AMPSEAL 16

CONNECTOR SERIES
FOR INDUSTRIAL & COMMERCIAL TRANSPORTATION

TERMINALS AND CONNECTORS

INDUSTRIAL & COMMERCIAL TRANSPORTATION /// AMPSEAL 16 CONNECTORS

INDUSTRIAL & COMMERCIAL TRANSPORTATION

WE GO TO EXTREMES
TO MAKE SURE EVERY
CONNECTION COUNTS.

TE Connectivity (TE) Industrial & Commercial Transportation is a reliable provider of solutions for even the
harshest environment. With a focus on employee expertise and durable products, we deliver the solutions
and support our customers can count on.

2,000+ 10,000+ 20,000+

Employees Customers Different Parts

Years ago, tractors, construction equipment, trucks, and boats had simple electrical systems that might have
included electrical starting and a basic lighting package. Today, ECUs, joysticks, fuel-efficient engines, LED
lights, and CAN systems are standard equipment. The need to protect sensitive electrical systems from
vibration, moisture, dust, dirt, salt, and airborne particles has never been greater. TE Industrial & Commercial
Transportation is a leader in supporting today’s increasingly complex and sophisticated equipment
and applications.

Our comprehensive line of products includes an unparalleled portfolio of rugged sensors, terminals, connectors,
relays, and hybrid electric mobility solutions. These solutions are designed to withstand the harshest
environmental conditions and to help vehicles operate safer, cleaner, and smarter.

Our solutions adapt to virtually

any harsh environment
application, including:
Motors and ABS/EBS Telematics Sensors Wire-To-Wire Infotainment
Gearboxes Brake Units Units Coupling at Applications
the Chassis

PAGE 2TE.COM/ICT
MARKETS WE SERVE

RECREATIONAL
ON-HIGHWAY OFF-HIGHWAY
TRANSPORTATION

ONLINE RESOURCES
To learn more about TE Connectivity Industrial & Commercial
Transportation, its products, and their corresponding
te.com/ict
documents and videos, please check out
the following pages on TE.com:

te.com/ictliterature

te.com/ictvideos

TE Solution Center
You can rely on TE Connectivity’s Solution Center team to
provide support for answers to your general information or
technical questions in an efficient and effective manner.
Connect with our Solution Center staff at:
te.com/support

INDUSTRIAL & COMMERCIAL TRANSPORTATION /// AMPSEAL 16 CONNECTORS PAGE 3

INDUSTRIAL & COMMERCIAL TRANSPORTATION

AMPSEAL 16
CONNECTOR SERIES
The AMPSEAL 16 connector system is targeted for off-road, heavy duty industrial, recreational and
agricultural applications. This wire-to-wire and wire-to-device connector line was designed to meet the
rigorous demands of an industry that requires the highest standards in performance.

Since the launch of our latest AMPSEAL 16 high temperature connector, this series now features an option
for extended on-engine, aftertreatment and powertrain applications, with an increased temperature range
of up to 150°C.

AMPSEAL 16 plug and cap housings offer a one-piece design and come fully assembled - reducing
installation time and enabling an efficient supply chain.

PAGE 4TE.COM/ICT
 CONNECTORS
AMPSEAL 16
Product Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Wire Sealing Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

AMPSEAL 16 Ordering Information . . . . . . . . . . . . . . . . . . . . . 9

AMPSEAL 16 High Temperature . . . . . . . . . . . . . . . . . . . . . 10-11

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13

Hybrid Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15

Mini Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-17

Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-19

Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21

How To Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-23

INDUSTRIAL & COMMERCIAL TRANSPORTATION /// AMPSEAL 16 CONNECTORS PAGE 5

INDUSTRIAL & COMMERCIAL TRANSPORTATION

AMPSEAL 16 CONNECTOR SERIES

BENEFITS

• Optimize applied costs with the Heavy Duty Stamped & Formed (HDSF) size 16 contacts rated up to
13 amps each.

• Protect from dust, water, and overspray with up to IP67 rugged sealing capabilities.

• Connect easily with the plug and cap housings one-piece approach that come fully assembled with
Terminal Position Assurance (TPA) and Connector Position Assurance (CPA).

• Quickly verify contact alignment and retention with the Primary Latch Reinforcement (PLR), using a
reliable assembly process.

• Enhance design flexibility with optional backshell and mounting clip accessory items.

• Design extended to on-engine, aftertreatment and powertrain applications with new high
temperature connectors.

KEY INDUSTRIES

AMPSEAL 16 products
can be utilized in the
truck, bus, construction,
agriculture, and special Truck Bus Construction Agriculture Special
vehicles industries.

APPLICATIONS

AMPSEAL 16
products can
be utilized in
the following Motors and ABS/ESC Hydraulic Sensors Wire-To-Wire Actuators Switches
applications: Gearboxes Brake Units Pumps

HIGH TEMPERATURE
APPLICATIONS
DOC

DPF SCR

On-Engine After treatment Cooling Engine

Control System Compartment

PAGE 6TE.COM/ICT
 CONNECTORS
AMPSEAL 16
PRODUCT DOCUMENTATION

Additional documentation is available for assistance with AMPSEAL 16 products.

The following TE Connectivity document numbers may be helpful:

108-2184 (Product Specification) 114-13045 (Application Specification, Contacts)
114-13065 (Application Specification) 408-8623 (Instruction Sheet)
501-708 (Qualification Test Report)

114-32363 (Application Specifications High Temperature)

108-32602 (Product Specifications High Temperature)
501-32504 (Qualification Test Report High Temperature)

PERFORMANCE SPECIFICATIONS MATERIAL SPECIFICATIONS

Current Up to 13 amps Wire Seal Silicone rubber

Operating at temperatures Plug

-40°C to +125°C Peripheral Silicone rubber
Temperature
(40°C to +150°C for high Seal
temperature connector)
Housing 15% Glass filled thermoplastic
Flammability Rated UL 94 V-0 CPA 15% Glass filled thermoplastic

Durability See note. 50 cycles. PLR 15% Glass filled thermoplastic

20 megohms minimum. SAE

J2030 6.3. Insulation resistance at
Insulation
1000 volts DC adjacent terminals
Resistance
measured after 60 seconds or
until stabilization occurs.

Immersion IP67 rating

No discontinuities. See note.

EIA-364-28 Subject mated
Random specimens to 21 G’s rms between
Vibration 25 to 2000 Hz. Twenty hours
in each of three mutually
perpendicular planes.

Voltage 250 volts DC

Note: Shall meet visual requirements, show no physical

damage, and meet requirements of additional tests as
specified in Product Qualification and Requalification
Test Sequence in Figure 3 of TE product document
108-2184.

INDUSTRIAL & COMMERCIAL TRANSPORTATION /// AMPSEAL 16 CONNECTORS PAGE 7

INDUSTRIAL & COMMERCIAL TRANSPORTATION

AMPSEAL 16 DIMENSIONS

B E
D
C A F

AMPSEAL 16 Plug Housing AMPSEAL 16 Cap Housing

Cavity Overall Length Overall Height Overall Width Overall Length Overall Height Overall Width
A B C D E F

2 1.45 (36.75) .93 (23.5) .80 (20.33) 1.87 (47.55) .75 (18.93) .77 (19.60)

3 1.45 (36.80) .93 (23.5) .98 (24.83) 1.87 (47.55) .75 (19.15) .95 (24.10)

4 1.44 (36.70) 1.06 (26.8) 1.00 (25.33) 1.87 (47.55) .88 (22.45) .97 (24.60)

6 1.44 (36.60) 1.22 (31.0) 1.00 (25.33) 1.87 (47.55) 1.05 (26.65) .97 (24.60)

8 1.45 (36.80) 1.24 (31.5) 1.15 (29.33) 1.87 (47.55) 1.05 (26.65) 1.13 (28.60)

12 1.45 (36.80) 1.24 (31.5) 1.51 (38.33) 1.87 (47.55) 1.05 (26.65) 1.48 (37.60)

Dimensions are for reference only.

AMPSEAL 16 CONFIGURATIONS

2 Positions 3 Positions 4 Positions 6 Positions 8 Positions 12 Positions

2 size 16 3 size 16 4 size 16 6 size 16 8 size 16 12 size 16

AMPSEAL 16 WIRE SEALING RANGE

The wire sealing range is the recommended outside diameter of the wire insulation required to maintain an
environmental seal in the rear connector cavities.

Reduced Diameter
Contact Size Standard Seal
Seal

HDSF 16
.086-.144 .051-.100
14-20 AWG (2.0-
(2.18-3.67) (1.30-2.54)
0.5mm2)

PAGE 8TE.COM/ICT
AMPSEAL 16 ORDERING INFORMATION

CONNECTORS
AMPSEAL 16
PLR Plug Housing Cap Housing Plug Housing Cap Housing
Position Keying
Color Standard Dia. Seal Standard Dia. Seal Reduced Dia. Seal Reduced Dia. Seal

Red Key A 776427-1 776428-1 776522-1 776534-1

Gray Key B 776427-2 776428-2 776522-2 776534-2

2
Yellow Key C 776427-3 776428-3 776522-3 776534-3

Green Key D 776427-4 776428-4 776522-4 776534-4

Red Key A 776429-1 776430-1 776523-1 776535-1

Gray Key B 776429-2 776430-2 776523-2 776535-2

3
Yellow Key C 776429-3 776430-3 776523-3 776535-3

Green Key D 776429-4 776430-4 776523-4 776535-4

Red Key A 776487-1 776488-1 776524-1 776536-1

Gray Key B 776487-2 776488-2 776524-2 776536-2

4
Yellow Key C 776487-3 776488-3 776524-3 776536-3

Green Key D 776487-4 776488-4 776524-4 776536-4

Red Key A 776433-1 776434-1 776531-1 776537-1

6 Gray Key B 776433-2 776434-2 776531-2 776537-2

Yellow Key C 776433-3 776434-3 776531-3 776537-3

Red Key A 776494-1 776495-1 776532-1 776538-1

Gray Key B 776494-2 776495-2 776532-2 776538-2

8
Yellow Key C 776494-3 776495-3 776532-3 776538-3

Green Key D 776494-4 776495-4 776532-4 776538-4

Red Key A 776437-1 776438-1 776533-1 776539-1

Gray Key B 776437-2 776438-2 776533-2 776539-2

12
Yellow Key C 776437-3 776438-3 776533-3 776539-3

Green Key D 776437-4 776438-4 776533-4 776539-4

Plug housing and cap housing PLR colors are mechanically Cap Housing
keyed to mate only with identical colors.

Part Number Suffix: CPA

(Connector Position
-1 = A key (red PLR)
Assurance)
-2 = B key (gray PLR)
-3 = C key (yellow PLR)
-4 = D key (green PLR)

PLR
(Primary Latch
Plug Reinforcement)
Housing

INDUSTRIAL & COMMERCIAL TRANSPORTATION /// AMPSEAL 16 CONNECTORS PAGE 9

INDUSTRIAL & COMMERCIAL TRANSPORTATION

AMPSEAL 16 HIGH TEMPERATURE

TE’s AMPSEAL 16 high temperature connector is the latest addition to the well-established AMPSEAL 16
product portfolio - built to withstand extreme heat conditions in a vast selection of on-engine, aftertreatment
and powertrain applications.

With a temperature range of up to 150°C (a 20% increase from the 125°C limit of the original), and a higher
flammability rating of UL94 V-0, the new AMPSEAL 16 connector delivers the ideal solution for high intensity
vehicles and machinery - providing two sealing options for SAE and ISO wires, to further support its
extensive functionality.

Differentiated by a new gray colored housing, TE’s high temperature variants can be effortlessly identified to aid
ease of assembly, with the four discrete color polorization keys also helping to prevent mismatching.

In combination with the fully assembled one-piece design, the new AMPSEAL 16 high temperature connector
provides a cost effective, easy-to-build extension of this all-encompassing product line - improving its
adaptability for a host of applications.

PAGE 10TE.COM/ICT
AMPSEAL 16 HIGH TEMPERATURE

CONNECTORS
AMPSEAL 16
PLR Plug Housing Cap Housing Plug Housing Cap Housing
Position Keying
Color Standard Dia. Seal Standard Dia. Seal Reduced Dia. Seal Reduced Dia. Seal

Tan Key A 2320920-1 2320913-1 2320932-1 2320926-1

Blue Key B 2320920-2 2320913-2 2320932-2 2320926-2

2
Purple Key C 2320920-3 2320913-3 2320932-3 2320926-3

Orange Key D 2320920-4 2320913-4 2320932-4 2320926-4

Tan Key A 2320921-1 2320914-1 2320933-1 2320927-1

Blue Key B 2320921-2 2320914-2 2320933-2 2320927-2

3
Purple Key C 2320921-3 2320914-3 2320933-3 2320927-3

Orange Key D 2320921-4 2320914-4 2320933-4 2320927-4

Tan Key A 2320922-1 2320915-1 2320934-1 2320928-1

Blue Key B 2320922-2 2320915-2 2320934-2 2320928-2

4
Purple Key C 2320922-3 2320915-3 2320934-3 2320928-3

Orange Key D 2320922-4 2320915-4 2320934-4 2320928-4

Tan Key A 2320923-1 2320916-1 2320935-1 2320929-1

6 Blue Key B 2320923-2 2320916-2 2320935-2 2320929-2

Purple Key C 2320923-3 2320916-3 2320935-3 2320929-3

Tan Key A 2320924-1 2320917-1 2320936-1 2320930-1

Blue Key B 2320924-2 2320917-2 2320936-2 2320930-2

8
Purple Key C 2320924-3 2320917-3 2320936-3 2320930-3

Orange Key D 2320924-4 2320917-4 2320936-4 2320930-4

Tan Key A 2320925-1 2320918-1 2320937-1 2320931-1

Blue Key B 2320925-2 2320918-2 2320937-2 2320931-2

12
Purple Key C 2320925-3 2320918-3 2320937-3 2320931-3

Orange Key D 2320925-4 2320918-4 2320937-4 2320931-4

Cap Housing
Plug housing and cap housing PLR colors are mechanically
keyed to mate only with identical colors.
Mechanical Key
High Temperature Part Number Suffix:
CPA
-1 = A key (tan PLR)
(Connector Position
-2 = B key (blue PLR) Assurance)
-3 = C Key (purple PLR)
-4 = D Key (orange PLR)
PLR
(Primary Latch
Reinforcement)
Plug
Housing

INDUSTRIAL & COMMERCIAL TRANSPORTATION /// AMPSEAL 16 CONNECTORS PAGE 11

INDUSTRIAL & COMMERCIAL TRANSPORTATION

AMPSEAL 16 ACCESSORIES

Backshells and mounting clips are accessory items available for use with AMPSEAL 16 connectors. These
accessories cover design requirements by assisting with mounting, providing additional protection, and offering
increased aesthetics.

BACKSHELLS – NEXT GENERATION

The new and improved AMPSEAL 16 backshells provide strain relief, environmental protection, and deliver
enhanced aesthetics for TE’s rugged AMPSEAL 16 connectors. They are constructed of robust thermoplastic
and install easily by snapping onto the connectors.

The new backshells are available in 180˚ and 90˚ versions for all AMPSEAL 16 plug and cap arrangements (2, 3,
4, 6, 8, and 12). The two-piece 180˚ version channels the wires directly out of the back of the connector, offering
a high level of protection and providing strain relief. The four-piece 90˚ version features an innovative elbow
that allows for 360˚ rotation, enabling the wires to be routed in various angles.

The backshells are available with either a smooth wire exit or a corrugated tubing style exit. The smooth wire
exit style has slots for a tie wrap, which hold the wires in place and provide strain relief. The corrugated tubing
style exit backshells allow a wide range of conduit sizes to nest within the rear of the backshell.

PAGE 12TE.COM/ICT
AMPSEAL 16 ACCESSORIES

CONNECTORS
AMPSEAL 16
BACKSHELLS - NEXT GENERATION

Plug Part Numbers Cap Part Numbers

Number of
Conduit Size Straight Backshell 90° Adapter Part Straight Backshell 90° Adapter Part
Positions
Part Number Number Part Number Number

Smooth 2292797-1 2292849-1 2292860-1 2292849-1

2 NC12/NW10 2292797-2 2292849-2 2292860-2 2292849-2

NC08/NW7.5 2292797-3 2292849-3 2292860-3 2292849-3

Smooth 2292798-1 2292849-1 2292861-1 2292849-1

3 NC12/NW10 2292798-2 2292849-2 2292861-2 2292849-2

NC08/NW7.5 2292798-3 2292849-3 2292861-3 2292849-3

Smooth 2292799-1 2292850-1 2292862-1 2292850-1

4 NC16/NW13 2292799-2 2292850-2 2292862-2 2292850-2

NC12/NW10 2292799-3 2292850-3 2292862-3 2292850-3

Smooth 2292800-1 2292850-1 2292863-1 2292850-1

6 NC16/NW13 2292800-2 2292850-2 2292863-2 2292850-2

NC12/NW10 2292800-3 2292850-3 2292863-3 2292850-3

Smooth 2292801-1 2292851-1 2292864-1 2292851-1

8 NC20/NW17 2292801-2 2292851-2 2292864-2 2292851-2

NC16/NW13 2292801-3 2292851-3 2292864-3 2292851-3

Smooth 2292802-1 2292851-1 2292865-1 2292851-1

12 NC16/NW13 2292802-2 2292851-2 2292865-2 2292851-2

NC12/NW10 2292802-3 2292851-3 2292865-3 2292851-3

MOUNTING CLIPS

Part Number Description

1924487-1 Mounting clip without anti-rotational feature

1924487-2 Mounting clip with anti-rotational feature

INDUSTRIAL & COMMERCIAL TRANSPORTATION /// AMPSEAL 16 CONNECTORS PAGE 13

INDUSTRIAL & COMMERCIAL TRANSPORTATION

AMPSEAL 16 HYBRID LEVER

The AMPSEAL 16 hybrid lever is a sealed connector system that features a lever slide mechanism for mating and
a slide in mounting clip. The mix of 24 size 16 and 4 size 12 terminals creates design flexibility for use in various
vehicle applications.

The tool-less mounting design, environmental protection, and temporary panel retention latches (which
temporarily hold the connector in place for one person mounting through the panel) all reduce application cost
and assembly time.

APPLICABLE PRODUCT DOCUMENTATION

Additional documentation is available for assistance with the AMPSEAL 16 hybrid lever product. The following
TE Connectivity document numbers may be helpful:

108-32036 (Product Specification) 501-32026 (Qualification Test Report)

114-32117 (Application Specification)

DIMENSIONS

B E

F
C
A D

AMPSEAL 16 Hybrid Lever Receptacle Housing AMPSEAL 16 Hybrid Lever Cap

Overall Length Overall Height Overall Width Overall Length Overall Height Overall Width
Cavity
A B C D E F

28 2.08 (52.95) 1.82 (46.25) 4.59 (116.5) 2.86 (72.75) 1.91 (48.45) 4.38 (111.25)

Dimensions are for reference only.

CONFIGURATION ORDERING INFORMATION

Position Keying Plug Housing Cap Housing

Key A 2138839-1 2138846-1

28
Key B 2138839-2 2138846-2

28 Positions
24 size 16, 4 size 12

PAGE 14TE.COM/ICT
AMPSEAL 16 HYBRID LEVER

CONNECTORS
AMPSEAL 16
ACCESSORIES

Wire covers and mounting clips are accessory items available for use with AMPSEAL 16 hybrid lever connectors.
These accessories cover design requirements by assisting with mounting and providing wire strain relief.

WIRE COVER

Part Number Description

2138853-1 Wire cover for 28 position AMPSEAL 16 hybrid lever

MOUNTING CLIPS

Part Number Description

2138852-1 Mounting clip, 5 mm panel

2138852-2 Mounting clip, 4 mm panel

2138852-3 Mounting clip, 3 mm panel

INDUSTRIAL & COMMERCIAL TRANSPORTATION /// AMPSEAL 16 CONNECTORS PAGE 15

INDUSTRIAL & COMMERCIAL TRANSPORTATION

AMPSEAL 16 MINI LEVER

TE Connectivity’s new AMPSEAL 16 mini lever connectors introduce additional flexibility to power and signal
bulkhead applications. The IP6K7/IP6K9K rating of this wire-to-wire option provides vital environmental
protection for industries operating in harsh environments.

The ergonomic lever lock system ensures ease of assembly, while the integrated Terminal Position Assurance
(TPA) and Connector Position Assurance (CPA) protect against accidental unlocking and ensure precise contact
position. Essential to correct panel mating are the tool-free, “drop and slide” mounting clips – available in 3
sizes. For wire bundling and corrugated tubing, 90° and 180° wire dress covers can also be purchased alongside
the AMPSEAL 16 mini lever connectors.

APPLICABLE PRODUCT DOCUMENTATION

Additional documentation is available for assistance with the AMPSEAL 16 hybrid lever product. The following
TE Connectivity document numbers may be helpful:

108-151063 (Product Specification)

114-151063 (Application Specification)

DESIGN FEATURE
PLUG

CPA

CAP

TPA

MOUNTING
CLIP

BACKSHELL

ELBOW

PAGE 16TE.COM/ICT
AMPSEAL 16 MINI LEVER

CONNECTORS
AMPSEAL 16
PART NUMBERS 16P

Part Number Description Remark

2203859-1 Plug Assembly, ML Conn, Key A, 16P

2272889-1 CAP Assembly, ML Conn, Key A, 16P 16 Way

12-Size 16
2203859-2 Plug Assembly, ML Conn, Key B, 16P 4-Size 12

2272889-2 CAP Assembly, ML Conn, Key B, 16P

PART NUMBERS 24P

Part Number Description Remark

2203859-4 Plug Assembly, ML Conn, Key D, 24P

24 Way
20-Size 20
4-Size 12
2272889-4 CAP Assembly, ML Conn, Key D, 24P

ACCESSORIES

Wire covers and mounting clips are accessory items available for use with AMPSEAL 16 mini lever connectors.
These accessories cover design requirements by assisting with mounting and providing wire strain relief.

WIRE COVER

Part Number Description

2203956-1 (Smooth) Plug/Cap Wire Dress/Cover (Backshell)

90 DEG ELBOW

Part Number Description

2272307-1 (Smooth) 90 Deg Elbow

MOUNTING CLIPS

Part Number Description

2203876-1 Mounting Clip, ML Conn, 5mm Panel

2203876-2 Mounting Clip, ML Conn, 4mm Panel

2203876-3 Mounting Clip, ML Conn, 3mm Panel

INDUSTRIAL & COMMERCIAL TRANSPORTATION /// AMPSEAL 16 CONNECTORS PAGE 17

INDUSTRIAL & COMMERCIAL TRANSPORTATION

AMPSEAL 16 CONTACTS

AMPSEAL 16 and AMPSEAL 16 hybrid lever connectors commonly use the HDSF
size 16 contact system. The contacts are round, stamped & formed contacts with
dual beam sockets.

HDSF 16 CONTACT PERFORMANCE SPECIFICATIONS

Durability Crimp Tensile Strength

SAE J2030 6.11. 50 cycles. See note. USCAR 21 @ 50mm/min
Wire Gauge Tensile Stregnth
Current Rating
Up to 13 amps, consult TE product document 18 AWG 90 N Min
108-2184. 16 AWG 120 N Min
14 AWG 180 N Min
Contact Retention
IEC 512-8, Test 51a. Apply axial load of 111 N to Voltage Drop
contacts at a maximum rate of 10 N per second
Contact Test Current Voltage Drop
(or 50mm per minute) and hold for 10 seconds.
Size Amps (millivolts max)
Contacts shall not dislodge.
18 8 100

16 10 100

14 13 100

Note: Shall meet visual requirements, show no physical damage, and meet requirements of additional tests as
specified in the Product Qualification and Requalification Test Sequence in Figure 3 of TE product document
108-2184. USCAR is a trademark.

SEALING PLUGS

Open cavities provide pathways for contaminates to enter the connectors. To maintain seal integrity, any unused
cavity must be filled with the appropriate size sealing plug.

Wire Gauge
Color Part Number Contact Size Description
Range

PBT, used with AMPSEAL 16

Yellow 776363-1 Size 16 16-20 AWG
(standard diameter cavities)

PBT, used with AMPSEAL 16

White 776364-1 Size 20 16-20 AWG
(reduced diameter cavities)

PAGE 18TE.COM/ICT
AMPSEAL 16 CONTACTS

CONNECTORS
AMPSEAL 16
HDSF 16 STAMPED & FORMED CONTACTS FOR AMPSEAL 16 CONNECTORS

Pin Part Numbers

Wire Size Insulation Wire
Pakcage Loose Pakcage
Size Strip Form AWG Diameter Insulation Finish
Quantity Piece Quantity
(mm2) (mm) Support
1924463-1 4000 1924579-1 1000 18-20 .107-.05 Gold
yes
1924463-3 4000 1924579-3 1000 (0.8-0.5) (2.72-1.27) Nickel
776349-1 4000 – – 18-20 .131-.089 Gold
yes
776349-3 4000 – – (0.8-0.5) (3.33-2.26) Nickel
638078-1 4000 776300-1 1000 14-18 .131-.089 Gold
yes
638078-3 4000 776300-2 1000 (2.0-0.8) (3.33-2.26) Nickel
HDSF 16
638112-1 4000 776298-1 1000 14-18 .155-.077 Gold
no
638112-3 4000 776298-2 1000 (2.0-0.8) (3.94-1.96) Nickel
2098250-1 4000 – – 18 .118-.065 Gold
yes
2098250-3 4000 – – (1.5-0.8) (3.00-1.65) Nickel
2098252-1 4000 – – 14 .128-.083 Gold
yes
2098252-3 4000 – – (2.0-1.5) (3.25-2.10) Nickel

Receptacle Part Numbers

Wire Size Insulation Wire
Pakcage Loose Pakcage
Size Strip Form AWG Diameter Insulation Finish
Quantity Piece Quantity
(mm2) (mm) Support
1924464-1 4000 1924580-1 1000 18-20 .107-.05 Gold
yes
1924464-2 4000 1924580-2 1000 (0.8-0.5) (2.72-1.27) Nickel
776493-1 4000 – – 18-20 .131-.089 Gold
yes
776493-2 4000 – – (0.8-0.5) (3.33-2.26) Nickel
776492-1 4000 776299-1 1000 14-18 .131-.089 Gold
yes
776492-2 4000 776299-2 1000 (2.0-0.8) (3.33-2.26) Nickel
HDSF 16
776491-1 4000 776297-1 1000 14-18 .155-.077 Gold
no
776491-2 4000 776297-2 1000 (2.0-0.8) (3.94-1.96) Nickel
2098251-1 4000 – – 18 .118-.065 Gold
yes
2098251-2 4000 – – (1.5-0.8) (3.00-1.65) Nickel
2098253-1 4000 – – 14 .128-.083 Gold
yes
2098253-2 4000 – – (2.0-1.5) (3.25-2.10) Nickel

INDUSTRIAL & COMMERCIAL TRANSPORTATION /// AMPSEAL 16 CONNECTORS PAGE 19

INDUSTRIAL & COMMERCIAL TRANSPORTATION

AMPSEAL 16 TOOLING

Tools are specific to the contact style. To create a proper crimp and achieve the highest performance
specifications, contacts must be crimped with the recommended tooling.

HAND TOOLS FOR HDSF 16 CONTACTS

PRO-CRIMPER III CERTI-CRIMP II

Socket Socket
Pin Strip Form Pin Loose Piece Tool P/N Description
Strip Form Loose Piece

1924463-1 1924579-1 1924464-1 1924580-1 PRO-CRIMPER III

2119118-1 hand tool and die
1924463-3 1924579-3 1924464-2 1924580-2 set assembly

638078-1 776492-1
638078-3 776300-1 PRO-CRIMPER III
776492-2 776299-1
91337-1 hand tool and die
776349-1 776300-2 776299-2
776493-1 776493- set assembly
776349-3 2

638112-1 776298-1 776297-1 CERTI-CRIMP II

776491-1
2217753-1 straight action
638112-3 776298-2 776491-2 776297-2 hand tool

Note: Base PRO-CRIMPER III tool part number with -2 suffix is the part number for the die set, which can be
ordered separately

EXTRACTION TOOL FOR HDSF 16 CONTACTS

Part Number Description

Contact extraction tool for

776106-1
HDSF 16 contacts

PAGE 20TE.COM/ICT
AMPSEAL 16 TOOLING

CONNECTORS
AMPSEAL 16
AUTOMATED TOOLING FOR HDSF 16 CONTACT

OCEAN end OCEAN side

feed applicator feed applicator

Socket
Pin Strip Form Applicator P/N Description
Strip Form

OCEAN end feed applicator with

2151962-1
1924463-1 1924464-1 mechanical feed
1924463-3 1924464-2 OCEAN end feed applicator with
2151962-2
pneumatic feed

638078-1 OCEAN end feed applicator with

776492-1 2151731-1
638078-3 mechanical feed
776492-2
776349-1 OCEAN end feed applicator with
776493-1 776493-2 2151731-2
776349-3 pneumatic feed

OCEAN end feed applicator with

2151239-1
638112-1 mechanical feed
776491-1
638112-3 776491-2
OCEAN end feed applicator with
2151239-2
pneumatic feed

OCEAN end feed applicator with

2151617-1
2098250-1 2098251-1 mechanical feed
2098250-3 2098251-2 OCEAN end feed applicator with
2151617-2
pneumatic feed

OCEAN side feed applicator that

1530207-1 crops the terminal strip, for use in
lead-maker

2098252-1 2098253-1 OCEAN side feed applicator that

1530207-2 crops the terminal strip,
2098252-3 2098253-2 for use in bench press

OCEAN side feed applicator that does

1530207-6 not crop the terminal strip,
for use in lead-maker

Note: Applicators with additional feed styles are available, contact your representative

INDUSTRIAL & COMMERCIAL TRANSPORTATION /// AMPSEAL 16 CONNECTORS PAGE 21

INDUSTRIAL & COMMERCIAL TRANSPORTATION

AMPSEAL 16 HOW-TO INSTRUCTIONS

CONTACT INSERTION

Step 1: Step 2: Step 3:

Grasp crimped contact Verify the PLR is in the Align the contact with the
approximately one inch pre-staged position, desired circuit cavity at
behind the contact barrel. unlocked. the rear of the housing
assembly.

Step 4: Step 5:
Push the contact straight When all of the required
into the connector cavity contacts have been
until the contact retention inserted, push the PLR
finger returns to its into the fully locked
normal position behind position.
the retention shoulder on
the contact. A slight tug
will verify the contact is
locked in place.

PAGE 22TE.COM/ICT
AMPSEAL 16 HOW-TO INSTRUCTIONS

CONNECTORS
AMPSEAL 16
CONTACT REMOVAL

Step 1: Step 2: Step 3:

Insert the removal tool Insert the tool into the Gently pull the wire until
into the PLR extraction contact cavity and deflect the contact is free from
slot and pull until the PLR the contact retention the housing.
is completely removed finger.
from the housing.

INDUSTRIAL & COMMERCIAL TRANSPORTATION /// AMPSEAL 16 CONNECTORS PAGE 23

INDUSTRIAL & COMMERCIAL TRANSPORTATION

NOTES

PAGE 24TE.COM/ICT
NOTES

INDUSTRIAL & COMMERCIAL TRANSPORTATION /// AMPSEAL 16 CONNECTORS PAGE 25

ABOUT TE CONNECTIVITY
TE Connectivity is a $12 billion global industrial technology leader creating a safer, sustainable, productive
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AMPSEAL 16, PRO-CRIMPER, CERTI-CRIMP, OCEAN, TE Connectivity, TE Connectivity (logo)

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illustration purposes only, is believed to be reliable. However, TE Connectivity makes no warranties as 4849 Hempstead Station Drive
to its accuracy or completeness and disclaims any liability in connection with its use. TE Connectivity‘s Kettering, OH 45429
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INDUSTRIAL & COMMERCIAL TRANSPORTATION /// AMPSEAL 16 CONNECTORS