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Application Specification PLASTI- GRIP* Terminals and Splices
NOTE
114-- 2161
31 JUL 09 Rev E
i
All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters [and inches]. Unless otherwise specified, dimensions have a tolerance of +0.13 [+.005] and angles have a tolerance of +2_. Figures and illustrations are for identification only and are not drawn to scale.
1. INTRODUCTION
This specification covers the requirements for application of PLASTI--GRIP terminals and splices for commercial applications. The terminals and splices consist of precision formed metal wire barrel insulated with vinyl with a maximum operating temperature of 90_C [194_F] for the splices and 105_C [221_F] for the terminals. The ring tongue terminals and butt splices are also available insulated with PVF2 (polyvinylidene fluoride); these terminals and splices can withstand a temperature range of --65 to 150_C [149 to 302_F]. The terminals are also available in heavy duty (HD) for extra mechanical strength. The terminals and splices accept solid or stranded wire for single applications. The flared end of the insulation allows insertion of wires that meet maximum voltage ratings: 600 V for building wiring and 1,000 V for fixture and sign wiring. The terminals and splices are color coded to provide a visual reference applicable to the wire size range suitable for the terminal or splice. In addition, terminals are marked on the tongue with the wire size range. The serrations or dimples inside the wire barrel provide maximum contact and tensile strength after crimping. The terminals suitable for mounting accept stud sizes M2 [2] through M12 [.50] (a diameter range of 2.18 through 12.7 [.086 through .500]). The terminals and splices are available in loose--piece for terminating with manual and pneumatically--powered hand--held tools, and in tape--mounted form for terminating with semi--automatic hand--held tools and electrically--powered machines. When corresponding with Tyco Electronics Personnel, use the terminology provided in this specification to facilitate your inquiries for information. Basic terms and features of this product are provided in Figure 1.
Short Spring Spade Terminal
Long Spring Spade Terminal
Flanged Spade Terminal
Hook Tongue Terminal
Rectangular Tongue Terminal
Multi Stud Ring Terminal
Ring Tongue Terminal
Ring Tongue Flag Terminal
Slotted Ring Tongue Terminal
Tube Cap Terminal Assembly
Plug Terminal
Ring Tongue 90_ Bend Terminal
3--Way Link Terminal
Figure 1
Parallel Splice
Butt Splice
TOOLING ASSISTANCE CENTER 1-- 800-- 722-- 1111 E2009 Tyco Electronics Corporation, Harrisburg, PA PRODUCT INFORMATION 1-- 800-- 522-- 6752 All International Rights Reserved TE logo and Tyco Electronics are trademarks. *Trademark. Other products, logos, and company names used are the property of their respective owners.
This controlled document is subject to change. For latest revision and Regional Customer Service, visit our website at www.tycoelectronics.com
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LOC B
PLASTI- GRIP Terminals and Splices 2. REFERENCE MATERIAL 2.1. Revision Summary
Revisions to this application specification include:
114- 2161
S Removed Crimping Die Assembly 1213098--1
2.2. Customer Assistance
Reference Product Base Part Number 32945 and Product Code 3040 are representative of PLASTI--GRIP terminals and splices. Use of these numbers will identify the product line and expedite your inquiries through a service network established to help you obtain product and tooling information. Such information can be obtained through a local Tyco Electronics Representative or, after purchase, by calling Product Information at the number at the bottom of page 1.
2.3. Drawings
Customer Drawings for product part numbers are available from the service network. If there is a conflict between the information contained in the Customer Drawings and this specification or with any other technical documentation supplied, call Product Information at the number at the bottom of page 1.
2.4. Instructional Material
Instruction Sheets (408--series) provide product assembly instructions or tooling setup and operation procedures and Customer Manuals (409--series) provide machine setup and operation procedures. Documents available which pertain to this product are:
A. Product
408--7424 408--9816 Checking Terminal Crimp Height or Gaging Die Closure Handling of Reeled Products Hand Crimping Tool 59270 Hand Crimping Tool 59239--4 Hand Crimping Tools 59489 and 59287--1 Pneumatic Tool 69015 Hand Crimping Tools 45160 and 45575--1 Hand Crimping Tools 45449 and 45450 Hand Crimping Tools 46121, 47386, and 47387 Hand Crimping Tools 48040 and 48049 "T"--HEAD* Crimping Tools 59250 and 59170 Crimping Dies 47806--2, 47807--1, and 47808--6 Crimping Dies 48858--1, 48859--1, 48861--1, and 47238--1 Crimping Dies 47820, 47821, 47822, and 47823 Crimping Dies 48752--1, 48753--1, 48754--1, and 48755--1 Hand Crimping Tool 69710--1 Crimping Die Assemblies 69877, 69878, 69872, 69873, and 68116--1 Hand Crimping Tool 69959 Hydraulic Crimping Head 69051 Hydraulic Crimping Head 69066 Crimping Head Cross--Reference for Pneumatic Tools Tool and Die Selection Chart Tool and Die Selection Chart for AMP* Terminals and Splices Crimping Die Assemblies 68247--1 and 68248--1 Crimping Die Assembly 69893 Crimping Die Assemblies 59826--1, 59827--1, 59828--1, and 69874 TETRA--CRIMP* Hand Crimping Tool 59824--1 Pneumatic Crimping Head 679300--1 Pneumatic TETRA--CRIMP Adapter 679305--1
B. Tooling
408--1256 408--1261 408--1263 408--1310 408--1502 408--1548 408--1559 408--1570 408--1610 408--1632 408--1724 408--1729 408--1758 408--2095 408--2423 408--2434 408--2450 408--2453 408--2498 408--2567 408--2575 408--2592 408--2667 408--2822 408--2823 408--4071 408--4099
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408--4105 408--4190 408--4198 408--4303 408--4321 408--6757 408--6764 408--6765 408--8044 408--8082 408--9177 408--9252 408--9535 408--9586 408--9684 408--9775 409--1950 409--1993 409--2586 409--2761 409--5128 409--5842 409--5852 409--5860 409--5862 409--5878
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Straight Action Crimper 217200--1 C--Head Pneumatic Adapter (Crimper) 318161--1 Pneumatic Crimping Head Assembly 314991--1 Pneumatic CERTI--CRIMP* Tool Holder Assemblies 356303--1 (Small) and 356302--1 (Large) Straight Action Tool Holder Assembly 356304--1 (Logic) Hydraulic Hand Crimping Tool 59974--1 CERTI--LOK* Hand Tool Frame Assembly 169400 Crimping Die Assembly 169404 Miniature Quick--Change Applicator 687658--1 (Side--Feed with Mechanical Feed System) Miniature Quick--Change Applicators 567200--2 and --3 (Side--Feed with Air Feed System) Crimping Dies 47378--1, 48756--1, and 48757--1 PRO--CRIMPER* III Hand Crimping Tool 58433--3 Hydraulic Crimping Head 58422--1 Pneumatic Crimping Heads 314269--1 and 314270--3 Inspection and Servicing of Hydraulic Crimping Heads 69051, 58422--1, and 69066 Pneumatic Crimping Heads 314868--1 and 314869--1 Hydraulic Power Units 69120--1 and 69120--2 AMP--TAPETRONIC* Machine 69875 AMP--TAPETRONIC Machine 68250--1 Pneudraulic Wiring Terminating Machine 68354--1 Basic AMP--O--LECTRIC* Model "K" Terminating Machine 471273--[ ] AMP--O--LECTRIC Model "G" Terminating Machine 354500--[ ] AMPOMATOR* CLS III--G Lead--Making Machine 122500--[ ] Hydraulic Hand Pump 314979--1 626 Pneumatic Tooling Assemblies 189721--[ ] and 189722--[ ] AMPOMATOR CLS IV Lead--Making Machine 356500--[ ]
3. REQUIREMENTS 3.1. Special Characteristics
Terminals with an open--ended tongue, such as spade terminals, can be installed and removed without complete removal of the mounting screw. The terminal flat sides provide a locking feature against lateral stress; flanged ends reduce possibility of terminal separation. The snap feature on spring spade terminals increases resistance to axial loads if the mounting screw becomes loosened. The closed--end tongue, in terminals such as ring tongue terminals, provides maximum protection against separation; these terminals are well suited for high vibration environments.
3.2. Material
The terminal body and splice body is made of copper plated with tin--except the spring spade terminal is made of phosphor bronze plated with tin or brass plated with tin, and the .093--Series plug terminal is made of brass. Rivets on the 3--way link terminal and tube cap assembly are made of brass and the tube cap on the tube cap assembly is made of copper zinc alloy. The insulation is made of vinyl or PVF2 (polyvinylidene fluoride). The vinyl insulation is highly resistant to abrasion. The PVF2 insulation is highly resistant to radiation and solvents.
3.3. Storage A. Shelf Life
The terminals and splices should remain in the shipping containers until ready for use to prevent deformation to the terminals and splices. The terminals and splices should be used on a first in, first out basis to avoid storage contamination that could adversely affect signal transmissions.
B. Ultraviolet Light
Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the terminal and splice insulation material.
C. Reeled Terminals and Splices
When using tape--mounted reeled terminals or splices, care must be taken to prevent stretching, sagging, or other distortion that would prevent smooth feeding of the tape through automatic machine feed mechanisms. Store coil wound reels horizontally and traverse wound reels vertically.
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PLASTI- GRIP Terminals and Splices 3.4. Chemical Exposure
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Do not store terminals or splices near any chemical listed below as they may cause stress corrosion cracking in the terminal or splices. Alkalies Amines Ammonia Carbonates Citrates Nitrites Phosphates Citrates Sulfur Nitrites Sulfur Compounds Tartrates
3.5. Wire Selection and Preparation
The terminals and splices will accept solid or stranded copper wire sizes 26 through 1/0 AWG and stranded wire sizes 8 through 2/0 AWG (509 through 150,500 circular mil area) with an insulation diameter range of 1.27 through 19.69 [.050 through .775]. Proper strip length is necessary to properly insert the wire into the terminal or splice. The strip length of the wire is shown in Figure 2. CAUTION Reasonable care must be taken not to nick, scrape, or cut any strands during the stripping operation.
!
3.6. Wire Placement
Stranded wire conductors must be inside the terminal or splice wire barrel. No strands can be folded back over the wire insulation. Conductor ends must be bottomed in the wire barrel. The wire insulation must be inside the insulation of the terminal or splice, but must not enter the wire barrel, to provide strain relief for the wire.
3.7. Crimp Requirements
The terminal or splice must be crimped to the wire according to instructions packaged with applicable tooling.
A. Wire Barrel Crimp
The crimp applied to the wire barrel portion of the terminal or splice is the most compressed area and is most critical in ensuring optimum electrical and mechanical performance of the crimped terminal or splice. The crimped area must be symmetrical on both sides of the wire barrel of the terminal or splice. The crimp may be off center on the wire barrel but not off the end of the wire barrel. See Figure 3.
B. Crimp Dot Code
Some tools with multiple crimping chambers will emboss a crimp dot code onto the terminal or splice insulation when crimped. The crimp dot code must be fully formed on the insulation to indicate that the correct product and tooling combination was used. The crimp dot code must correspond with the wire size marking on the tooling. See Figure 3.
C. Wire Conductor and Insulation Location
After crimping, all conductors must be held firmly inside the wire barrel. No strands can be folded back over the wire insulation. The wire insulation must be inside the insulation barrel of the terminal or splice, but must not enter the wire barrel. Conductor ends must be flush with, or extend slightly beyond, the end of the wire barrel; or, in splices with a wire stop inside the center of the splice, conductor ends must butt against the wire stop. See Figure 3. CAUTION Wire insulation shall NOT be cut or broken during the crimping operation. Reasonable care should be taken to provide undamaged wire terminations.
!
D. Terminal or Splice Insulation
The terminal or splice insulation must not be deformed, cut, or show uneven stress marks. See Figure 3.
E. Bellmouth
There shall be no rear bellmouth. The front bellmouth shall be evident as shown in Figure 3.
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PLASTI- GRIP Terminals and Splices
Stranded Wire Solid Wire
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Strip Length Conductor Insulation
WIRE INSULATION DIA RANGE 1.27--2.03 [.050--.080] 2.03--3.18 [.080--.125] -- -- -- 2.92--4.32 [.115--.170] -- -- -- -- -- -- -- -- -- -- -- -- -- 1.27--13.08 [.050--.515] -- 12.19--14.22 [.480--.560] -- -- 16.00--19.68 [.630--.775]
Strip Length
TERMINAL OR SPLICE INSULATION SIZE COLOR 26--22 24--20 22--16 6 20--16 HD 16--14 6 16--14 16 14 HD Yellow White Red Natural/Red Black Natural/Green Blue Natural/Blue Black Yellow/Black Black Yellow 12--10 0 Natural/Yellow Black Red 8 Natural/Red Blue 6 Natural/Blue Yellow 4 Natural/Yellow Red 2 Natural/Red 1/0 Blue Yellow 2/0 Natural/Yellow
WIRE STRIP LENGTH TERMINAL -- 4.75--5.54 [.187--.218] 5.16--5.94 5 16 5 94 [.203--.234] [ 203-- 234] 5.16--5.94 [.203--.234] 5.16--5.94 5 16 5 94 [.203--.234] [ 203-- 234] 7.92 8.71 7.92--8.71 [.312--.343] 7.92--8.71 7 92 8 71 [.312--.343] [ 312-- 343] 11.51 12.29 11.51--12.29 [.453--.484] 8.33--9.12 [.328--.359] 15.47--16.26 [.609--.640] 9.93--10.72 [.391--.422] 15.47--16.26 [.609--.640] 9.93--10.72 [.391--.422] 11.51--12.29 [.453--.484] 11.51--12.29 [.453--.484] 18.67--21.82 [.735--.859] 18.67--21.82 [.735--.859] 18.67--21.82 [.735--.859] Figure 2 BUTT SPLICE 4.34--5.16 [.171--.203] -- 6.35--7.14 6 35 7 14 [.250--.281] [ 250-- 281] -- 6.35--7.14 6 35 7 14 [.250--.281] [ 250-- 281] -- 7.92--8.71 7 92 8 71 [.312--.343] [ 312-- 343] 8.33 9.12 8.33--9.12 [.328--.359] -- 9.93--10.72 [.391--.422] -- -- -- -- -- -- -- -- PARALLEL SPLICE -- -- 7.87--8.64 7 87 8 64 [.310--.340] [ 310-- 340] -- 7.87--8.64 7 87 8 64 [.310--.340] [ 310-- 340] -- 7.92--8.71 7 92 8 71 [.312--.343] [ 312-- 343] --
WIRE CIRCULAR MIL AREA (CMA) 202--810 320--1,290 509 3, 60 509--3,260 810--3,260 2,050--5,180 ,050 5, 80 2,050--5,180 2 050 5 180
5, 80 3, 00 5,180--13,100
13,100--20,800 13 100 20 800 -- -- 20,800--33,100 20 800 33 100 -- -- 33,100--52,600 33 100 52 600 -- -- 52,600--83,700 52 600 83 700 -- -- -- 119,500--150,500 119 500 150 500 -- 83,700--119,500
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PLASTI- GRIP Terminals and Splices
Terminal Wire Conductor Location Front Bellmouth Must Be Visible End of Conductors Must Be Flush With, or Extend Slightly Beyond End of Wire Barrel Wire Insulation Location Plug Terminal Front Bellmouth Must Be Visible
114- 2161
Crimp Dot Code (Ref) Crimp Centered on Wire Barrel (Crimp May Be Off Center, But Not Off End of Wire Barrel)
Splice
Wire Conductor Location Wire Insulation Location
Wire Conductor Location Wire Insulation Location
Crimp Centered on Wire Barrel (Crimp May Be Off Center, But Not Off End of Wire Barrel)
SOLDER SLUG TERMINAL O S C OR SPLICE SIZE 26--22 24--20 22--16 20--16 HD 16--14 16--14 HD 12--10 8 6 4 2 1/0 2/0 CRIMP HEIGHT RANGE (See Notes) DIAMETER CRESCENT CRIMP 1.60--1.75 [.063--.069] 2.26--2.41 [.089--.095] 2.77--2.92 [.109--.115] 3.02--3.18 [.119--.125] 3 02 3 18 [ 119 125] 4.29--4.44 [ 169 175] 4 29 4 44 [.169--.175] 5.11--5.26 [.201--.207] 6.02--6.17 [.237--.243] 6.83--6.98 [.269--.275] 8.10--8.26 [.319--.325] 10.19--10.34 [.401--.407] 10.67--12.83 [.499--.505] CRIMP PRODUCED BY TETRA-- CRIMP TOOLING -- -- 1.98--2.18 [.078--.086] 2.34--2.54 [ 092 100] 2 34 2 54 [.092--.100] 3.25--3.45 [ 128 136] 3 25 3 45 [.128--.136] -- -- -- -- -- --
3.18 [ 125] 3 18 [.125] 3.18 [.125] 4.76 [ 188] 4 76 [.188] 6.35 [ 250] 6 35 [.250] 6.35 [.250] 6.35 [.250] 9.53 [.375] 9.53 [.375] 12.70 [.500] 15.88 [.625]
Note: The resilience of the terminal and splice insulation prevents accurate direct measurement of crimp height. Crimp height can be obtained by measuring a crimped solder slug (60% tin and 40% lead) with a diameter comparable to the wire size. The slug must be measured over the most compressed area of the slug with a standard micrometer or crimp height comparator (refer to Instruction Sheet 408-- 7424 for specific instructions). The solder slug diameter and crimp height must be within the dimensions provided. Note: Each crimp dimension represents the functional range of a wire/terminal or splice combination. There are tool designs available to meet various application requirements. The developed crimp configuration is unique for each tool design and is acceptable provided the crimp height is within the functional range. For crimp dimensions of a specific tool, refer to instruction sheet packaged with manual tools and applicator log packaged with power tools.
Figure 3
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PLASTI- GRIP Terminals and Splices F. Tensile Strength
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Crimped terminals or splices must hold the wire firmly and have a crimp pull--out test value meeting that specified in Figure 4. NOTE Adjust tensile testing machine for head travel of 25.4 [1.0] per minute. Directly and gradually apply force for one minute.
WIRE SIZE (AWG) 26 24 22 20 18 16 14 12 10 8 6 4 2 1/0 2/0 Figure 4 TENSILE FORCE (N [lb]) Min 13.4 [3] 22.3 [5] 35.6 [8] 57.9 [13] 89.0 [20] 133.5 [30] 222.5 [50] 311.5 [70] 356.0 [80] 400.5 [90] 445.0 [100] 623.0 [140] 801.0 [180] 1112.5 [250] 1235.0 [300]
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G. Bend Allowance
The force applied during crimping may cause some bending between the wire barrel and wire. Such deformation is acceptable within the following limits. 1. Up and Down The crimped portion must not be bent beyond the limits shown in Figure 5. 2. Side--to--Side The crimped portion must not be bent from one side to the other beyond the limits shown in Figure 5.
3.8. Repair
Damaged terminals and splices or terminals and splices that do not meet crimp dimension requirements must be removed from wires, discarded, and replaced with new ones. When removing a terminal or splice, cut the wires as close as possible to the end of the wire barrel.
4. QUALIFICATION
PLASTI--GRIP terminals and splices are Listed by Underwriters Laboratories Inc. (UL) in File E13288, and Certified by CSA International in File LR7189; except multi stud ring, ring tongue bent 90_, and tube cap terminals.
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PLASTI- GRIP Terminals and Splices
Up and Down Bend Terminal Datum Line 11_ Plug Terminal Datum Line 11_ 11_ Datum Line 11_ Splice 11_ 11_ 11_
114- 2161
11_
Side- to- Side Bend Terminal Datum Line 11_ Plug Terminal Datum Line 11_ 11_ Datum Line 11_
Figure 5
11_
11_
Splice
11_
11_
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PLASTI- GRIP Terminals and Splices 5. TOOLING
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Hand tools for manual application of loose piece terminals and splices, and automatic and semi--automatic machines for power assisted application of tape--mounted terminals and splices are available to cover the full wire size range. Tooling part numbers and instructional material packaged with the tooling are shown in Figure 6. NOTE Modified designs and additional tooling concepts may be available to meet other application requirements. Tool Engineers have designed machines for a variety of application requirements. For assistance in setting up prototype and production line equipment, contact Tool Engineering through your local Tyco Electronics Representative or call the Tooling Assistance Center at the number at the bottom of page 1.
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5.1. Hand Crimping Tool
The hand crimping tools consist of a handle assembly with integral fixed jaws or fixed dies, or a head that accepts various die assemblies. The jaws or dies have one or more crimping chambers used to crimp terminals and splices onto pre--stripped wire. The hand tool assemblies have a ratchet, except the hydraulic hand crimping tool which uses hydraulic fluid, to ensure full crimping pressure is applied to the terminal or splice.
5.2. 626 Pneumatic Tooling System
The pneumatic tooling system consists of a pneumatic power unit, tool holder assembly, and variety of crimping heads used to crimp terminals and splices onto pre--stripped wire. This tooling system was developed to reduce operator fatigue and provide interchangeability of die assemblies. The system is designed for prototype and medium--volume application of loose piece terminals and splices.
5.3. Pneumatic Tool
The pneumatic tool uses a pneumatic crimping head which contains jaws to crimp terminal and splices onto pre--stripped wires. This tool uses a filter and moisture separator, regulator, and lubricator. This tool is designed for low--volume application.
5.4. Applicator
The applicators are designed to crimp tape--mounted terminals and splices onto pre--stripped wire, for high volume, heavy duty production requirements. These applicators accept interchangeable crimping dies and must be installed onto a power unit.
5.5. Power Unit A. Hydraulic Machine
The hydraulic power units combine the convenience of a hand tool with the power of a larger machine to crimp loose piece terminals and splices onto pre--stripped wire. Each unit uses a hydraulic head and interchangeable dies. These units are, basically, a portable crimping unit which uses a handle or foot control to activate a pump. They are used primarily for low--volume production or at locations where electrical power sources are not readily available.
B. Pneudraulic Machine
Pneudraulic power units provide the force required for automatic crimping tape--mounted terminals and splices. These machines accept interchangeable dies and are air--operated using a foot valve. These machines use a filter and moisture separator, regulator, and lubricator and are designed to be bench--mounted.
C. Semi- Automatic Machine
These power units provide the force required to drive applicators for crimping tape--mounted terminals and splices. They provide for medium--volume applications. These machines are designed to be bench mounted.
D. Automatic Machine
These power units provide the force required to drive applicators for crimping tape--mounted terminals and splices. They can be set up to automatically measure, cut, strip, and terminate wire. They provide for high volume, heavy duty production requirements. These machines are designed to be floor standing.
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"T"-- HEAD Crimping Tools 59250, 59170 (408-- 1610)
TETRA-- CRIMP Hand Crimping Tool 59824-- 1 (408-- 2823)
PRO-- CRIMPER Hand Crimping Tool 58433-- 3 (408-- 9252)
Hand Crimping Tool 48040, 48049 (408-- 1570)
Hand Crimping Tool 69710-- 1 (408-- 2095) 59239-- 4 (408-- 1261) 69959 (408-- 2434) 59489, 59287-- 1 (408-- 1263) 59270 (408-- 1256) CERTI-- LOK Hand Tool Frame Assembly 169400 (408-- 6764)
Hand Crimping Tools 46121, 47386, 47387 (408-- 1559) 45160, 45575-- 1 (408-- 1502) 45449, 45450 (408-- 1548)
Hydraulic Hand Crimping Tool 59974-- 1 (408-- 6757)
Crimping Die Assemblies 69877, 69878, 69872, 69873, 68116-- 1 (408-- 2423) 59826-- 1, 59827-- 1, 59828-- 1, 69874 (408-- 2822) 69893 (408-- 2667) 68247-- 1, 68248-- 1 (408-- 2592) 68355-- 1 (408-- 2575) 68356-- 1 (408-- 2567)
Crimping Die Assembly 169404 (408-- 6765)
Crimping Dies 47806-- 2, 47807-- 1, 47808-- 6 (408-- 1632)
Crimping Dies 47820, 47821, 47822, 47823 (408-- 1729) 48752-- 1, 48753-- 1, 48754-- 1, 48755-- 1 (408-- 1758) 47238-- 1, 48858-- 1, 48859-- 1, 48861-- 1 (408-- 1724) 47378-- 1, 48756-- 1, 48757-- 1 (408-- 9177)
Figure 6 (Cont'd)
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Pneumatic Crimping Heads 314868-- 1, 314869-- 1 (408-- 9775) 314269-- 1 , 314270-- 3 (408-- 9586)
Pneumatic Crimping Head 679300-- 1 (408-- 4071)
Pneumatic TETRA-- CRIMP Adapter 679305-- 1 (408-- 4099)
Large Tool Holder Assembly 189767-- 1 (Non-- Logic) (409-- 5862) 356302-- 1 (Logic) (408-- 4303)
Straight Action Tool Holder Assembly 189928-- 1 (Non-- Logic) (409-- 5862) 356304-- 1 (Logic) (408-- 4321)
CERTI-- CRIMP (Small) Tool Holder Assembly 189766-- 1 (Non-- Logic) (409-- 5862) 356303-- 1 (Logic) (408-- 4303)
Straight Action Crimper 217200-- 1 (408-- 4105)
C-- Head Pneumatic Adapter (Crimper) 318161-- 1 (408-- 4190)
626 Pneumatic Tooling Assemblies 189721-- [ ], 189722-- [ ] (409-- 5862)
Pneumatic Tool 69015 (408-- 1310)
Pneumatic Crimping Head Assembly 314991-- 1 (408-- 4198)
Hydraulic Crimping Head 69051 (408-- 2450) 58422-- 1 (408-- 9535) 69066 (408-- 2453)
Miniature Quick-- Change Applicator 687658-- 1 (Side-- Feed with Air Feed System) (408-- 8044) 567200-- 3, 567200-- 2 (Side-- Feed with Air Feed System) (408-- 8082)
Figure 6 (Cont'd)
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Hydraulic Hand Pump 314979-- 1 (409-- 5860)
Hydraulic Power Units 69120-- 1, 69120-- 2 (409-- 1950)
Pneudraulic Wire Terminating Machine 68354-- 1 (409-- 2761)
AMPOMATOR CLS III-- G Lead-- Making Machines 122500-- [ ] (409-- 5852)
AMPOMATOR CLS IV+ Lead-- Making Machines 356500-- [ ] (409-- 5878)
AMP-- TAPETRONIC Machine 68250-- 1 (409-- 2586) 69875 (409-- 1993)
AMP-- O-- LECTRIC Model "K" Terminating Machine 1-- 471273-- 3 or 565435-- 5 (Modified)
No Longer Manufactured New
AMP-- O-- LECTRIC Model "G" Terminating Machines 354500-- 1 (409-- 5842)
(409-- 5128)
Figure 6 (Cont'd)
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TOOL HOLDER ASSEMBLY -- -- -- -- -- 189928--1 or 356304--1 189928--1 or 356304--1 189767--1 or 356302--1 189766--1 or 356303--1 -- --
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PRODUCT TYPE
WIRE SIZE (AWG) 24--20
CRIMPING DIE 69878 -- -- -- -- 47806--2 47806--2
HAND TOOL -- 59250 59170 47386 59824--1 189721--1 or 189722--1 189721--2 or 189722--2 189721--1 or 189722--1 189721--1 or 189722--1 169400 --
HEAD OR ADAPTER -- -- -- -- -- 217200--1 318161--1 679305--1 314270--3 -- --
APPLICATOR 567200--2 or 567200--3 -- -- -- -- -- -- -- -- -- 687658--1
POWER UNIT 69875 or -- -- -- -- -- -- -- -- --
Terminals: g Flag Multi St d M lti Stud Ring Spade Tube Cap Wire Pin
-- 22--16 -- 169404 59826--1, 69872, or 69893 59826--1, 69872, or 69893 59826--1 or 69872 59826--1 or 69872 20--16 HD --
-- -- -- 48040
-- -- -- --
-- -- -- --
-- 567200--3 567200--2 --
69875
1--471273--2 or 565435--5 (Modified) --
122500--2, 122500--3, 356500--1, 356500--2 354500--1 Figure 6 (Cont'd)
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TOOL HOLDER ASSEMBLY -- -- -- -- 189928--1 or 356304--1 189928--1 or 356304--1 189767--1 or 356302--1 189766--1 or 356303--1 -- -- -- -- -- 189767--1 or 356302--1 189928--1 or 356304--1 189928--1 or 356304--1 -- -- -- -- -- --
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PRODUCT TYPE
WIRE SIZE (AWG)
CRIMPING DIE -- -- -- -- 47807--1 47807--1 --
HAND TOOL 59250 59170 47387 59824--1 189721--1 or 189722--1 189721--2 or 189722--2 189721--1 or 189722--1 189721--1 or 189722--1 169400 -- -- -- -- 189721--1 or 189722--1 189721--1 or 189722--1 189721--2 or 189722--2 69710--1 169400 59824--1 58433--3 48049 59239--4
HEAD OR ADAPTER -- -- -- -- 217200--1 318161--1 679305--1 314269--1 -- -- -- -- -- 679300--1 or 679305--1 217200--1 318161--1 -- -- -- -- -- --
APPLICATOR -- -- -- -- -- -- -- -- -- 687658--1 -- 567200--3 567200--2 -- -- -- -- -- -- -- -- --
POWER UNIT -- -- -- -- -- -- -- -- --
16--14 16 14
-- 169404
Terminals: Flag Hook Multi Stud Ring Spade 3 Way 3--Way Link Wire Pin
59827--1 or 69873 59827--1 or 69873 59827--1 or 69873 59827--1 or 69873 -- 47808--6 47808--6 16--14 HD 6 47808--6 169404 -- -- -- --
69875
354500--1 -- -- -- -- -- -- -- -- --
122500--2, 122500--3, 356500--1, 356500--2 354500--1 Figure 6 (Cont'd)
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Tyco Electronics Corporation
Rev E
PLASTI- GRIP Terminals and Splices
TOOL HOLDER ASSEMBLY -- -- -- -- 189767--1 or 356302--1 189928--1 or 356304--1 189928--1 or 356304--1 -- -- -- -- -- -- -- -- -- -- -- --
114- 2161
PRODUCT TYPE
WIRE SIZE (AWG)
CRIMPING DIE -- -- -- -- --
HAND TOOL 59239--4 59824--1 58433--3 48049 189721--1 or 189722--1 189721--1 or 189722--1 189721--2 or 189722--2 169400 -- -- -- -- 69959 59974--1 -- -- -- -- --
HEAD OR ADAPTER -- -- -- -- 679300--1 or 67305--1 217200--1 318161--1 -- -- -- -- -- -- -- 69051 58422--1 or 69066 -- -- --
APPLICATOR -- -- -- -- -- -- -- -- 687658--1 -- 567200--3 567200--2 -- -- -- -- -- -- --
POWER UNIT -- -- -- -- -- -- -- --
Terminals: Flag Ring Spade Wire Pin
47808--6 12--10 47808--6 169404 59828--1 or 69874 59828--1 59828--1 or 69874 59828--1 or 69874 -- 47820 or 48752--1
69875
354500--1 -- --
Terminals: Ring
8
47820 or 48752--1 48858--1 68247--1 68116--1 68355--1
68250--1 69875 68354--1
122500--2, 122500--3, 356500--1, 356500--2 354500--1 69120--1, 69120--2, or 314979--1 Figure 6 (Cont'd)
Rev E
Tyco Electronics Corporation
15 of 19
PLASTI- GRIP Terminals and Splices
TOOL HOLDER ASSEMBLY -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --
114- 2161
PRODUCT TYPE
WIRE SIZE (AWG)
CRIMPING DIE 47821 or 48753--1 47821 48859--1
HAND TOOL 59974--1 -- -- -- -- -- -- 59974--1 69015 -- -- 59974--1 -- -- -- -- --
HEAD OR ADAPTER -- 69051 58422--1 or 69066 69051 58422--1 or 69066 -- -- -- 314991--1 69051 58422--1 or 69066 -- 69051 69066 or 58422--1 69066 or 58422--1 58422--1 58422--1 or 69066
APPLICATOR -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --
POWER UNIT
314979--1
6
48753--1 48859--1 68248--1 68356--1 47822 or 48754--1
68250--1 68354--1 -- --
Terminals: T il Ring
-- 4 47822 or 48754--1 47238--1 47823 or 48755--1 2 47823 or 48755--1 48861--1 47378--1 or 48756--1 48861--1 2/0 48757--1
--
1/0
69120--1, 69120--2, or 314979--1
Figure 6 (Cont'd)
16 of 19
Tyco Electronics Corporation
Rev E
PLASTI- GRIP Terminals and Splices
TOOL HOLDER ASSEMBLY -- 189766--1 or 356303--1 -- -- 189766--1 or 356303--1 189928--1 or 356304--1 189767--1 or 356302--1 -- -- -- -- -- -- --
114- 2161
PRODUCT TYPE
WIRE SIZE (AWG)
CRIMPING DIE --
HAND TOOL 45160 189721--1 or 189722--1 59250 47387 189721--1 or 189722--1 189721--1 or 189722--1 189721--1 or 189722--1 59824--1 58433--3 169400 -- -- -- --
HEAD OR ADAPTER -- 314868--1 -- -- 314269--1 -- 679305--1 -- -- -- -- -- -- --
APPLICATOR -- -- -- -- -- -- -- -- -- -- 687658--1 -- 567200--3 567200--2
POWER UNIT -- -- -- -- -- -- -- -- -- --
22--16
-- -- -- -- 47807--1 --
SHUR--PLUG* SHUR PLUG* Terminals 16 14 16--14
-- -- 169404 59827--1 or 69873 59827--1 or 69873 59827--1 or 69873 59827--1 or 69873
69875
1--471273--2 or 565435--5 (Modified)
122500--2, 122500--3, 356500--1, 356500--2 354500--1 Figure 6 (Cont'd)
Rev E
Tyco Electronics Corporation
17 of 19
PLASTI- GRIP Terminals and Splices
TOOL HOLDER ASSEMBLY -- -- -- -- -- -- -- 189766--1 or 356303--1 -- -- -- -- -- -- 189766--1 or 356303--1 -- -- -- -- -- -- -- -- -- -- -- --
114- 2161
PRODUCT TYPE
WIRE SIZE (AWG)
CRIMPING DIE -- 69877
HAND TOOL 46121 -- -- -- -- 45160 58433--3 189721--1 or 189722--1 -- -- -- -- 45575--1 58433--3 189721--1 or 189722--1 -- -- -- 59287--1 59489 58433--3 -- -- -- 45449 45450 59270
HEAD OR ADAPTER -- -- -- -- -- -- -- 314868--1 -- -- -- -- -- -- 314869--1 -- -- -- -- -- -- -- -- -- -- -- --
APPLICATOR -- 687658--1 -- 567200--3 567200--2 -- -- -- 687658--1 -- 567200--3 567200--2 -- -- -- -- 567200--3 567200--2 -- -- -- 687658--1 567200--3 -- -- -- --
POWER UNIT --
26--22
69877 69877 69877 -- -- --
69875
354500--1 -- -- --
22--16
69872 69872 69872
69875
Butt Splice
69872 -- -- 16--14 -- 69873 69873 69873 -- -- 12--10 12 10 -- 69874 69874 69874 22--16 -- -- --
354500--1 -- -- -- 69875
354500--1 -- -- --
69875 -- -- --
Parallel Splice p
16--14 12--10
122500--2, 122500--3, 356500--1, 356500--2 354500--1 Figure 6 (End)
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Tyco Electronics Corporation
Rev E
PLASTI- GRIP Terminals and Splices 6. VISUAL AID
114- 2161
Figure 7 shows a typical application of PLASTI--GRIP terminals and splices. This illustration should be used by production personnel to ensure a correctly applied product. Applications which DO NOT appear correct should be inspected using the information in the preceding pages of this specification and in the instructional material shipped with the product or tooling.
WIRE INSULATION MUST BE UNDAMAGED WIRE INSULATION MUST BE INSIDE INSULATION BARREL BUT MUST NOT ENTER WIRE BARREL WIRE SIZE MUST BE SAME AS WIRE SIZE STAMPED ON TERMINAL INSULATION BARREL MUST BE IN FIRM CONTACT WITH WIRE INSULATION ALL CONDUCTORS MUST BE HELD FIRMLY INSIDE WIRE BARREL END OF CONDUCTORS MUST BE FLUSH WITH, OR EXTEND SLIGHTLY BEYOND END OF WIRE BARREL CRIMP DOT CODE MUST BE FORMED WHEN USING TOOL WITH COLOR CODING WIRE MUST BE FULLY INSERTED TERMINAL MUST NOT BE BENT OR DEFORMED IN ANY WAY
THERE MUST BE NO NICKED OR MISSING CONDUCTOR STRANDS
SPLICE MUST NOT BE BENT OR DEFORMED IN ANY WAY
CRIMP DOT CODE MUST BE FORMED WHEN USING TOOL WITH COLOR CODING
END OF CONDUCTORS MUST BE AGAINST WIRE STOP OR MUST BE FLUSH WITH, OR EXTEND SLIGHTLY BEYOND, END OF WIRE BARREL FIGURE 7. VISUAL AID
SPLICE INSULATION MUST BE IN FIRM CONTACT WITH WIRE INSULATION
Rev E
Tyco Electronics Corporation
19 of 19

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