FCI APEX Connection Systems Guide

N e v e r S h o r t o n S o l u t i o n s
www. tti i nc. com

FCI
APEX Connection Systems
The APEX family of electrical connection systems incorporates proven technology for harsh
environments in automotive, off-highway, and specialty vehicles. These inline connectors are
designed for applications where heat, vibration and moisture are a concern.
Superior Design and Construction
These pre-assembled connectors minimize stocking inventory and are very easy to assemble
and service. There are both sealed and unsealed versions in many configurations from 2-way to
24-way systems, capable of carrying up to 42 amps.
The APEX 150 connection systems are the smaller connector, designed for wires sizes from 22
to 16 AWG, and are compatible with USCAR cavity specifications.
The APEX 2.8 connection systems offer a wider range of sizes, circuits and options to meet your
unique design requirements.
A new APEX 24-way Hybrid connection system combines circuits from both the 150 and 2.8
for maximum versatility in a compact package.
FCI offers a complete range of
innovative and reliable interconnect
solutions for Automotive applications.
Typical installations include engine
compartment, interiors, body harness,
safety systems, electronic control units
and multimedia.
FCI is a global company with
approximately 13,000 employees and
more than 30 production facilities
operating in 30 countries throughout the
world and in 15 different languages.
TTI Inc. Transportation Business Unit
6480 Rockside Woods Boulevard
Suite #110
Independence, OH 44131
Phone# 1-877-884-4288
(1-877-TTI 4-AUTO)
Fax# 1-216-750-9642
Email tbu@ttiinc.com
www.ttiinc.com/transportation
APEX Connector Systems:
Better By Design
Connection Systems
APEX
APEX 2.8
APEX 150
Contents
4
Connection Systems
APEX
APEX 2.8
APEX 150 Connectors Features and Benefits
FEATURE Benefit
1 Polarization molded-in, up to 4 indexes, scoop proof Design flexibility
2 Pre-assembled integral Connector Position Assurance, CPA Ease of assembly
3 Clip slot on male connectors Flexibility for mounting
4 Plastic is molded with smooth well-rounded corners Ergonomics for assembly
5 Double shroud design, protected interface seal Increased durability and handling protection
6 Primary connector lock, audible, tactile, one-hand operation Reliable and easy to mate
7 Pre-assembled integral Terminal Position Assurance, TPA Ease of assembly
8 Blade lead-in / probe protection Durability for service in the field
9 Pre-assembled Rear Mat seal with retainer Ease of assembly
Performance Characteristics
Temperature Ranges:
Class 3: 40C to +125C
Exceeds USCAR2, 20 Performance
Specifications
Meets USCAR 21 Crimp Specifications
Current Rating: 25 Amps based on
USCAR Specification
Construction
Connector, Mat Seal, Seal Retainer,
Interface Seal, TPA and CPA make up the
connector assembly
Housing Material: PBT 30% GF
Interface Seal: Silicone
Terminal Compatibility
Mat Seal: Silicone
1
3
2
4
6
5
7
8
9
5
Connection Systems
APEX
APEX Terminals Features and Benefits

Main Features of
APEX terminals
Two-piece construction with an
integrated floating spring made of
beryllium copper
Terminal designed to have high
current carrying capacity
1. Optimized contact function with:
Two stable contact lines
One contact point with the
spring
2. Fully protected front entry with
rounded corners in the four
directions:
Resistant to probe damage
Guides mating blade
3. Protected contact area with a
closed box
4. Dimples provide overstress
protection of the spring
5. Two symmetrical locking areas:
Positive retention achieved in
the housing without a vulnerable
locking tang
Reversibility at 180
6. Box material is a highly conductive
copper alloy for exceptional current
rating.
7. Coined edges eliminate the
potential to tear the rear mat seal.
Non-polarized
terminals
6
Connection Systems
APEX
FCI 10 Way APEX 150 Connection System

INDEX
TYPE
HOUSING
COLOR
PLUGGED SEAL POSITIONS (X) FEMALE
ASSEMBLY
PART NUMBER
MALE ASSEMBLY
PART NUMBER
(SLOT 1)
MALE ASSEMBLY
PART NUMBER
(SLOT 2)
1 2 3 4 5 6 7 8 9 10
A BLACK 54241030 54241000 54241004
B GREY 54241031 54241001 54241005
C BROWN 54241032 54241002 54241006
D GREEN 54241033 54241003 54241007
A BLACK X 54241034 54241008 54241010
B GREY X 54241035 54241009 54241011
A BLACK X X 54241036 54241012 54241014
B GREY X X 54241037 54241013 54241015
NOTE 1: Assembly part numbers also available without CPA. See sale drawing for part numbers
NOTE 2: See Page 9 for explanation of clip slot type 1 and clip slot type 2.
Additional plugged cavity configurations are available upon request.
FEMALE MALE
7
Connection Systems
APEX
FCI 14 Way APEX 150 Hybrid Connection System

*
Shorting bar exists in this position.
INDEX
TYPE
HOUSING
COLOR
PLUGGED SEAL POSITIONS (X)
FEMALE
ASSEMBLY
PART NUMBER
MALE ASSEMBLY
PART NUMBER
(SLOT 1)
MALE ASSEMBLY PART
NUMBER
(SLOT 2)
1 2 3 4 5 6 7 8 9 10 11 12 13 14
A BLACK 55251400 54251400 54251404
B GREY 55251401 54251401 54251405
C BROWN 55251402 54251402 54251406
D GREEN 55251403 54251403 54251407
A BLACK X X 55251408 54251412
B GREY X X 55251409 54251413
A BLACK X 55251410 54251416 54251418
B GREY X 55251411 54251417 54251419
A BLACK X X 55251412 54251420 54251422
B GREY X X 55251413 54251421 54251423
A BLACK X X X 55251414 54251424 54251426
B GREY X X X 55251415 54251425 54251427
A BLACK X X X X 55251416 54251428 54251430
B GREY X X X X 55251417 54251429 54251431
E YELLOW
* *
55251404 54251408
F YELLOW
* * * *
55251405 54251409
G YELLOW
* *
55251406 54251410
H YELLOW
* * * *
55251407 54251411
FEMALE MALE
8
Connection Systems
APEX
FCI 16 Way APEX 150 Connection System

INDEX
TYPE
HOUSING
COLOR
PLUGGED SEAL POSITIONS (X)
FEMALE ASSEMBLY
PART NUMBER
MALE ASSEMBLY
PART NUMBER
(SLOT 1)
MALE ASSEMBLY
PART NUMBER
(SLOT 2) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
A BLACK 54241630 54241600 54241604
B GREY 54241631 54241601 54241605
C BROWN 54241632 54241602 54241606
D GREEN 54241633 54241603 54241607
A BLACK X 54241634 54241608 54241610
B GREY X 54241635 54241609 54241611
A BLACK X X 54241636 54241612 54241614
B GREY X X 54241637 54241613 54241615
A BLACK X X X 54241638 54241616 54241618
B GREY X X X 54241639 54241617 54241619
A BLACK X X X X 54241640 54241620 54241622
B GREY X X X X 54241641 54241621 54241623
FEMALE MALE
9
Connection Systems
APEX
FCI Sealed 24 Way APEX Hybrid (1.5 mm/2.8 mm)

Connection System
FEMALE MALE
INDEX TYPE HOUSING COLOR
FEMALE ASSEMBLY
PART NUMBER
MALE ASSEMBLY
PART NUMBER
A BLACK F934000 F254000
B GRAY F044000 F354000
C BROWN F144000 F454000
D GREEN F244000 F554000
APPLICATION NOTES:
APEX 150 CAVITY DESIGNATIONS: CAVITIES 3,4,5,6,7,8,9,10 and 15,16,17,18,19,20,21,22
APEX 2.8 CAVITY DESIGNATIONS: CAVITIES 1,2,11,12,13,14,23,24
ALLOWABLE WIRE SIZE RANGE FOR 1.5 mm CAVITIES: 22-16 AWG TXL (1.50 mm min. to 2.35 mm max.)
ALLOWABLE WIRE SIZE RANGE FOR 2.8 mm CAVITIES: 18-12 AWG TXL (1.91 mm min. to 3.30 mm max.)
ASSOCIATED COMPONENTS: CAVITY PLUG FOR APEX 150 CAVITIES: 54241629
CAVITY PLUG FOR FEMALE APEX 2.8 CAVITIES: 54240002
CAVITY PLUG FOR MALE APEX 2.8 CAVITIES: 54240003
FEATURES CHRYSLER TYPE CLIP SLOT
10
Connection Systems
APEX
APEX Connector Clip Mounting Features

CLIP SELECTION TYPE 1 ONLY
M5 WELD STUD CLIP
FCI PART NUMBER: 54200002
DOUBLE X-TREE
SUPPLIER: FCI
FCI PART NUMBER: 54200010
(CHRYSLER TYPE)
11
Connection Systems
APEX
APEX 150 Terminals & Cavity Plug

FEMALE MALE
FEMALE
TERMINAL
PART NUMBER
WIRE GAGE
TERMINAL
MATERIAL
TERMINAL
PLATING
54002000 20-22 CuSn Sn
54001625 16-18 CuSn Sn
54001627 16-18 CuTeSn NiPdAu
MALE TERMINAL
PART NUMBER
WIRE GAGE
TERMINAL
MATERIAL
TERMINAL
PLATING
54002001 20-22 CuSn Sn
54001626 16-18 CuSn Sn
MALE TERMINAL FOR SHORTING BAR APPLICATIONS
PART NUMBER DESCRIPTION
54241629 APEX 150 Cavity Plug
12
Connection Systems
APEX
APEX 150 Tools

Crimp Applicator For Wire Sizes Up To 6 mm
2
Hand Crimp Tool Extraction Tool
QUICK-CRIMP 947 is the crimp applicator for economical processing of stripped
crimp terminals. The side feed applicator for left-feed terminals has a mechanical
advance. It can be used in semi-automatic bench presses, stripper crimpers or fully
automatic wire processing machines. Includes 7 digit cycle counter.
Technical Details
Wire Cross Section: 0.08 to 6.0 mm
2
Mechanical feed (transversal):
Feed Length: 3 to 30 mm
Stroke: 40 to 44 mm
Shut Height: 135.78 mm
Weight: 4 kg
Dimensions: 170 mm wide x 160 mm
high x 100 mm deep
Options
Select crimp height adjustment
from self-locking adjustment disks,
steps every 0.02 mm
Counter 7-digits (not resettable)
Ejector between conductor and
insulation punch
Optional stroke of 30 mm
Quick changeover to other terminal
with conversion kit
54900049 Hand Crimp Tool, 22/20 & 18/16 AWG
54241678 Terminal Extraction Tool
13
Connection Systems
APEX
Terminal Winding Options For Wire Harness Manufacturers

STANDARD FCI WINDING IS B.
TO ORDER WINDING A USE THE FOLLOWING
SUFFIX: 5400xxxxRWA
TO ORDER WINDING C USE THE FOLLOWING
SUFFIX: 5400xxxxRWC
TO ORDER WINDING D USE THE FOLLOWING
SUFFIX: 5400xxxxRWD
14
Connection Systems
APEX
APEX 150 Terminal De-Rating Curve

APEX 150 Current Derating Discrete Terminals 16 AWG (1.2mm
2
) Wire
15
Date of Request Date Required by
FCI Representative (Female Connector) Customer & Contact Information (Female Connector)
FCI Representative (Male Connector) Customer & Contact Information (Male Connector)
Connector Usage Forecast
Vehicle Platform Model Year EAU
Ramp Volume Begins Model Year EAU
Connector Configuration (Common)
A Black
Connector Polarization (A, B, C, D, E, F, G, H, J or Doesn't Matter) B Grey
C Brown
NOTE: Polarizations and Connector Colors are available as shown in chart. D Green
Connectors with Shorting Bars are yellow, unless otherwise requested below. E-H Yellow
FEMALE Connector Configuration
CPA Needed (Yes/No) # Total Blocked Cavities Harness Reference
Assigned Circuits (1.5) Assigned Circuits (2.8) Total
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
MALE Connector Configuration
Clip Slot (Type 1 or 2) # Total Blocked Cavities Harness Reference
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
NOTE: Shorting Bars only short terminals on Male connector when not mated.
Any Special Notes or Requests;
FCI Engineering Use Only
Request Received By Date
Part Numbers Assgned By Date
FCI Part Number Female Male
Customer Part Number Female Male
Form: 24 Way Request Form (06SEP2007)
APEX 2.8mm cavities APEX 2.8mm cavities
APEX 2.8mm cavities APEX 2.8mm cavities
Cavity numbers as viewed from Rear (wire exits) of Female Connector (See USCAR-12 Appendix A)
Cavity numbers as viewed from Front of Male Connector (opposite wire exits - See USCAR-12 Appendix A)
All Fields in RED are Required
SB5 SB6 SB7 SB8
SB1 SB2 SB3 SB4
APEX 150 24 Way Hybrid Custom Configuration Request Form
16
Connector Application
A Black
Connector Polarization (A, B, C, D or Doesn't Matter) B Grey
C Brown
CPA Needed (Yes/No) # Blocked Cavities Check if Same Plug Config as Male.
Assigned Circuits (1.5)
Example: Cavities 2, 8 blocked.
1 2 3 4 5
6 7 8 9 10
Cavity numbers as viewed from Rear (wire exits) of
of Female Connector (See USCAR-12 Appendix A)
Clip Slot (Type 1 or 2) # Blocked Cavities Check if Same Plug Config as Female
1 2 3 4 5
6 7 8 9 10
Cavity numbers as viewed from Front of Male Connector
(opposite wire exits - See USCAR-12 Appendix A)
Engineering Use Only
Form: 10 Way Request Form (06MAR2007)
Apex 150 10 Way Sealed Custom Configuration Request Form
1 2X 3 4 5
6 7 8X 9 10
1 2X 3 4 5
6 7 8X 9 10
17
A Black
Connector Polarization (A, B, C, D, E, F, G, H or Doesn't Matter) B Grey
C Brown
Connectors with Shorting Bars are yellow, unless otherwise requested below. E-H Yellow
2.8mm cavities 2.8mm cavities Harness Reference
Example: Cavities 1, 5 blocked, Circuits 2,3 shorted.
1 2 3 4 5 6 7
8 9 10 11 12 13 14
2.8mm cavities 2.8mm cavities Harness Reference
Type 'YES' if/where shorting bars needed.
SB1 SB2 Example: Cavities 1, 5 blocked, Circuits 2,3 shorted.
1 2 3 4 5 6 7
8 9 10 11 12 13 14
SB3 SB4
NOTE: Shorting Bars only short terminals on Male connector when not mated.
2.8mm cavities 2.8mm cavities
SB1 YES SB2
1X 2 3 4 5X 6 7
8 9 10 11 12 13 14
SB3 SB4
2.8mm cavities 2.8mm cavities
SB1 YES SB2
1X 2 3 4 5X 6 7
8 9 10 11 12 13 14
SB3 SB4
18
A Black
Connector Polarization (A, B, C, D or Doesn't Matter) B Grey
C Brown
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
16 15 14 13 12 11 10 9
8X 7 6 5 3 3 2X 1
16 15 14 13 12 11 10 9
8X 7 6 5 3 3 2X 1
19
2008 FCI USA, Inc. Novi, Michigan. All rights reserved. APEX is a registered Trademark of FCI. www.fci.com
This controlled document is subject to change. For latest revision, sample orders, service tools and hand crimpers, visit
www.fciapex.com or call 1-866-FCISMPL (1-866-324-7675)
Application Specification
K53030
07 MAY 2009 Rev D
APEX 150 Hybrid Connector Family
(Terminal Replacement)
1 of 3
Rev D
1 Introduction.
This document applies to the proper procedure and
steps required to manually install and replace APEX
2.8 (2.8mm) and APEX 150 (1.5mm) terminals in
the APEX 150 Hybrid Connector Family.
1.1 Reference
FCI Terminal Drawings:
J54009-CUST APEX 150 Female Terminal
J54011-CUST APEX 150 Male Terminal
C15004-CUST APEX 2.8 Female Terminal
C15005-CUST APEX 2.8 Male Terminal
FCI Connector Drawings:
K53001
K53002
Required Tools:
Small Needle Nose Pliers
(Recommended: Sears Craftsman #45664)
APEX 150 Service Tool (54241678)
APEX 2.8 Service Tool (5490002)
2 Terminal Insertion Instructions
2.1 Female Terminals
Make sure TPA is in the pre-lock position in the
female housing. See figure 1.
Orient the female terminals correctly with each
terminal position opening in the retainer of female
connector assembly as shown in figure 2.
Carefully insert the terminal into the cavity opening.
Only slight force should be needed. If the force to
install each terminal seems high or the terminal will
not seat Stop! Remove the terminal, recheck its
orientation, verify the cavity does not have a seal
plug, and verify the TPA is fully in the pre-lock
position.
When the terminal is correctly installed, there will
be a small click and some tactile feedback.
Once all the terminals are inserted in the correct
position, then press the TPA into the final lock
position as shown in figure 1. If the TPA will not
move into the final-lock position, verify that all
terminals are fully seated.
2.2 Male Terminals
Make sure TPA is in the pre-lock position in the
female housing. See figures 5 and 6.
Orient the male terminals correctly with each
terminal position opening in the male connector
assembly as shown in Figure 3.
Carefully insert the terminal into the cavity opening.
If the force to install each terminal seems high or
the terminal will not seat Stop! Remove the
terminal, recheck its orientation, verify the cavity
Final-Lock
Pre-Lock
Figure 1
Figure 2
Figure 3
2008 FCI USA, Novi, Michigan. All rights reserved. APEX is a registered Trademark of FCI. This controlled document is subject to change.
20
K53030
07 MAY 2009 Rev D
2 of 3
Rev D
does not have a seal plug and verify the TPA is
fully in the pre-lock position (Figure 4).
When the terminal is correctly installed, there will
be a small click and some tactile feedback.
position, then press the TPA into the final lock
position as shown in figure 5. If the TPA will not
move into the final-lock position, verify that all
terminals are fully seated.
3 Terminal Replacement Instruction
3.1 Female Connector
Insert a small flat blade screw driver in the slot
provided in the TPA and apply pressure to Bridge
area of connector as shown in figure 6.
Gently pry or pivot the screw driver thus sliding
the TPA into the Pre-Lock position. WARNING:
Do not grab or grip the Shorting Bar tabs if so
equipped. Tabs may be damaged leading to a
failure of the shorting bar function.
With the TPA in the pre-lock position, insert the tip
of the Service Tool into the service port of the
terminal in be removed/replaced. (Figure 7). NOTE:
Care should be used so as to not insert the service
tool into the terminal opening.
Push The Service Tool until resistance is felt.
Carefully press harder until the service tool moves
slightly further into the connector (this may be
accompanied by a small tactile sensation). At this
point the selected terminal is ready to be removed.
While maintaining pressure on the service tool, the
selected terminal may be removed from the rear of
the connector by pulling it out by the wire. To help
maintain seal integrity, if possible, pull the wire at a
small angle away from the connector center as
shown in Fig 8 (Not required for 2.8mm terminals).
NOTE: Terminal removal should require only a
gentle pulling force applied to the wire. If the
terminal stays retained or seems stuck, try
reinserting the service tool.
Pre-Lock
Figure 4
Figure 7
Service Ports
Figure 6
Final-Lock
Figure 5
21
K53030
07 MAY 2009 Rev D
3 of 3
Rev D
To attach a new terminal to the wire see the
appropriate APEX Terminal Crimping Guide.
3.1 Male Connector
Grip the TPA with a pair of serrated needle nose
pliers by using the appropriate holes in the center
of the TPA (Figure 9).
Gently pull the TPA into the Pre-Lock position.
The TPA should not be removed from the
connector. WARNING: Care must be used so the
pliers do not slip out of the service holes and
damage any exposed terminal blades or pinch the
operators hands.
With the TPA in the pre-lock position, insert the tip
of the Service Tool into the service port for the
terminal in be removed/replaced. Use care to be
sure the service tool stays in the service port track.
(Fig 10).
Push The Service Tool until resistance is felt.
Gently press harder until the service tool moves
slightly further into the connector (this may be
accompanied by a small tactile sensation).
selected terminal may be removed from the rear of
the connector by simply pulling it out by its wire.
NOTE: Terminal removal should require only a
gentle pulling force applied to the wire. If the
terminal stays retained or seems stuck, try
reinserting the service tool.
Figure 9
Figure 8
Service
Port
Figure 10
K53032
19 FEB 2008 Rev B
APEX 150 ErgoMate Connector Family
1 of 4
Rev B
1 Introduction
This document applies to the proper procedures and steps
required to manually install and replace APEX 2.8 (2.8mm)
and APEX 150 (1.5mm) terminals in the APEX 150
ErgoMate Connector Family. Also, general application
suggestions are covered.
1.1 Reference
FCI Terminal Drawings:
J54009-CUST APEX 150 Female Terminal
J54011-CUST APEX 150 Male Terminal
C15004-CUST APEX 2.8 Female Terminal
C15005-CUST APEX 2.8 Male Terminal
FCI Connector Drawings:
PCC0377483 ErgoMate 24 Way Female
PCC0377514 ErgoMate 24 Way Male
PCC0529876 ErgoMate 24 Way Female for MVM
PCC0529925 ErgoMate 24 Way Male for MVM
Recommended Tools:
Small Needle Nose Pliers (Sears Craftsman #45664)
APEX 150 Service Tool (54241678)
APEX 2.8 Service Tool (5400EXT)
1.2 Terminology
2 Terminal Insertion Instructions
2.1 Female Terminals
Make sure TPA is in the pre-lock position in the female
housing. See Figure 2.1a.
Orient the female terminals correctly with each terminal
position opening in the retainer of female connector
assembly as shown in figure 2.1c. The APEX 2.8
terminals can
Carefully insert the terminal into the cavity opening. Only
slight force should be needed. If the force to install each
terminal seems high or the terminal will not seat Stop!
Remove the terminal, recheck its orientation, verify the
Figure 2.1c
Pre-Lock
Figure 2.1a
Final-Lock
Figure 2.1b
Female
CPA
TPA
Slider
Slider Lock
Release
Male
TPA
Clip-Slot Feature
22
23
K53032
19 FEB 2008 Rev B
2 of 4
Rev B
cavity does not have a seal plug, and verify the TPA is
fully in the pre-lock position.
When the terminal is correctly installed, there will be a
small click and some tactile feedback.
position, then press the TPA into the final lock position
as shown in figure 2.1b. If the TPA will not move into the
final-lock position, verify that all terminals are fully
seated.
2.2 Male Terminals
Make sure TPA is in the pre-lock position in the female
housing. See figure 2.2a.
Orient the male terminals correctly with each terminal
position opening in the male connector assembly as
shown in Figure 2.2c.
Carefully insert the terminal into the cavity opening. If the
force to install each terminal seems high or the terminal
will not seat Stop! Remove the terminal, recheck its
orientation (Figure 2.2c), verify the cavity does not have
a seal plug and verify the TPA is fully in the pre-lock
position (Figure 2.2a).
When the terminal is correctly installed, there will be a
small click and some tactile feedback.
position, then press the TPA into the final lock position
as shown in figure 2.2b. If the TPA will not move into the
final-lock position, verify that all terminals are fully
seated.
3 Mating and Un-mating the ErgoMate System
3.1 Un-mating
Slide the CPA (if so equipped) from the Locked position
to the Un-Locked position. Doing so unlocks the
Gear/Cam so the system can be disconnected.
Squeeze the Slider lock release in the location shown &
then pull the slider axially in the direction shown. (See
figure 3.1b).
Figure 2.2c
Pre-Lock
Figure 2.2a
Final-Lock
Figure 2.2b
Figure 3.1a
CPA Un-Locked CPA Locked
Figure 3.1b
24
K53032
19 FEB 2008 Rev B
3 of 4
Rev B
3.2 Mating
Grip the Female Connector by the slider. Engage the
male and female connector halves in the proper
orientation by sliding the female connector onto the male
side. When adequate engagement is achieved, the slider
will release from the female connector and begin to slide
along the system. (See Figure 3.2a)
When the connectors are fully engaged, the CPA can be
pushed into the Locked position. (See Figure 3.1a)
The connector system is now fully mated.
4 Servicing and Replacing Terminals
4.1 Female Connector
Gently pull the TPA into Pre-Lock position by gripping
the TPA as shown in figure 4.1a. To avoid damaging the
TPA, use care to not pull the TPA out of the connector!
WARNING: Do not grab or grip the Shorting Bar tabs if
so equipped (see Figure 4.1b). Tabs may be damaged
leading to a failure of the shorting bar function.
With the TPA in the pre-lock position, insert the tip of
the Service Tool into the service port of the terminal to
be removed/replaced. (Figure 4.1c). NOTE: Care should
be used so as to not insert the service tool into the
terminal opening.
Push The Service Tool until resistance is felt. Carefully
press harder until the service tool moves slightly further
into the connector (this may be accompanied by a small
tactile sensation). At this point the selected terminal is
ready to be removed.
selected terminal may be removed from the rear of the
connector by pulling it out by the wire. To help maintain
seal integrity, if possible, pull the wire at a small angle
away from the connector center as shown in Figure 4.1d
(Not required for 2.8mm terminals). NOTE: Terminal
removal should require only a gentle pulling force
applied to the wire. If the terminal stays retained or
seems stuck, try reinserting the service tool.
Figure 3.2a
Service Ports
Terminal Openings
1.5mm
2.8mm
Figure
4.1b
Figure
4.1a
Figure 3.2a
25
K53032
19 FEB 2008 Rev B
4 of 4
Rev B
To attach a new terminal to the wire see the appropriate
APEX Terminal Crimping Guide.
4.2 Male Connector
Grip the TPA with a pair of serrated needle nose pliers
by using the center of the rib on the TPA (Figure 4.2a).
Gently pull the TPA into the Pre-Lock position. The
TPA should not be removed from the connector.
WARNING: Care must be used so the pliers do not slip
off of the rib and damage any exposed terminal blades
or pinch the operators hands.
NOTE: Do NOT remove the male TPA from the
connector! Doing so may cause permanent damage to
the TPA and make replacement effort difficult.
With the TPA in the pre-lock position, insert the tip of
the Service Tool into the service port for the terminal in
be removed/replaced. (Fig 4.2b).
Push The Service Tool until resistance is felt. Gently
press harder until the service tool moves slightly further
into the connector (this may be accompanied by a small
tactile sensation).
selected terminal may be removed from the rear of the
connector by simply pulling it out by its wire. NOTE:
Terminal removal should require only a gentle pulling
force applied to the wire. If the terminal stays retained or
seems stuck, try reinserting the service tool.
5 Application Guide
5.1 Clearances
When designing applications and harnesses that utilize
ErgoMate connectors, care must be use to assure that
there is sufficient clearance around the connector to
access the CPA and mate and un-mate the connector as
described in section 3.
5.2 Special Applications
Female Clip-Slot: The ErgoMate system may be
configured with a clip-slot on the female slider in
combination with no clip-slot on the male connector. In
this configuration, the slider will be fixed and the internal
body of the female connector will slide backward (at
least 23mm) during the mating process. It will be
necessary to dress the wire bundle to the left or the right
to assure low mate forces (see example in figure 5.2)
and to be sure there is sufficient clearance behind the
female connector wire bundle to assure proper mating.
In this configuration, single handed mating is possible by
simply pushing the male connector into the female
connector, however, two hands will be required to un-
mate the connector in this case, one to release the
female slider lock, and another to pull out the male
connector.
5.3 Connector Orientation
As is true with any sealed connector system used in a
wet environment, the in service orientation of the
connector should have the mating axis of the connector
in as horizontal an orientation as possible. This prevents
water from pooling in the wire openings.
Figure 4.1d
Service
Port
Terminal
Opening
Figure
4.2b
Figure 4.2a
Figure 5.2
26
Connection Systems
APEX
APEX 2.8
APEX 2.8 mm Connectors Features and Benefits
Performance Characteristics
Temperature Ranges:
Exceeds USCAR-2 Performance
Specification
Validated for Diesel Engines Applications
Construction
Connector, Mat Seal, Seal Retainer,
Interface Seal, TPA and CPA make up the
connector assembly
Housing Material: Nylon 35% GF
Interface Seal: Silicone
Mat Seal: Silicone
Terminal Compatibility
APEX 2.8: Tin or Gold Plated
FEATURE BENEFIT
1 Polarization molded-in, up to 4 indexes (7 on 10-ways), scoop proof Design flexibility
2 Pre-assembled integral Connector Position Assurance, CPA Ease of assembly
3 Clip slot on all male and 2-, 10- and 14-way female connectors Flexibility for mounting
4 Plastic is molded with smooth well-rounded corners Ergonomics for assembly
5 Double shroud design, protected interface seal Increased durability
6 Primary connector lock, audible, tactile, one-hand operation Reliable and easy to mate
7 Pre-assembled integral Terminal Position Assurance, TPA Ease of assembly
8 Blade lead-in/probe protection Durability for service in the field
9 Molded-in locking finger Audible seat and ease of service
10 Pre-assembled Rear Mat seal with retainer Ease of assembly
11 Available in 2, 3, 4, 5, 6, 10 and 14 cavity configurationssealed and unsealed Design flexibility
12 Sealed and Unsealed housings use the same connectors and terminals Terminal standardization
13 Fewer part number to manage in OEM database Reduce engineering costs
14 Optional material for Class 4 (40C to +150C) applications Extreme temperatures
15 No special tools required to service the connector & terminal Ease of service
27
Connection Systems
APEX
FCI 2-Way APEX 2.8 mm Connection System

INDEX
TYPE
HOUSING
COLOR
SEALED/
UNSEALED
FEMALE ASSEMBLY
PART NUMBER
MALE ASSEMBLY
PART NUMBER
TEMPERATURE
RATING OF
MATERIAL
WIRE INSULATION
RANGE PER CAVITY (mm)
A DK GRN SEALED 55200200 54200273 40C to +150C 1.70 3.35
B DK BLUE SEALED 54200260 54200274 40C to +150C 1.70 3.35
C DK BROWN SEALED 54200261 54200275 40C to +150C 1.70 3.35
D TAN SEALED 54200262 54200276 40C to +150C 1.70 3.35
A BLK SEALED 54200206 54200210 40C to +125C 1.70 3.35
A BLK SEALED 54200213 54200215 40C to +125C 3.07 4.09
A BLK UNSEALED 54200200 54200204 40C to +125C 1.50 4.09
B LT GREY SEALED 54200207 54200211 40C to +125C 1.70 3.35
B LT GREY UNSEALED 54200201 54200205 40C to +125C 1.50 4.09
C DK GREY SEALED 54200208 55200204 40C to +125C 1.70 3.35
D NATURAL SEALED 54200209 55200205 40C to +125C 1.70 3.35
Note: Additional configurations available. Please consult sales drawing.
Female part numbers with the N suffix are without CPA latch.
FEMALE MALE
Sealed Assembly Unsealed Assembly Sealed Assembly Unsealed Assembly
28
Connection Systems
APEX

INDEX
TYPE
HOUSING
COLOR
SEALED/
UNSEALED
FEMALE ASSEMBLY
PART NUMBER
MALE ASSEMBLY
PART NUMBER
TEMPERATURE
RATING OF
MATERIAL
WIRE INSULATION
A DK GRN SEALED 54200346 54200354 40C to +150C 1.70 2.77
A BLK SEALED 54200308 54200312 40C to +125C 1.70 2.77
D NATURAL UNSEALED 54200303 54200307 40C to +125C 1.50 4.09
C DK GREY UNSEALED 54200302 54200306 40C to +125C 1.50 4.09
A BLACK SEALED 54200335N* SEAL W/O HOLES USED AS CAP
A BLACK SEALED 54200337* SEAL W/O HOLES USED AS CAP
* Plug for same index (A) mating part.
Note: Female part numbers with the N suffix are without CPA latch.
3.35mm wire diameter sealing is available in select configurations. Consult sales drawing.
Additional configurations available. Please consult sales drawing.
FEMALE MALE
29
Connection Systems
APEX

INDEX
TYPE
HOUSING
COLOR
SEALED/
UNSEALED
FEMALE ASSEMBLY
PART NUMBER
MALE ASSEMBLY
PART NUMBER
TEMPERATURE
RATING OF
MATERIAL
WIRE INSULATION
A BLK SEALED 54200409 54200413 40C to +125C 1.70 2.77
B LT GREY SEALED 54200450* SEAL W/O HOLES USED AS CAP
FEMALE MALE
30
Connection Systems
APEX

INDEX
TYPE
HOUSING
COLOR
SEALED/
UNSEALED
FEMALE ASSEMBLY
PART NUMBER
MALE ASSEMBLY
PART NUMBER
TEMPERATURE
RATING OF
MATERIAL
WIRE INSULATION
A BLK UNSEALED 54200517 DIRECT CONNECT 40C to +125C 1.70 3.35
B LT GREY UNSEALED 54200518 DIRECT CONNECT 40C to +125C 1.70 3.35
C DK GREY UNSEALED 54200519 DIRECT CONNECT 40C to +125C 3.07 4.09
D NATURAL UNSEALED 54200520 DIRECT CONNECT 40C to +125C 1.50 4.09
A BLK SEALED 54200521 DIRECT CONNECT 40C to +125C 1.70 3.35
B LT GREY SEALED 54200522 DIRECT CONNECT 40C to +125C 1.50 4.09
C DK GREY SEALED 54200523 DIRECT CONNECT 40C to +125C 1.70 3.35
D NATURAL SEALED 54200524 DIRECT CONNECT 40C to +125C 1.50 3.35
FEMALE DIRECT CONNECT INTERFACE
Sealed Assembly Unsealed Assembly
31
Connection Systems
APEX

INDEX
TYPE
HOUSING
COLOR
SEALED/
UNSEALED
FEMALE ASSEMBLY
PART NUMBER
MALE ASSEMBLY
PART NUMBER
TEMPERATURE
RATING OF
MATERIAL
WIRE INSULATION
A BLK SEALED 54200608 54200612 40C to +125C 1.70 2.77
FEMALE MALE
32
Connection Systems
APEX

INDEX
TYPE
HOUSING
COLOR
SEALED/
UNSEALED
FEMALE ASSEMBLY
PART NUMBER
MALE ASSEMBLY
PART NUMBER
TEMPERATURE
RATING OF
MATERIAL
WIRE INSULATION
A BLK SEALED 54201009 54201016 40C to +125C 1.70 3.35
C LT GRN SEALED 54201012 54201018 40C to +125C 1.70 3.35
C LT GRN UNSEALED 54201002 54201008 40C to +125C 1.50 4.09
G LT BRN SEALED 54201043 54201042 40C to +125C 1.70 3.35
A BLACK SEALED 54201051N* SEAL W/O HOLES USED AS CAP
B LT GREY SEALED 54201024* SEAL W/ O HOLES USED AS CAP
C LT GRN SEALED 54201059* SEAL W/ O HOLES USED AS CAP
* Plug for same index (A, B or C) mating connector.

FEMALE MALE
33
Connection Systems
APEX

INDEX
TYPE
HOUSING
COLOR
SEALED/
UNSEALED
FEMALE ASSEMBLY
PART NUMBER
MALE ASSEMBLY
PART NUMBER
TEMPERATURE
RATING OF
MATERIAL
WIRE INSULATION
A BLACK SEALED 54201411 54201415 40C to +125C 1.70 3.35
A BLACK UNSEALED 54201442 54201404 40C to +125C 1.50 4.09
C DK GRAY SEALED 54201413 54201417 40C to +125C 1.70 3.35
D TAN SEALED 54201414 54201418 40C to +125C 1.70 3.35
A BLACK SEALED 54201445N SEAL W/NO HOLES USED AS CAP*
A BLACK SEALED 54201459 SEAL W/NO HOLES USED AS CAP*
B LT GREY SEALED 54201462 SEAL W/NO HOLES USED AS CAP*
B DK GREY SEALED 54201463 SEAL W/NO HOLES USED AS CAP*
C NATURAL SEALED 54201464 SEAL W/NO HOLES USED AS CAP*
*Cap for corresponding connector index type.
FEMALE MALE
34
Connection Systems
APEX
FCI 14-Way APEX 2.8 Power Shunt Unsealed

INDEX
TYPE
HOUSING
COLOR
SEALED/
UNSEALED
POWER SHUNT
PART NUMBER
MATING FEMALE
ASSEMBLY
PART NUMBER
TEMPERATURE
RATING OF
MATERIAL
WIRE INSULATION
RANGE PER CAVITY
(mm)
B LT GREY UNSEALED 54201410
54201453
w/clip slot
40C to +125C 1.50 4.09
B LT GREY UNSEALED 54201465
54201453
w/finger grip and
w/o clip slot
40C to +125C 1.50 4.09
54201465
(14-Way Shunt)
54201410
(12-Way Shunt 2x6 bus bars)
35
Connection Systems
APEX
Flanged 6-Way Male APEX 2.8 Connector

Part No. 54200638 (Pass-Through Connection)
INDEX
TYPE
HOUSING
COLOR
SEALED/
UNSEALED
MATING FEMALE ASSEMBLY
PART NUMBER
TEMPERATURE RATING
OF MATERIAL
WIRE INSULATION RANGE
PER CAVITY (mm)
A BLACK SEALED 54200608 40C to +125C 1.70 2.77
Note: Additional sealing configuration available to accommodate larger (3.35mm) wire.
36
Connection Systems
APEX
PCB 14+4 APEX 2.8 Header Connector

Part No. 54451800 (PCB Header)
INDEX
TYPE
HOUSING
COLOR
SEALED/
UNSEALED
MATING FEMALE ASSEMBLY
PART NUMBER
TEMPERATURE RATING
OF MATERIAL
WIRE INSULATION RANGE
PER CAVITY (mm)
37
Connection Systems
APEX
APEX 2.8 mm Terminals & Cavity Plug

APEX 2.8 mm Cavity Plug
FEMALE
TERMINAL
PART NUMBER
WIRE GAGE
TERMINAL
MATERIAL
TERMINAL
PLATING
54002200 22 CuTeSn/CuBe Sn
54001800 18-20 CuTeSn/CuBe Sn
54002203 22 CuTeSn/CuBe NiPdAu
54001803 18-20 CuTeSn/CuBe NiPdAu
FEMALE MALE
Part No. 54200005
Note: The Nickel/Palladium/Gold plating is recommended for
diesel engine applications.
Nyogel 8917 low friction insertion grease available on female
terminal.
NYE 7606 grease available on female terminal for dry circuit
applications.
MALE
TERMINAL
PART NUMBER
WIRE GAGE
TERMINAL
MATERIAL
TERMINAL
PLATING
54002201 22 CuTeSn Sn
54001801 18-20 CuTeSn Sn
54001401 14-16 CuTeSn Sn
54001001 10-12 CuTeSn Sn
54002230 22 CuTeSn NiPdAu
54002229 22 CuTeSn NiAu
54001819 18-20 CuTeSn NiAu
Note: Locks on seal retainers.
38
Connection Systems
APEX
APEX 2.8 mm Connector Clips

M5 Weld Stud Clip
Part No. 54200002
Fits both male & female Chrysler type
connector clip slot.
Single X-Tree Clip
Part No. 4625797
Double X-Tree
Part No. 04707091
Double X-Tree
Part No. 54200010
Fits male side only Chrysler type connector clip slot.
Provides <200N push through retention.
39
Connection Systems
APEX
APEX 2.8 mm Tools

Crimp Applicator For Wire Sizes Up To 6 mm
2
Hand Crimp Tool Extraction Tool
APEX2.8MM18/20
Hand Crimp Tool for 18-20 AWG APEX 2.8
mm Terminals
APEX2.8MM14/16
mm Terminals
APEX2.8MM10/12
mm Terminals
5400EXT Terminal Extraction Tool - APEX 2.8 mm
QUICK-CRIMP 947 is the crimp applicator for economical processing of stripped
crimp terminals. The side feed applicator for left-feed terminals has a mechanical
advance. It can be used in semi-automatic bench presses, stripper crimpers or fully
automatic wire processing machines. Includes 7 digit cycle counter.
Technical Details
Wire Cross Section: 0.08 to 6.0 mm
2
Mechanical feed (transversal):
Feed Length: 3 to 30 mm
Stroke: 40 to 44 mm
Shut Height: 135.78 mm
Weight: 4 kg
Dimensions: 170 mm wide x 160 mm
high x 100 mm deep
Options
Select crimp height adjustment
from self-locking adjustment disks,
steps every 0.02 mm
Counter 7-digits (not resettable)
Ejector between conductor and
insulation punch
Optional stroke of 30 mm
Quick changeover to other terminal
with conversion kit
40
Connection Systems
APEX
Terminal Winding Options For Wire Harness Manufacturers

STANDARD FCI WINDING IS B.
TO ORDER WINDING A USE THE FOLLOWING
SUFFIX: 5400xxxxRWA
TO ORDER WINDING C USE THE FOLLOWING
SUFFIX: 5400xxxxRWC
TO ORDER WINDING D USE THE FOLLOWING
SUFFIX: 5400xxxxRWD
41
Connection Systems
APEX
APEX 2.8 mm Terminal De-Rating Curves

FCI AUTO PART NO.
GROUP FEMALE MALE WIRE TYPE
14 Gage 54001400 54001401 14 ga. TXL
18 Gage 54001800 54001801 18 ga. TXL
2.5 mm 54001400 54001401 2.5 mm FLRY - B
1.5 mm 54001400 54001401 1.5 mm FLRY - B
1.0 mm 54001800 54001801 1.0 mm FLRY - B
0.75 mm 54001800 54001801 0.75 mm FLRY - B
0.50 mm 54001800 54001801 0.5 mm FLRY - B
0.35 mm 54002200 54002201 0.35 mm FLRY - B
42
Connection Systems
APEX
APEX 2.8 mm Connector Assembly Instructions

FEMALE MALE
CPA
TPA
TPA
1 CPA and TPA in pre-staged position
3 Seat male terminal into connector cavity.
Listen for audible click.
1 CPA and TPA in pre-staged position
2 Insert male terminal through rear mat seal. The grip may
be oriented either up or down.
2 Insert male terminal through rear mat seal. The grip may
be oriented either up or down.
3 Seat male terminal into connector cavity.
Listen for audible click.
4 Push TPA into its locked position. 4 Push TPA into its locked position.
43
Connection Systems
APEX
APEX 2.8 mm Terminal Extraction Instructions

FEMALE MALE
1 Remove TPA from connector.
Pull from slotted post/rib.
1 Remove TPA from connector.
Pull from post.
Flat Tip
TPA TPA
2 Use extraction tool to remove
the terminals after removal
of TPA.
2 Use extraction tool to remove
the terminals after removal
of TPA.
3 Slightly lift plastic finger lock in the cavity
while pulling on the wire to remove
the terminals out of the rear
of the connection housing.
3 Slightly lift plastic finger lock in the
cavity while pulling on the wire
to remove the terminals out
of the rear of the
connection housing.
CM5K 05/09
FSC LOGO 11M tall
TTI Inc. Transportation Business Unit
6480 Rockside Woods Boulevard Suite #110
Independence, OH 44131
Phone# 1-877-884-4288
Fax# 1-216-750-9642
Email tbu@ttiinc.com

FCI APEX Connection Systems Guide

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FCI 3-Way APEX 2.8 mm Connection System

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PCB 14+4 APEX 2.8 Header Connector

APEX 2.8 mm Terminals & Cavity Plug

APEX 2.8 mm Connector Clips

APEX 2.8 mm Tools

Terminal Winding Options For Wire Harness Manufacturers

APEX 2.8 mm Terminal De-Rating Curves

APEX 2.8 mm Connector Assembly Instructions

APEX 2.8 mm Terminal Extraction Instructions

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