Application Specification
114-2162
STRATO-THERM* Terminals,
LOC B
1
of 19
E
2008 Tyco Electronics Corporation, Harrisburg, PA
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.
TOOLING ASSISTANCE CENTER 1-800-722-1111
PRODUCT INFORMATION 1-800-522-6752 This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
www.tycoelectronics.com
Splices, and Spare Wire Caps
19 NOV 08 Rev C
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 STRATO–THERM terminals, splices, and spare
wire caps for high temperature applications. There are two types of these terminals, splices, and spare wire
caps. One type is insulated, which consist of PIDG* (pre–insulated diamond grip) ring tongue terminals,
splices, and spare wire caps insulated with polytetrafluoroethylene (PTFE), post–insulated, or pre–insulated ;
and the other type is uninsulated, which consist of DIAMOND GRIP* (insulation support) ring tongue terminals,
spade tongue terminals, and splices with SOLISTRAND* (non–insulation support). The uninsulated are
available in heat resistant and high temperature. The terminals, splices, and spare wire caps accept solid or
stranded wire for single applications.
The pre–insulated terminals, splices, and spare wire caps are designed for reliable performance at maximum
temperatures of 288
_
C [550
_
F] and at 260
_
C [500
_
F] for silver–plated post–insulated terminals and splices.
The uninsulated heat resistant terminals and splices operate at maximum temperature of 343
_
C [650
_
F], and
at 649
_
C [1200
_
F] for high temperature terminals and splices.
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 are suitable for mounting and accept stud sizes M2.5 [4] through M8 [.375] (inside diameter range of
2.95 through 9.80 [.116 through .386]). The terminals, splices, and spare wire caps 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 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.
Figure 1 (Cont’d)
Spare Wire Cap
PIDG Insulated Terminals
Ring Tongue
Terminal Insulating Restricting (IR)
Ring Tongue Terminal
Post-Insulated Terminals and Splices
Butt Splice
Pre-Insulated Splices and Spare Wire Caps
Butt SpliceRing Tongue
Terminal
Window Butt Splice
NOTE
i
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Figure 1 (End)
DIAMOND GRIP Heat Resistant
Uninsulated Terminals and Splices DIAMOND GRIP High Temperature
Uninsulated Terminals and Splices
Ring Tongue Terminal Strap Butt Splice Ring Tongue Terminal Strap Butt Splice
SOLISTRAND High Temperature
Uninsulated Terminals and Splices
Ring Tongue Terminal Spade Tongue Terminal Butt SpliceParallel Splice
SOLISTRAND Heat Resistant
Uninsulated Terminals and Splices
Strap Butt SpliceParallel SpliceRing Tongue Terminal Butt Splice
Strap Butt Splice
2. REFERENCE MATERIAL
2.1. Revision Summary
Revisions to this application specification include:
S
Updated application specification to corporate requirements
S
Added note to Machine 565435–5 in Section 5 and removed reference to 409–5128 from Paragraph 2.4
S
Removed Tool 59083, Machines 1338600–[ ], and Crimping Heads 356744–1 and 356744–2
2.2. Customer Assistance
Reference Product Base Part Number 50836 and Product Code 3027 are representative of STRATO–THERM
terminals, splices, and spare wire caps. 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 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 assembly instructions and Customer Manuals (409–series) provide
machine setup and operation procedures. Documents available which pertain to this product are:
A. Product
408–7424 Checking Terminal Crimp Height or Gaging Die Closure
408–9816 Handling of Reeled Products
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B. Tooling
408–1254 Crimping Tool 69355
408–1259 STRATO–THERM Hand Crimping Tools 59294 and 59461
408–1310 Pneumatic Tool 69015
408–1311 Pneumatic Crimping Heads 48172, 48173, 48174, 48183, and 49956
408–1532 Hand Crimping Tools 45730 and 46468
408–1535 STRATO–THERM Hand Crimping Tools 46673, 46673–1, and 46988
408–1542 Hand Crimping Tool 46447
408–1610 “T”–Head* Crimping Tools 69692–1 and 69693–1
408–1632 Crimping Dies 69731, 69732, 69733, 69734, and 69735
408–1697 SOLISTRAND Crimping Dies 45433, 45436, 46133, 46134, 46135, 46136, 46137, 46138,
46145, 46146, 69216, 69217, and 69218
408–1745 DYNA–CRIMP* Head 69069
408–1826 STRATO–THERM Post–Insulated Terminal and Splice Die Assembly 69211–1
408–1836 Hand Crimping Tool 69272–1 for Pre–Insulated Spare Wire Caps
408–1927 ROTA–CRIMP* Hand Crimping Tool 600850
408–1939 Crimping Dies 69327, 69328, and 69329 for Pre–Insulated Splices
408–2095 Hand Crimping Tool 69710–1
408–2395 Terminal and Splice Crimping Jaws 68135
408–2423 Crimping Die Assembly 69937
408–2452 Hydraulic Crimping Head 69065
408–2454 Hydraulic Crimping Head 69067
408–2457 DYNA–CRIMP Crimping Head 69097
408–2458 DYNA–CRIMP Crimping Head 69099
408–2498 Crimping Head Cross–Reference for Pneumatic Tools
408–2648 AMP–TAPEMATIC* Crimping Dies 69930, 69931, 69932, 69954, 69955, and 69956
408–4072 626 Pneumatic Crimping Heads 1338757–1 and 1338758–1
408–4105 Straight Action Crimper 217200–1
408–4110 626 Pneumatic Crimping Head 217206–1
408–4190 C–Head Pneumatic Adapter 318161–1
408–4303 Pneumatic CERTI–CRIMP* Tool Holder Assembly (Large) 356302–1
408–4321 Pneumatic CER TI–CRIMP Tool Holder 356304–1
408–4450 626 Pneumatic Crimping Head 904870–1
408–6758 Hydraulic Hand Crimping Tool 59975–1
408–6803 Hydraulic Hand Crimping Tool 59973–1
408–8044 Miniature Quick–Change Applicator (Side–Feed with Mechanical Feed System) 687658–1
408–8082 Miniature Quick–Change Applicators (Side–Feed with Air Feed System) 567200–2
and 567200–3
408–9684 Inspection and Servicing of Hydraulic Crimping Heads 69065 and 69067
408–9786 Crimping Dies 48126, 48127, 48128, 48129, 48130, 48131, 48132, and 48355 for
SOLISTRAND Terminals and Splices
409–1950 Hydraulic Power Units 69120–1 and 69120–2
409–1993 AMP–TAPETRONIC* Machine 69875
409–2426 Pneumatic Tool 68068
409–2500 Pneumatic Tool 68068–3
409–5842 AMP–O–LECTRIC Model “G” Terminating Machines 354500–[ ]
409–5852 AMPOMATOR* CLS III–G Lead–Making Machines 122500–[ ]
409–5860 Hydraulic Hand Pump 314979–1
409–5862 626 Pneumatic Tooling Assemblies 189721–[ ] and 189722–[ ]
409–5878 AMPOMATOR CLS IV+ Lead–Making Machines 356500–[ ]
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3. REQUIREMENTS
3.1. Special Characteristics
PIDG IR terminals prevent insulation of thin–wall insulated wire from entering the wire barrel during crimping.
3.2. Material
A. Insulated
These terminals, splices, and spare wire caps consist of precision formed metal wire barrel and support
sleeve (except spare wire caps) insulated with PTFE.
PIDG Terminals and Pre-Insulated Terminals and Splices
The body is made of copper and plated with nickel or gold over nickel. The metallic sleeve is made of
copper and plated with nickel.
Post-Insulated Terminals and Splices
The body is made of copper and plated with gold over nickel, silver, or nickel. The ring is made of
aluminum or copper and plated with nickel. The bushing is made of PTFE insulation.
B. Uninsulated
These terminals and splices consist of precision formed metal wire barrel with or without a support sleeve.
SOLISTRAND Terminals and Splices
The heat resistant body is made of copper and plated with nickel. The high temperature body is made
of nickel.
DIAMOND GRIP Terminals and Splices
The heat resistant body is made of copper and plated with nickel. The high temperature body is made
of nickel, alumel, or chromel. The metallic sleeve is made of nickel silver.
3.3. Storage
A. Shelf Life
The product should remain in the shipping containers until ready for use to prevent deformation to the
terminals, splices, or spare wire caps. The product 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 product
insulation material.
C. Reeled Product
When using tape–mounted reeled product, 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.
3.4. Wire Selection and Preparation
The terminals, splices, and spare wire caps accept copper wire sizes 26 through 1/0 AWG (238 through
119,500 circular mil area) with an insulation diameter range of 1.17 through 7.87 [.046 through .310].
PIDG terminals and splices must be used with stranded wire; and PIDG insulation restricting terminals, and
post–insulated and uninsulated terminals and splices with solid or stranded wire. The splices can
accommodate different wire combinations. Proper strip length is necessary to properly insert the wire into the
terminal or splice. The wire must be stripped to the dimensions provided in the instructional material supplied
with the product or application tooling.
Reasonable care must be taken not to nick, scrape, or cut any strands during the stripping operation.
The spare wire caps must be used with
unstripped
PTFE insulated stranded wire with insulation diameter
range of 0.91 through 3.50 [.036 through .138].
CAUTION
!
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Tyco Electronics Corporation
3.5. Wire Placement
The solid wire conductor or stranded wire conductors must be inside the terminal, splice, or spare wire cap wire
barrel. No strands can be folded back over the wire insulation. The conductor end(s) must be flush with, or
extend slightly beyond, the end of the wire barrel; or, for splices with a wire stop in the center of the splice, the
conductor end(s) must butt against the wire stop. The wire insulation must be inside the insulation of the
product, but must not enter the wire barrel, to provide strain relief for the wire.
3.6. Crimp Requirements
The terminal, splice, or spare wire cap must be crimped to the wire according to instructions packaged with
applicable tooling.
Wire insulation shall NOT be cut or broken during the crimping operation. Reasonable care should be taken to provide
undamaged wire terminations.
A. Wire Barrel Crimp
The crimp applied to the wire barrel portion of the terminal, splice, or spare wire cap is the most
compressed area and is most critical in ensuring optimum electrical and mechanical performance of the
crimped product. The crimped area must be symmetrical on both sides of the wire barrel. The crimp may
be off center on the wire barrel but not off the end of the wire barrel. See Figure 2.
The resilience of the product insulation prevents accurate direct measurement of crimp height. Tooling used to crimp
product must be dimensionally correct to ensure quality crimp configurations.
B. Crimp Dot and Hashmark Code
Some tools with multiple crimping chambers will emboss a crimp dot code or hashmark code onto the
product insulation when crimped. The dot or hashmark code must be fully formed on the insulation to
indicate that the correct product and tooling combination was used. The crimp dot or hashmark code must
correspond with the wire size marking on the tooling.
The hashmark code should appear on the bottom (side opposite the crimp indents) for high temperature and
heat-resistant terminals and splices.
C. Wire Conductor and Insulation Location
The wire insulation must be inside, and in firm contact with, the insulation barrel of the product. The wire
insulation must not enter the wire barrel. The conductor end(s) must be flush with, or extend slightly
beyond, the end of the wire barrel; or, for splices with a wire stop in the center of the splice, the conductor
end(s) may butt against the wire stop. See Figure 2.
D. Product Insulation
The terminal, splice, or spare wire cap insulation must not be deformed, cut, or show uneven stress
marks. Some insulation flash or extruded insulation is normal. Holes and thin spots in the insulation
provides evidence of either improper crimping or defective tooling.
E. Bellmouths
The rear bellmouth length must be within 0.51 to 1.27 [.020 to .050], and the front bellmouth must not
exceed 0.51 [.020]. Refer to Figure 2.
F. Sleeve, Ring, and Bushing Position (Post-Insulated Terminal and Splice Only)
After crimping post–insulated terminals or splices, rings, bushings, and a sleeve must be assembled onto
the terminal or splice. The sleeve must be centered over the crimped terminal wire barrel or crimped
splice. The sleeve must extend from the ring and the bushing must extend from the sleeve to the
dimensions shown in Figure 2.
CAUTION
!
NOTE
i
NOTE
i
114-2162
STRATO-THERM Terminals, Splices, and Spare Wire Caps
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of 19 Tyco Electronics Corporation
Wire Insulation
Location
Wire Conductor
Location
Crimp Centered on Wire Barrel
(Crimp May Be Off Center, But
Not Off End of Wire Barrel) Crimp Centered on Wire Barrel (Crimp
May Be Off Center, But Not Off End of
Wire Barrel) (Applies to Both)
Wire Insulation Location
(Applies to Both
Insulation Barrels)
Wire Conductor Location
(Applies to Both Wire
Barrels)
Some Insulation Flash or Extruded Insulation
May Be Visible in Crimped Area
Crimp Dot Code (Ref)
Hashmark Code (Ref)
(Bottom of Splice)
Wire Conductor Against
Wire Stop (Ref)
0.51 to 1.27 [.020 to .050]
Rear Bellmouth
0.51 [.020] (Max)
Front Bellmouth
Hashmark Code (Ref)
(Bottom of Terminal)
Terminal Splice
Figure 2
No Holes or Thin Spots
in Insulation Allowed
No Holes or Thin
Spots in Insulation
Allowed
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 3.
2. Side–to–Side
The crimped portion must not be bent from one side to the other beyond the limits shown in Figure 3.
3.7. Repair
Damaged terminals, splices, and spare wire caps or product that does not meet crimp dimension requirements
must be removed from wires, discarded, and replaced with new ones. When removing a terminal, splice, or
spare wire cap, cut the wires as close as possible to the end of the wire barrel.
4. QUALIFICATION
No qualifying support for STRATO–THERM terminals, splices, and spare wire caps was defined at the time of
publication of this document.
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Up and Down Bend
Side-to-Side Bend
Datum Line
11
_
11
_
Datum Line
11
_
11
_
11
_
11
_
Datum Line
11
_
11
_
11
_
11
_
Datum Line
11
_
11
_
Terminal
Splice
Terminal
Splice
Figure 3
5. TOOLING
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 4.
Modified designs and additional tooling concepts may be available to meet other application requirements. Machines
can be designed for a variety of application requirements. For assistance in setting up prototype and production line
equipment, call the TOOLING ASSISTANCE CENTER at the number at the bottom of page 1.
5.1. Crimping Dies, Hand Tools, Tool Holder Assemblies, and Heads and Adapters
The hand 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 tools 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.
The 626 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
NOTE
i
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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.
The pneumatic tools use a pneumatic crimping head which contains jaws to crimp terminals and splices onto
pre–stripped wires. These tools use a filter and moisture separator, regulator, and lubricator. These tools are
designed for low–volume application.
5.2. Applicators
The applicators are designed to crimp tape–mounted terminals and splices onto pre–stripped wire, and
provides for high volume, heavy duty production requirements. These applicators accept interchangeable
crimping dies and must be installed onto a power unit.
5.3. Power Units
A. Hydraulic Machines
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 or
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 Machines
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 Machines
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 Machines
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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Crimping Dies
STRATO-THERM Post-Insulated Terminal
and Splice Die Assembly 69211-1 (408-1826) Crimping Dies 48126, 48127, 48128, 48129, 48130,
48131, 48132, and 48355 for SOLISTRAND
Terminals and Splices (408-9786)
Also:
Crimping Dies 69731, 69732, 69733, 69734, and 69735 (408-1632)
SOLISTRAND Crimping Dies 45433, 45436, 46133, 46134, 46135, 46136, 46137, 46138, 46145,
46146, 69216, 69217, and 69218 (408-1697)
Crimping Dies 69327, 69328, and 69329 for Pre-Insulated Splices (408-1939)
Terminal and Splice Crimping Jaws 68135 (408-2395)
Crimping Die Assembly 69937 (408-2423)
AMP-TAPEMATIC Crimping Dies 69930, 69931, 69932, 69954, 69955, and 69956 (408-2648)
Hand Tools
Hand Crimping Tools 46468
and 45730 (408-1532) STRATO-THERM Hand
Crimping Tools 46673, 46673-1,
and 46988 (408-1535)
T"-Head Crimping Tools
69692-1 and 69693-1
(408-1610)
Hand Crimping Tool
69710-1 (408-2095)
Hydraulic Hand Crimping
Tool 59975-1 (408-6758) 626 Pneumatic Tooling Assemblies
189721-[ ] and 189722-[ ] (409-5862)
Also:
Crimping Tools 69355 (408-1254)
STRATO-THERM Hand Crimping Tools 59294 and 59461 (408-1259)
Hand Crimping Tool 46447 (408-1542)
Hand Crimping Tool 69272-1 for Pre-Insulated Spare Wire Caps (408-1836)
ROTA-CRIMP Hand Crimping Tool 600850 (408-1927)
Single-Action, Double-Action Hand Tool Assembly 46467 (No Document)
Hydraulic Hand Crimping Tool 59973-1 (408-6803)
Pneumatic Tool 69015 (408-1310)
Pneumatic Tool 68068 (409-2426)
Pneumatic Tool 68068-3 (409-2500)
Figure 4 (Cont’d)
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Tool Holder Assemblies
Pneumatic CERTI-CRIMP Tool Holder
Assembly 356302-1 (Large) (408-4303) Pneumatic CERTI-CRIMP Tool
Holder 356304-1 (408-4321)
Also:
Straight Action Pneumatic Holder 189928-1 (No Document)
Pneumatic Tool Holder 189767-1 (No Document)
Heads and Adapters
Pneumatic Crimping Heads
48172, 48173, 48174,
48183, and 49956
(408-1311)
Hydraulic Crimping Head
69065 (408-2452) 626 Pneumatic Crimping
Heads 1338757-1 and
1338758-1 ( 408-4072)
Straight Action Crimper
217200-1 (408-4105)
C-Head Pneumatic Adapter
318161-1 (408-4190)
Also:
DYNA-CRIMP Head 69069 (408-1745)
Hydraulic Crimping Head 69067 (408-2454)
DYNA-CRIMP Crimping Head 69097 (408-2457)
DYNA-CRIMP Crimping Head 69099 (408-2458)
626 Pneumatic Crimping Head 217206-1 (408-4110)
626 Pneumatic Crimping Head 904870-1 (408-4450)
Figure 4 (Cont’d)
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Applicators
Miniature Quick-Change Applicator
687658-1 (For Tape-Mounted Closed
Barrel Terminals) (408-8044)
Also:
Miniature Quick-Change Applicators 567200-2 and 567200-3 (Side-Feed Type with
Air Feed for Tape-Mounted Terminals) (408-8082)
Power Units
Hydraulic Power Units
69120-1 and 69120-2
(409-1950)
AMP-TAPETRONIC
Machine 69875 (409-1993) AMP-O-LECTRIC Model G"
Terminating Machine 354500-[ ]
(409-5842)
AMP-O-LECTRIC Model K"
Terminator Machine
565435-5 (409-5128)
No Longer Manufactured New
AMPOMATOR CLS III-G
Lead-Making Machine
122500-[ ] (409-5852)
Hydraulic Hand Pump
314979-1 (409-5860) AMPOMATOR CLS IV+
Lead-Making Machine
356500-[ ] (409-5878)
Figure 4 (Cont’d)
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PRODUCT WIRE SIZE
(AWG) CRIMPING
DIE HAND TOOL TOOL
HOLDER
ASSEMBLY
HEAD OR
ADAPTER APPLICATOR POWER UNIT
Ċ 69692-1 Ċ Ċ
69731 69710-1 Ċ Ċ
26-24 69731 189721-1 or
189722-1 356304-1 217200-1 or
318161-1 Ċ Ċ
69731 189721-2 or
189722-2 189928-1 217200-1 or
318161-1
Ċ 69692-1 Ċ Ċ
69732 69710-1 Ċ Ċ
22-20 69732 189721-1 or
189722-1 356304-1 217200-1 or
318161-1 Ċ Ċ
69732 189721-2 or
189722-2 189928-1 217200-1 or
318161-1
Ċ 69693-1 Ċ Ċ
69733 69710-1 Ċ Ċ
PIDG Ring Tongue
Terminal 18-16 69733 189721-1 or
189722-1 356304-1 217200-1 or
318161-1 Ċ Ċ
69733 189721-2 or
189722-2 189928-1 217200-1 or
318161-1
69937 Ċ Ċ Ċ Ċ 69875
69734 69710-1 Ċ Ċ
14
69734 189721-1 or
189722-1 356304-1 217200-1 or
318161-1
14
69734 189721-2 or
189722-2 189928-1 217200-1 or
318161-1
Ċ Ċ
Ċ 69693-1 Ċ Ċ
69735 69710-1 Ċ Ċ
12-10 69735 189721-1 or
189722-1 356304-1 217200-1 or
318161-1 Ċ Ċ
69735 189721-2 or
189722-2 189928-1 217200-1 or
318161-1
Figure 4 (Cont’d)
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PRODUCT WIRE SIZE
(AWG) CRIMPING
DIE HAND TOOL TOOL
HOLDER
ASSEMBLY
HEAD OR
ADAPTER APPLICATOR POWER UNIT
Ċ 69692-1 Ċ Ċ
69731 69710-1 Ċ Ċ
24 69731 189721-1 or
189722-1 356304-1 217200-1 or
318161-1 Ċ Ċ
69731 189721-2 or
189722-2 189928-1 217200-1 or
318161-1
Ċ 69692-1 Ċ Ċ
PIDG Insulation
Rtiti Ri
69732 69710-1 Ċ Ċ
Restricting Ring
Tongue Terminal 22 69732 189721-1 or
189722-1 356304-1 217200-1 or
318161-1 Ċ Ċ
69731 189721-2 or
189722-2 189928-1 217200-1 or
318161-1
69735 69710-1 Ċ Ċ
12 69732 189721-1 or
189722-1 356304-1 217200-1 or
318161-1 Ċ Ċ
69731 189721-2 or
189722-2 189928-1 217200-1 or
318161-1
22-20 Ċ 46467 Ċ Ċ Ċ Ċ
Post-Insulated Ring
Tongue Terminal
8
46146 and
46145 Ċ Ċ 69097 69120-1,
69120 2 or
Tongue Terminal
8
69216 or
69211-1 Ċ Ċ 69099
Ċ
69120
-
2
,or
314979-1
26-24 Ċ 45730 Ċ Ċ Ċ Ċ
22-20 Ċ 46467 Ċ Ċ Ċ Ċ
Post
-
Insulated
18-16 Ċ 46468 Ċ Ċ Ċ Ċ
Post Insulated
Splice
8
69216 or
69211-1 Ċ Ċ 69099 69120-1,
69120 2 or
8
46146 and
46145 Ċ Ċ 69097
Ċ
69120
-
2
,or
314979-1
69327 69710-1 Ċ Ċ
22-20 69327 189721-2 or
189722-2 189928-1 318161-1 Ċ Ċ
69328 69710-1 Ċ Ċ
Pre-Insulated
Window Butt Splice 18-16 69328 189721-2 or
189722-2 189928-1 318161-1 Ċ Ċ
69329 69710-1 Ċ Ċ Ċ Ċ
14-12 69329 189721-2 or
189722-2 189928-1 318161-1 Ċ 69120-1,
69120-2, or
314979-1
Pre-Insulated
Spare Wire Caps Ċ Ċ 69272-1 Ċ Ċ Ċ Ċ
Figure 4 (Cont’d)
114-2162
STRATO-THERM Terminals, Splices, and Spare Wire Caps
Rev
C14
of 19 Tyco Electronics Corporation
PRODUCT WIRE SIZE
(AWG) CRIMPING
DIE HAND TOOL TOOL
HOLDER
ASSEMBLY
HEAD OR
ADAPTER APPLICATOR POWER UNIT
Ċ 46673 Ċ Ċ
22-16 Ċ 46673-1 Ċ Ċ Ċ Ċ
69930 Ċ Ċ Ċ Ċ 69875
DIAMOND GRIP
HtRitt d
Ċ 46988 Ċ Ċ
Heat Resistant and
High Temperature
16-14 Ċ 59294 Ċ Ċ Ċ Ċ
High Temperature
Ring Tongue
Te i al
69931 Ċ Ċ Ċ Ċ 69875
T
erm
i
na
l
Ċ 59461 Ċ Ċ
12-10 Ċ189721-1 or
189722-1 189767-1 or
356302-1 904870-1 Ċ Ċ
69932 Ċ Ċ Ċ Ċ 69875
22-16 Ċ 46673 or
46673-1 ĊĊĊĊ
DIAMOND GRIP
Heat Resistant and
High Temperature
16-14 Ċ 46988 or
59294 ĊĊĊĊ
High Temperature
Butt Splice Ċ 59461 Ċ Ċ
p
12-10 Ċ189721-1 or
189722-1 189767-1 or
356302-1 904870-1 Ċ Ċ
SOLISTRAND
Ċ 46447 Ċ Ċ
SOLISTRAND
Heat Resistant
Ring Tongue
Til
16-14 Ċ189721-1 or
189722-1 189767-1 or
356302-1 217206-1 Ċ Ċ
Terminal 69955 Ċ Ċ Ċ Ċ 69875
Ċ 69355 Ċ Ċ Ċ Ċ
SOLISTRAND 69216 Ċ Ċ 69099 Ċ 69120-1 or
69120-2
Heat Resistant
Parallel Splice 868135 68068 or
68068-3 Ċ Ċ
48126 and
48355 59973-1 Ċ 69065 or
69067
Ċ Ċ
Ċ 46447 Ċ Ċ Ċ Ċ
SOLISTRAND
High Temperature
Ri T
16
-
14
Ċ189721-1 or
189722-1 189767-1 or
356302-1 217206-1 Ċ Ċ
Ring Tongue
Terminal
16 14
69955 Ċ Ċ Ċ 567200-2 69875,
565435-5
D
,or
354500-1
D
No Longer Manufactured New
Figure 4 (Cont’d)
114-2162
STRATO-THERM Terminals, Splices, and Spare Wire Caps
Rev
C 15
of 19
Tyco Electronics Corporation
PRODUCT WIRE SIZE
(AWG) CRIMPING
DIE HAND TOOL TOOL
HOLDER
ASSEMBLY
HEAD OR
ADAPTER APPLICATOR POWER UNIT
SOLISTRAND
High Temperature
Ċ 46447 Ċ Ċ
Hi
g
hT
empera
t
ure
Spade Tongue
Terminal
16-14 Ċ189721-1 or
189722-1 189767-1 or
356302-1 217206-1 Ċ Ċ
Ċ 46447 Ċ Ċ
Ċ189721-1 or
189722-1 189767-1 or
356302-1 217206-1 Ċ Ċ
SOLISTRAND
Heat Resistant and
High Temperature
22 16
69954 Ċ Ċ Ċ 687658-1
122500-2,
122500-3,
356500-1, or
356500-2
Hi
g
hT
empera
t
ure
Ring Tongue
22
-
16
69954 Ċ Ċ Ċ Ċ 69875
gg
Terminal 69954 Ċ Ċ Ċ 567200-2 565435-5
D
or
354500-1
69954 Ċ Ċ Ċ 567200-3
354500-1,
354500-2,
354500-9, or
1-354500-1
Ċ189721-1 or
189722-1 189767-1 or
356302-1 217206-1 Ċ Ċ
Ċ 46447 Ċ Ċ
69956 Ċ Ċ Ċ Ċ 69875
12-10 69956 Ċ Ċ Ċ 687658-1
122500-2,
122500-3,
356500-1, or
356500-2
69956 Ċ Ċ Ċ 567200-2 565435-5
D
SOLISTRAND
Heat Resistant and
High Temperature
Ring Tongue
Terminal
69956 Ċ Ċ Ċ 567200-3
354500-1,
354500-2,
354500-9, or
1-354500-1
Ċ 69355 Ċ Ċ
Ċ189721-1 or
189722-1 189767-1 or
356302-1 1338757-1 Ċ Ċ
Ċ 69015 Ċ 49956
848126 and
48355 Ċ Ċ 69065 or
69067
69120-1
69216 Ċ Ċ 69099 Ċ
69120
-
1
,
69120-2, or
314979 1
46146 and
46145 Ċ Ċ 69097 314979-1
D
No Longer Manufactured New
Figure 4 (Cont’d)
114-2162
STRATO-THERM Terminals, Splices, and Spare Wire Caps
Rev
C16
of 19 Tyco Electronics Corporation
PRODUCT WIRE SIZE
(AWG) CRIMPING
DIE HAND TOOL TOOL
HOLDER
ASSEMBLY
HEAD OR
ADAPTER APPLICATOR POWER UNIT
Ċ189721-1 or
189722-1 189767-1 or
356302-1 1338758-1 Ċ Ċ
69217 Ċ Ċ 69099 Ċ 69120-1 or
69120-2
48127 and
48128 Ċ Ċ 69065 or
69067 Ċ69120-1 or
69120-2
Ċ 69015 Ċ 48172
6
48127 and
48128 59973-1 Ċ Ċ Ċ Ċ
6
48127 and
48128 Ċ Ċ 69067
48127 and
48128 Ċ Ċ 69065 Ċ 314979-1
69217 Ċ Ċ 69099
46133 and
46134 Ċ Ċ 69067 Ċ 69120-1 or
69120-2
SOLISTRAND
Heat Resistant and
High Temperature
46133 and
46134 Ċ Ċ 69097 Ċ 314979-1
High Temperature
Ring Tongue
Terminal 46133 and
46135 Ċ Ċ 69097 Ċ 69120-1 or
69120-2
69218 Ċ Ċ 69099 Ċ 69120-1 or
69120-2
Ċ 59975-1 Ċ Ċ
Ċ 69015 Ċ 48173 Ċ Ċ
Ċ Ċ Ċ 69069 Ċ 69120-1
4
Ċ Ċ Ċ 69069 Ċ 314979-1
446133 and
46135 Ċ Ċ 69097 Ċ 314979-1
69218 Ċ Ċ 69099 Ċ 314979-1
48127 and
48129 Ċ Ċ 69065 or
69067 Ċ69120-1 or
69120-2
48127 and
48129 59973-1 Ċ Ċ Ċ Ċ
48127 and
48129 Ċ Ċ 69065 or
69067 Ċ 314979-1
Figure 4 (Cont’d)
114-2162
STRATO-THERM Terminals, Splices, and Spare Wire Caps
Rev
C 17
of 19
Tyco Electronics Corporation
PRODUCT WIRE SIZE
(AWG) CRIMPING
DIE HAND TOOL TOOL
HOLDER
ASSEMBLY
HEAD OR
ADAPTER APPLICATOR POWER UNIT
Ċ Ċ Ċ 69069
46133 and
46136 Ċ Ċ 69097 Ċ69120-1 or
69120-2
45433 Ċ Ċ 69099
Ċ 69015 Ċ 48174 Ċ Ċ
48127 and
48130 Ċ Ċ 69065 or
69067 Ċ69120-1 or
69120-2
248127 and
48130 59973-1 Ċ Ċ Ċ Ċ
Ċ Ċ Ċ 69069
48127 and
48130 Ċ Ċ 69067
SOLISTRAND
Heat Resistant and
46133 and
46136 Ċ Ċ 69097 Ċ 314979-1
H
ea
tR
es
i
s
t
an
t
an
d
High Temperature
Ring Tongue
48127 and
48130 Ċ Ċ 69065
gg
Terminal 45436 Ċ Ċ 69099 Ċ 69120-1 or
69120-2
Ċ 69015 Ċ 48183
Ċ 600850 Ċ Ċ Ċ Ċ
48131 and
48132 Ċ Ċ 69065 or
69067 Ċ69120-1 or
69120-2
1/0 48131 and
48132 59973-1 Ċ Ċ Ċ Ċ
48131 and
48132 Ċ Ċ 69065 or
69067 Ċ 314979-1
45436 Ċ Ċ 69099 Ċ 314979-1
46137 and
46138 Ċ Ċ 69097 Ċ 69120-1,
69120-2, or
314979-1
Ċ 46447 Ċ Ċ
22-16 Ċ189721-1 or
189722-1 189767-1 or
356302-1 217206-1
SOLISTRAND
Heat Resistant and
Ċ 46447 Ċ Ċ
H
ea
tR
es
i
s
t
an
t
an
d
High Temperature
Splice
16-14 Ċ189721-1 or
189722-1 189767-1 or
356302-1 217206-1 Ċ Ċ
p
Ċ 46447 Ċ Ċ
12-10 Ċ189721-1 or
189722-1 189767-1 or
356302-1 217206-1
Figure 4 (End)
114-2162
STRATO-THERM Terminals, Splices, and Spare Wire Caps
Rev
C18
of 19 Tyco Electronics Corporation
6. VISUAL AID
The illustration below shows a typical application of STRATO–THERM terminals, splices, and spare wire caps.
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.
FIGURE 5. VISUAL AID (CONT’D)
SPARE WIRE CAP
WIRE MUST BE FULLY
BOTTOMED IN CAP
FULL LENGTH OF RINGS
MUST BE CRIMPED
TERMINALS
END OF WIRE CONDUCTORS MUST BE
FLUSH WITH OR EXTEND SLIGHTLY
BEYOND END OF WIRE BARREL
WIRE MUST BE FULLY INSERTED
AND INSULATION MUST NOT
ENTER TERMINAL WIRE BARREL
WIRE SIZE MUST BE WITHIN WIRE SIZE
RANGE MARKED ON TERMINAL
CRIMP MUST NOT BE OFF
END OF WIRE BARREL
TERMINAL MUST NOT BE BENT
OR DEFORMED IN ANY WAY
COLOR CODE, CRIMP DOT
OR HASHMARK CODE,
AND TOOL COMBINATION
MUST MATCH
CRIMP DOT CODE (OR HASHMARK
CODE ON BOTTOM OF TERMINAL)
MUST BE FULLY FORMED ON
INSULATION OF TERMINAL
THERE MUST BE NO NICKED OR
MISSING CONDUCTOR STANDS
FOR TERMINALS WITH INSULATION SUPPORT
,
INSULATION BARREL MUST BE IN FIRM
CONTACT WITH WIRE INSULATION
THIS RING COLOR CODE MUST
MATCH TOOLING COLOR CODE
THIS RING COLOR CODE MUST
BE WITHIN WIRE INSULATION
DIAMETER RANGE
FOR POST-INSULATED TERMINAL,
SLEEVE MUST EXTEND SLIGHTLY
FROM RING
FOR POST INSULATED TERMINAL,
SLEEVE MUST BE CENTERED
OVER WIRE BARREL
THERE MUST BE NO
HOLES OR THIN SPOTS
IN TERMINAL INSULATION
THERE MUST BE NO HOLES OR THIN SPOTS
IN INSULATION OF SPARE WIRE CAP
114-2162
STRATO-THERM Terminals, Splices, and Spare Wire Caps
Rev
C 19
of 19
Tyco Electronics Corporation
FIGURE 5. VISUAL AID (END)
SPLICES
CRIMP MUST NOT BE OFF END
OF SPLICE WIRE BARREL
END OF WIRE CONDUCTORS MUST BE
FLUSH WITH OR EXTEND SLIGHTLY
BEYOND END OF WIRE BARREL
FOR WINDOW BUTT SPLICE,
WIRE CONDUCTOR MUST BE
VISIBLE IN WINDOW INDENT
FOR STRAP BUTT SPLICE,
END OF WIRE CONDUCTORS MUST BE
AGAINST SPLICE WIRE STOP, FLUSH
WITH OR EXTEND SLIGHTLY BEYOND
END OF WIRE BARREL
FOR ALL INSULATED SPLICES,
INSULATION BARREL MUST BE
IN FIRM CONTACT WITH WIRE
INSULATION
WIRE SIZE MUST BE WITHIN
WIRE SIZE RANGE MARKED
ON SPLICE
WIRE MUST BE FULLY INSERTED AND
INSULATION MUST NOT ENTER
SPLICE WIRE BARREL
THERE MUST BE NO
NICKED OR MISSING
CONDUCTOR STANDS
FOR SPLICE WITH INSPECTION HOLE,
WIRE CONDUCTOR MUST BE VISIBLE
IN INSPECTION HOLE
CRIMP DOT CODE (OR HASHMARK
CODE ON BOTTOM OF SPLICE)
MUST BE FULLY FORMED ON
INSULATION OF SPLICE
COLOR CODE, CRIMP DOT OR
HASHMARK CODE, AND TOOL
COMBINATION MUST MATCH
FOR POST-INSULATED SPLICE,
SLEEVE MUST EXTEND SLIGHTLY
FROM RING AND BUSHING MUST
EXTEND SLIGHTLY FROM SLEEVE
FOR POST-INSULATED SPLICE,
SLEEVE MUST BE CENTERED
OVER SPLICE
THERE MUST BE NO HOLES
OR THIN SPOTS IN SPLICE
INSULATION
FOR PRE-INSULATED BUTT SPLICE,
END OF WIRE CONDUCTOR MUST BE
AGAINST SPLICE WIRE STOP, FLUSH
WITH OR EXTEND SLIGHTLY BEYOND
END OF WIRE BARREL
