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SAE J928-2022 Guide: Pin and Receptacle Electrical Terminals Standards
This article covers the essential specifications and requirements of SAE J928-2022 for pin and receptacle type electrical terminals used in surface vehicles. It highlights dimensional standards, material and force recommendations, and design considerations to ensure reliable, interchangeable connections.
Scope and General Requirements
This standard covers general requirements and terminal interface dimensions for pin and receptacle type terminals, which may be used for terminating wire ends or circuits on devices. Terminals must be free from burrs, corrosion, or any foreign matter, and they must have a temper that permits attachment without fracturing or cracking. The standard also specifies that insulation grips are required for terminals assembled to wire sizes of 2 mm² (14 ga) and smaller unless other strain relief is provided.
🛠️ Engineering Design Insight: Insulation grips are mandatory for small-gauge wires to prevent strain at the connection point. This is critical in vibration-prone automotive environments to maintain electrical integrity over the vehicle lifetime.
Type I and Type II Pin Terminals: Dimensional Specifications
The standard defines two types of pin terminals—Type I (larger) and Type II (smaller)—with specific dimensions to ensure interchangeability across manufacturers. Below is a summary of key dimensional data from the standard.
| Type | Nominal Diameter (mm) | Wire Size Range | Min Insertion Length A (mm) | Min Insertion Length B (mm) |
|---|---|---|---|---|
| Type I | 3.96 | 0.35–3.0 mm² (22–12 AWG) | 8.7 | 8.7 |
| Type I | 4.57 | 0.35–5.0 mm² (22–10 AWG) | 10.2 | 10.2 |
| Type II | 2.18 | 0.35–2.0 mm² (22–14 AWG) | 4.4 | 4.4 |
| Type II | 2.36 | 0.35–2.0 mm² (22–14 AWG) | 5.4 | 5.4 |
| Type II | 3.96 | 0.35–3.0 mm² (22–12 AWG) | 5.1 | 5.1 |
Note: The full tables (Table 1 and 2 in the standard) include additional dimensions such as pin diameters, tolerances, and detent features. Refer to the original document for detailed specifications.
Insertion Forces and Material Considerations
Insertion and removal forces are variables that must be controlled to ensure consistent performance and avoid damage. The standard recommends that single connections with indentures not exceed 67 N (15 lb) and multiple connections without indentures not exceed 31 N (7 lb) per connection. Material type, thickness, and finish may vary by application, but all terminals must meet the general requirements and the performance requirements of SAE J163.
⚠️ Common Mistake: Exceeding the recommended insertion forces can cause permanent deformation of the receptacle or pin, leading to intermittent connections. Always verify insertion force during connector assembly and use appropriately rated tools.
Stabilization Status and Continuing Applicability
As of August 2022, SAE J928 has been stabilized by the SAE Connector Systems Standards Committee. This status means the technology is mature and unlikely to change in the foreseeable future. Users are responsible for verifying that the standard’s requirements remain suitable for their applications, especially if newer connector technologies have emerged since stabilization.
Frequently Asked Questions
Q1: What are the dimensional specifications for a 3.96 mm nominal diameter pin terminal?
For Type I, the 3.96 mm pin has minimum insertion lengths of 8.7 mm (dimensions A and B) and supports wire sizes from 0.35 to 3.0 mm² (22–12 AWG). For Type II, the same nominal diameter has a minimum insertion length of 5.1 mm and also supports 0.35–3.0 mm² wire.
Q2: What are the recommended maximum insertion forces for single and multiple connections?
Single connections with indentures: 67 N (15 lb). Multiple connections without indentures: 31 N (7 lb) per connection. These values are recommended limits to avoid damaging the terminal or mating connector.
Q3: Which wire sizes are compatible with Type I and Type II pin terminals?
Type I terminals accommodate wires from 0.35 mm² (22 AWG) up to 5.0 mm² (10 AWG), depending on the specific pin size. Type II terminals generally cover 0.35 mm² (22 AWG) to 2.0 mm² (14 AWG) for smaller pins, with larger Type II pins supporting up to 3.0 mm² (12 AWG). Always confirm compatibility using the standard’s wire size range column.
Q4: Is SAE J928-2022 still current, or has it been superseded by newer technology?
The standard is currently stabilized—meaning it is still valid but no longer actively updated. Engineers should assess whether newer connector designs or standards better suit their application, but J928-2022 remains a reliable reference for traditional pin and receptacle terminal interfaces.
For the complete specification, including all dimensions and tolerances, refer to the official SAE document at SAE J928-2022. 🛠️
