Pos Wire Cover A 44 B 44Pos Wire Cover B 44 C 44Pos Wire Cover C 44 IV 44Pos Wire Cover ype IV 60 60Pos Plug Assembly 104 104Pos Cap Assembly 60 E E TE logo is a trademark Other products logos and company names might be trademarks of their respective owners LOCB Instruction Sheet TE connectivity 41 1 8 1 2 1 1 2 Contact Part Numbers Description Applicable Wire Applicable insulation diameter 025 rio 2 1717148 1 Clean Body 025 Contact S 0 3 0 5mm 1 1 1 7mm 025 0 1318329 1 Clean Body 025 Contact M 0 5 0 85mm lt 1 25 1 9mrm 040 1612776 1 Clean Body 040 C
11. each same mark the same Fig 15 6 1 Connector Mating 1 5 2 Check contact latching condition Droper wire tie up position and Retainer is in final lock condition Retainer must be adjusted to final condition if it is in initial lock condition Refer par 5 2 2 In the next step check no contact has deformation discolor damage rust and housing has no deformation crack breakage and discolor IN In case of any trouble is found replace it to new one Rev B2 17 of 20 Instruction Sheet TE connectivity 3 Lever Position Confirmation 411 78121 Check Lever is at initial lock position
12. PP IT Se Tie strip end with a wire neatly Fig 6 3 2 Housind 1 5 35C 45 85 RH Avoid storing the contact reel in a moist or dusty place Stock the reel in a comparatively dry and clean place 5 35C 45 85 RH away from direct sunlight Avoid leaving or carrying the housing In an open area without wrapping It In Droper material 3 Do not drop or shock the housing when carrying It 4 CRIMPING OPARATION Any crimping of contact must be performed by using appropriate Tyco tools according to the applicable Instruction Sheet and Specrification 4 1 Wire 4 1 1 Applicable Wire Fig 2 See Fig 2 for applicable wire Rev B2 5 Of 20 Instruction Sheet TE connectivity 411 78121 4 1 2 Notes for Stripping Wire End
13. _ a Instruction Sheet connectivity 411 78121 7 Dec 11 Rev B2 CLEAN BODY 025 040 SEALED 132 104 60 POS CONNECTOR CLEAN BODY 025 040 SEALED 132 104 60 1 Product Descriptions and 1 1 Connectors Part Numbers Part Numbers Description 190326 1 1939152 1 1939153 1 60Pos Cap Assembly Fig 1 Tyco Electronics Japan G K This is a Class Il confidential document belonging to Tyco Electronics Japan G K A Class ll 1 Of 20 a TE Connectivity Ltd Company Trademark document may not be disclosed to any non Tyco Electronics persons without 1 the written All Rights Reserved approval of a Tyco Electronics manager and 2 the signing of a Confidential Disclosure Agreement 1 2 TE Connectivity Ltd 44 OC 44Pos Plug Assembly C 44 CB 44Pos Plug Assembly B 44 A 44Pos Plug Assembly A Cavity Plug 34
14. ced in an Open area until the next day 2 Care should be taken for tangle and deform of contacts in case of the leads should be in bands 3 Do not stack the product so many layers It makes electrical connection defective and low contact retention force by catch together or by deform causing the weight of themselves 4 Must no hit tip of the contacts to coordinate the bundle It makes mating or electrical defective Rev B2 7 Of 20 Instruction Sheet TE connectivity 411 78121 5 HARNESS MAKING 5 1 Insertion Female Contact into Housing 1
15. e before the operation above mentioned 1 eS gt SS 2 _ WM IT MO Detail Entrance of exclusive tool NN Lance is Fell 4 A hl Exclusive tool Male Contact Insertion Window Insertion Direction Fig 12 Rev B2 12 of 20 Instruction Sheet a TE connectivity 411 81 21 3 IN Plug Assembly must be exchanged for new one if insertion and separatind Of contacts js to three times to the same rubber NOI Do not insert the exclusive tool into inside of the female contact In case of the Insertion no reuse is allowed and must be replaced with new female contact Rev B2 13 of 20 Instruction Sheet TE connec
16. lowed Confirm wires are inside of the Wire Cover neatly Fig 16 KIO Be aware Lever position The operation should be done with same Lever position as shipping condition See Fig 16 for Lever shipping condition 15 of 20 Rev B2 Instruction Sheet TE connectivity 411 78121 5 7 Wire Harness Control 5 7 1 HandIing Do not apply too much force or shock against connector or harness 5 7 2 Wire tie up and taping 30mm Wires are tied up at apart from 30mm more from the end of connector The operation be conducted carefully so that too much force is applied against the wireSs 5 7 3 Conductivity Check 1
17. ontact S 0 3 0 5mm 1 25 1 7mm 040 A 0 75 1 25mrm2 1 6 2 2mm I Clean Body 040 Contact M 040 0 CAN SY Clean Body 040 Contact CAN Mk25Ni Fi 2 Rev B2 2 of 20 Instruction Sheet TE connectivity 411 78121 1 3 CONTENTS Plug Assembly 040 040 Female Contact 025 025 Female Contact Wire Cover Fig 3 Cap Assembly Rev B2 3 Of 20 Instruction Sheet TE connectivity 411 78121 2 CUSTOMER RECEIVING INSPECTION Tyco Tyco conducts inspections according to their quality control regulations to maintain an over all lot control In addition the customers should conduct receiving Inspections based on the specific Customer drawings 3 STORAGE AND CARRYNG 3 1 Contact 1
18. tion must be restart ed And then return to 4 operation Rev B2 19 of 20 Instruction Sheet a TE connectivity 411 81 21 6 2 Connector unmating 1 Release Lever lock by pressing down final lock device 2 Lock Lever at initial lock device by operating rotating it 3 Release female housing from male housing Release Lever Release Lever lock by pressing down Lever at mating complete position Lever at initial position Fig 19 Rev B2 20 of 20
19. tivity 411 78121 5 5 Insertion Cavity Plug into Housing Only in the case the cavity plug is attached 025 040 025 040 Fig 13 The cavity plug can be used for 025 and 040 sizes in common Insert the cavity plug in 025 cavities until stopping as shown in Fig 13 Insert the cavity plug in 040 cavities untll just withdrawing to the inside as shown in Fig 13 040 IN Do not push the cavity plug into the interior of 040 cavities too much In case of the Insertion no reuse is allowed and Plug Assembly must be exchanaed for new one 040Cavity 025Cavity Before Insertion TRC AV W es 040Cavity lt 025Cavity 3 Fig 13 Rev B2 14 of 20 a Ins
20. truction Sheet TE 411 78121 connectivity 5 6 Wire Cover Attach Operation Onlyin the case the wire cover is attached 1 Bend wire harness to specified direction 2 Insert the back side lock of the Lever Assembly into hole for latch at Plug Assembly 3 It turns centering on a plug and close an opposite lock 4 Close the hook of the wire cover Insert the wire taking out side lock of the Lever Assembly into hole for latch at Plug Assembly 4 gt Close the hook 2 Fig 14 NIO IS No improper Wire Cover Attach Operation is al
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