Application Specification 114-2162 STRATO-THERM* Terminals, Splices, and Spare Wire Caps NOTE 19 NOV 08 All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters [and Rev C _ inches]. Unless otherwise specified, dimensions have a tolerance of +0.13 [+.005] and angles have a tolerance of +2 . i 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. PIDG Insulated Terminals Post-Insulated Terminals and Splices Ring Tongue Insulating Restricting (IR) Ring Tongue Terminal Ring Tongue Terminal Terminal Butt Splice Butt Splice Pre-Insulated Splices and Spare Wire Caps Window Butt Splice Spare Wire Cap Figure 1 (Cont'd) E 2008 Tyco Electronics Corporation, Harrisburg, PA All International Rights Reserved TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, TE logo and Tyco Electronics are trademarks. *Trademark. Other products, logos, and company names used are the property of their respective owners. visit our website at www.tycoelectronics.com 1 of 19 LOC B STRATO-THERM Terminals, Splices, and Spare Wire Caps 114-2162 DIAMOND GRIP Heat Resistant Uninsulated Terminals and Splices Ring Tongue Terminal DIAMOND GRIP High Temperature Uninsulated Terminals and Splices Strap Butt Splice Ring Tongue Terminal Strap Butt Splice SOLISTRAND Heat Resistant Uninsulated Terminals and Splices Ring Tongue Terminal Parallel Splice Butt Splice Strap Butt Splice SOLISTRAND High Temperature Uninsulated Terminals and Splices Ring Tongue Terminal Spade Tongue Terminal Parallel Splice Butt Splice Strap Butt Splice Figure 1 (End) 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 408-9816 2 of 19 Checking Terminal Crimp Height or Gaging Die Closure Handling of Reeled Products Tyco Electronics Corporation Rev C STRATO-THERM Terminals, Splices, and Spare Wire Caps 114-2162 B. Tooling 408-1254 408-1259 408-1310 408-1311 408-1532 408-1535 408-1542 408-1610 408-1632 408-1697 408-1745 408-1826 408-1836 408-1927 408-1939 408-2095 408-2395 408-2423 408-2452 408-2454 408-2457 408-2458 408-2498 408-2648 408-4072 408-4105 408-4110 408-4190 408-4303 408-4321 408-4450 408-6758 408-6803 408-8044 408-8082 408-9684 408-9786 409-1950 409-1993 409-2426 409-2500 409-5842 409-5852 409-5860 409-5862 409-5878 Rev C Crimping Tool 69355 STRATO-THERM Hand Crimping Tools 59294 and 59461 Pneumatic Tool 69015 Pneumatic Crimping Heads 48172, 48173, 48174, 48183, and 49956 Hand Crimping Tools 45730 and 46468 STRATO-THERM Hand Crimping Tools 46673, 46673-1, and 46988 Hand Crimping Tool 46447 "T"-Head* Crimping Tools 69692-1 and 69693-1 Crimping Dies 69731, 69732, 69733, 69734, and 69735 SOLISTRAND Crimping Dies 45433, 45436, 46133, 46134, 46135, 46136, 46137, 46138, 46145, 46146, 69216, 69217, and 69218 DYNA-CRIMP* Head 69069 STRATO-THERM Post-Insulated Terminal and Splice Die Assembly 69211-1 Hand Crimping Tool 69272-1 for Pre-Insulated Spare Wire Caps ROTA-CRIMP* Hand Crimping Tool 600850 Crimping Dies 69327, 69328, and 69329 for Pre-Insulated Splices Hand Crimping Tool 69710-1 Terminal and Splice Crimping Jaws 68135 Crimping Die Assembly 69937 Hydraulic Crimping Head 69065 Hydraulic Crimping Head 69067 DYNA-CRIMP Crimping Head 69097 DYNA-CRIMP Crimping Head 69099 Crimping Head Cross-Reference for Pneumatic Tools AMP-TAPEMATIC* Crimping Dies 69930, 69931, 69932, 69954, 69955, and 69956 626 Pneumatic Crimping Heads 1338757-1 and 1338758-1 Straight Action Crimper 217200-1 626 Pneumatic Crimping Head 217206-1 C-Head Pneumatic Adapter 318161-1 Pneumatic CERTI-CRIMP* Tool Holder Assembly (Large) 356302-1 Pneumatic CERTI-CRIMP Tool Holder 356304-1 626 Pneumatic Crimping Head 904870-1 Hydraulic Hand Crimping Tool 59975-1 Hydraulic Hand Crimping Tool 59973-1 Miniature Quick-Change Applicator (Side-Feed with Mechanical Feed System) 687658-1 Miniature Quick-Change Applicators (Side-Feed with Air Feed System) 567200-2 and 567200-3 Inspection and Servicing of Hydraulic Crimping Heads 69065 and 69067 Crimping Dies 48126, 48127, 48128, 48129, 48130, 48131, 48132, and 48355 for SOLISTRAND Terminals and Splices Hydraulic Power Units 69120-1 and 69120-2 AMP-TAPETRONIC* Machine 69875 Pneumatic Tool 68068 Pneumatic Tool 68068-3 AMP-O-LECTRIC Model "G" Terminating Machines 354500-[ ] AMPOMATOR* CLS III-G Lead-Making Machines 122500-[ ] Hydraulic Hand Pump 314979-1 626 Pneumatic Tooling Assemblies 189721-[ ] and 189722-[ ] AMPOMATOR CLS IV+ Lead-Making Machines 356500-[ ] Tyco Electronics Corporation 3 of 19 STRATO-THERM Terminals, Splices, and Spare Wire Caps 114-2162 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. CAUTION 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]. 4 of 19 Tyco Electronics Corporation Rev C STRATO-THERM Terminals, Splices, and Spare Wire Caps 114-2162 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. CAUTION 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. NOTE 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. i 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. NOTE The hashmark code should appear on the bottom (side opposite the crimp indents) for high temperature and heat-resistant terminals and splices. i 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. Rev C Tyco Electronics Corporation 5 of 19 STRATO-THERM Terminals, Splices, and Spare Wire Caps 114-2162 Terminal Splice Wire Conductor Wire Conductor Location Location (Applies to Both Wire Barrels) Wire Insulation Location No Holes or Thin Wire Insulation Location Spots in Insulation (Applies to Both Allowed Insulation Barrels) Crimp Dot Code (Ref) No Holes or Thin Spots Crimp Centered on Wire Barrel in Insulation Allowed (Crimp May Be Off Center, But Crimp Centered on Wire Barrel (Crimp Not Off End of Wire Barrel) May Be Off Center, But Not Off End of Wire Barrel) (Applies to Both) 0.51 [.020] (Max) 0.51 to 1.27 [.020 to .050] Front Bellmouth Rear Bellmouth Wire Conductor Against Wire Stop (Ref) Some Insulation Flash or Extruded Insulation May Be Visible in Crimped Area (Bottom of Splice) (Bottom of Terminal) Hashmark Code (Ref) Hashmark Code (Ref) Figure 2 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. 6 of 19 Tyco Electronics Corporation Rev C STRATO-THERM Terminals, Splices, and Spare Wire Caps Up and Down Bend Terminal 114-2162 11_ Datum Line 11_ 11_ 11_ Splice Datum Line 11_ 11_ Side-to-Side Bend Terminal 11_ Datum Line 11_ 11_ Splice 11_ Datum Line 11_ 11_ 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. NOTE 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 i 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 Rev C Tyco Electronics Corporation 7 of 19 STRATO-THERM Terminals, Splices, and Spare Wire Caps 114-2162 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. 8 of 19 Tyco Electronics Corporation Rev C STRATO-THERM Terminals, Splices, and Spare Wire Caps 114-2162 Crimping Dies STRATO-THERM Post-Insulated Terminal Crimping Dies 48126, 48127, 48128, 48129, 48130, and Splice Die Assembly 69211-1 (408-1826) 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 STRATO-THERM Hand T"-Head Crimping Tools Hand Crimping Tool and 45730 (408-1532) Crimping Tools 46673, 46673-1, 69692-1 and 69693-1 69710-1 (408-2095) and 46988 (408-1535) (408-1610) Hydraulic Hand Crimping 626 Pneumatic Tooling Assemblies Tool 59975-1 (408-6758) 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) Rev C Tyco Electronics Corporation 9 of 19 STRATO-THERM Terminals, Splices, and Spare Wire Caps 114-2162 Tool Holder Assemblies Pneumatic CERTI-CRIMP Tool Holder Pneumatic CERTI-CRIMP Tool Assembly 356302-1 (Large) (408-4303) 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 Hydraulic Crimping Head 626 Pneumatic Crimping 48172, 48173, 48174, 69065 (408-2452) Heads 1338757-1 and 48183, and 49956 1338758-1 ( 408-4072) (408-1311) C-Head Pneumatic Adapter Straight Action Crimper 318161-1 (408-4190) 217200-1 (408-4105) 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) 10 of 19 Tyco Electronics Corporation Rev C STRATO-THERM Terminals, Splices, and Spare Wire Caps 114-2162 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 AMP-TAPETRONIC AMP-O-LECTRIC Model K" AMP-O-LECTRIC Model G" 69120-1 and 69120-2 Machine 69875 (409-1993) Terminator Machine Terminating Machine 354500-[ ] 565435-5 (409-5128) (409-5842) (409-1950) No Longer Manufactured New AMPOMATOR CLS III-G Hydraulic Hand Pump AMPOMATOR CLS IV+ Lead-Making Machine 314979-1 (409-5860) Lead-Making Machine 122500-[ ] (409-5852) 356500-[ ] (409-5878) Figure 4 (Cont'd) Rev C Tyco Electronics Corporation 11 of 19 STRATO-THERM Terminals, Splices, and Spare Wire Caps PRODUCT WIRE SIZE CRIMPING (AWG) DIE 26-24 22-20 PIDG Ring Tongue Terminal 18-16 TOOL HAND TOOL HOLDER ASSEMBLY HEAD OR ADAPTER 69692-1 69731 69710-1 69731 189721-1 or 189722-1 356304-1 217200-1 or 318161-1 69731 189721-2 or 189722-2 189928-1 217200-1 or 318161-1 69692-1 69732 69710-1 69732 189721-1 or 189722-1 356304-1 217200-1 or 318161-1 69732 189721-2 or 189722-2 189928-1 217200-1 or 318161-1 69693-1 69733 69710-1 69733 189721-1 or 189722-1 356304-1 217200-1 or 318161-1 69733 189721-2 or 189722-2 189928-1 217200-1 or 318161-1 69937 69734 69710-1 69734 189721-1 or 189722-1 356304-1 217200-1 or 318161-1 69734 189721-2 or 189722-2 189928-1 217200-1 or 318161-1 69693-1 69735 69710-1 69735 189721-1 or 189722-1 356304-1 217200-1 or 318161-1 69735 189721-2 or 189722-2 189928-1 217200-1 or 318161-1 14 12-10 114-2162 APPLICATOR POWER UNIT 69875 Figure 4 (Cont'd) 12 of 19 Tyco Electronics Corporation Rev C STRATO-THERM Terminals, Splices, and Spare Wire Caps PRODUCT WIRE SIZE CRIMPING (AWG) DIE 24 TOOL HAND TOOL HOLDER ASSEMBLY HEAD OR ADAPTER 69692-1 69731 69710-1 69731 69731 PIDG Insulation 114-2162 189721-1 or 189722-1 189721-2 or 189722-2 356304-1 189928-1 217200-1 or APPLICATOR POWER UNIT 69120-2, 69120 2 or 318161-1 217200-1 or 318161-1 69692-1 69732 69710-1 R Restricting t i ti Ring Ri Tongue Terminal 22 69732 69731 69735 12 69732 69731 22-20 46146 and Post-Insulated Ring Tongue Terminal 46145 189722-1 189721-2 or 189722-2 69710-1 189721-1 or 189722-1 189721-2 or 189722-2 356304-1 189928-1 356304-1 189928-1 217200-1 or 318161-1 217200-1 or 318161-1 217200-1 or 318161-1 217200-1 or 318161-1 46467 69097 8 69216 or 69211-1 Post-Insulated Post Insulated 189721-1 or 69099 45730 22-20 46467 18-16 46468 69099 69120 2 or 69120-2, 69216 or 69211-1 8 46146 and 46145 69327 22-20 69327 69328 18-16 69328 Window Butt Splice 69329 14-12 69329 Pre-Insulated Spare Wire Caps 314979-1 26-24 Splice Pre-Insulated 69120-1, 69097 69710-1 189928-1 318161-1 189928-1 318161-1 189928-1 189721-2 or 189722-2 69710-1 189721-2 or 189722-2 69710-1 189721-2 or 189722-2 69272-1 69120-1, 314979-1 318161-1 69120-2, or 69120-1, 314979-1 Figure 4 (Cont'd) Rev C Tyco Electronics Corporation 13 of 19 STRATO-THERM Terminals, Splices, and Spare Wire Caps PRODUCT WIRE SIZE CRIMPING (AWG) DIE 22-16 DIAMOND GRIP 114-2162 TOOL HAND TOOL HOLDER ASSEMBLY HEAD OR ADAPTER 16-14 Ring Tongue POWER UNIT 69875 69875 46673 46673-1 69930 46988 59294 69931 59461 189721-1 or 189767-1 or 189722-1 356302-1 69875 59461 189721-1 or 189767-1 or 189722-1 356302-1 46447 189721-1 or 189767-1 or 189722-1 356302-1 69955 69875 69355 69216 69099 H Heat t R Resistant i t t and d High Temperature APPLICATOR Te Terminal i al 12-10 69932 22-16 16-14 DIAMOND GRIP Heat Resistant and 46673 or 46673-1 46988 or 59294 904870-1 High Temperature Butt Splice p 12-10 904870-1 SOLISTRAND Heat Resistant 16-14 Ring Tongue T Terminal i l 217206-1 SOLISTRAND Heat Resistant 8 68135 Parallel Splice 48126 and 48355 SOLISTRAND High Temperature 16-14 16 14 68068 or 68068-3 59973-1 46447 189721-1 or 189767-1 or 189722-1 356302-1 69120-2 217206-1 567200-2 69065 or 69067 Ri T Ring Tongue Terminal 69120-1 or 69875, 69955 565435-5 D, or 354500-1 D No Longer Manufactured New Figure 4 (Cont'd) 14 of 19 Tyco Electronics Corporation Rev C STRATO-THERM Terminals, Splices, and Spare Wire Caps PRODUCT WIRE SIZE CRIMPING (AWG) DIE SOLISTRAND High Temperature 16-14 Spade Tongue Terminal 114-2162 TOOL HAND TOOL HOLDER ASSEMBLY 46447 189721-1 or 189767-1 or 189722-1 356302-1 46447 189721-1 or 189767-1 or 189722-1 356302-1 HEAD OR ADAPTER APPLICATOR POWER UNIT 217206-1 217206-1 122500-2, 69954 SOLISTRAND 687658-1 Heat Resistant and High Temperature 122500-3, 356500-1, or 356500-2 22 16 22-16 Ring g Tongue g 69954 69954 567200-2 Terminal 69875 565435-5 D or 354500-1 354500-1, 69954 567200-3 354500-2, 354500-9, or 1-354500-1 189721-1 or 189767-1 or 189722-1 356302-1 46447 69956 217206-1 69875 122500-2, 122500-3, 69956 687658-1 12-10 356500-1, or 356500-2 69956 567200-2 SOLISTRAND 565435-5 D 354500-1, Heat Resistant and 354500-2, High Temperature 69956 567200-3 354500-9, or Ring Tongue Terminal 1-354500-1 8 48126 and 48355 69355 189721-1 or 189767-1 or 189722-1 356302-1 69015 69099 69097 1338757-1 69120-2, or 49956 69065 or 69067 69120-1 69120-1, 69216 314979 1 314979-1 46146 and 46145 D No Longer Manufactured New Figure 4 (Cont'd) Rev C Tyco Electronics Corporation 15 of 19 STRATO-THERM Terminals, Splices, and Spare Wire Caps PRODUCT WIRE SIZE CRIMPING (AWG) DIE 6 SOLISTRAND Heat Resistant and High Temperature Ring Tongue Terminal 4 114-2162 TOOL HAND TOOL HOLDER ASSEMBLY HEAD OR ADAPTER APPLICATOR POWER UNIT 189721-1 or 189722-1 189767-1 or 356302-1 1338758-1 69217 69099 69120-1 or 69120-2 48127 and 48128 69065 or 69067 69120-1 or 69120-2 69015 48172 48127 and 48128 59973-1 48127 and 48128 69067 48127 and 48128 69065 314979-1 69217 69099 46133 and 46134 69067 69120-1 or 69120-2 46133 and 46134 69097 314979-1 46133 and 46135 69097 69120-1 or 69120-2 69218 69099 69120-1 or 69120-2 59975-1 69015 48173 69069 69120-1 69069 314979-1 46133 and 46135 69097 314979-1 69218 69099 314979-1 48127 and 48129 69065 or 69067 69120-1 or 69120-2 48127 and 48129 59973-1 48127 and 48129 69065 or 69067 314979-1 Figure 4 (Cont'd) 16 of 19 Tyco Electronics Corporation Rev C STRATO-THERM Terminals, Splices, and Spare Wire Caps PRODUCT WIRE SIZE CRIMPING (AWG) DIE HOLDER ASSEMBLY HEAD OR ADAPTER 69069 69097 45433 69099 69015 48174 59973-1 69069 69067 69097 69065 45436 69099 69015 48183 600850 59973-1 46136 48127 and 48130 48127 and 48130 48127 and 48130 46133 and SOLISTRAND TOOL HAND TOOL 46133 and 2 114-2162 46136 69065 or 69067 APPLICATOR POWER UNIT 69120-1 or 69120-2 69120-1 or 69120-2 314979-1 Heat Resistant and 48127 and High Temperature 48130 Ring g Tongue g Terminal 48131 and 48132 1/0 48131 and 48132 48131 and 48132 45436 46137 and 46138 22-16 SOLISTRAND Heat Resistant and 16-14 High Temperature p Splice 12-10 69065 or 69067 69120-1 or 69120-2 69120-1 or 69120-2 314979-1 69099 314979-1 69097 69120-2, or 69065 or 69067 69120-1, 314979-1 46447 189721-1 or 189767-1 or 189722-1 356302-1 46447 189721-1 or 189767-1 or 189722-1 356302-1 46447 189721-1 or 189767-1 or 189722-1 356302-1 217206-1 217206-1 217206-1 Figure 4 (End) Rev C Tyco Electronics Corporation 17 of 19 STRATO-THERM Terminals, Splices, and Spare Wire Caps 114-2162 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. TERMINALS CRIMP MUST NOT BE OFF END OF WIRE BARREL END OF WIRE CONDUCTORS MUST BE FLUSH WITH OR EXTEND SLIGHTLY BEYOND END OF WIRE BARREL THERE MUST BE NO NICKED OR WIRE MUST BE FULLY INSERTED MISSING CONDUCTOR STANDS AND INSULATION MUST NOT ENTER TERMINAL WIRE BARREL WIRE SIZE MUST BE WITHIN WIRE SIZE TERMINAL MUST NOT BE BENT RANGE MARKED ON TERMINAL OR DEFORMED IN ANY WAY FOR TERMINALS WITH INSULATION SUPPORT, FOR POST-INSULATED TERMINAL, INSULATION BARREL MUST BE IN FIRM SLEEVE MUST EXTEND SLIGHTLY CONTACT WITH WIRE INSULATION FROM RING CRIMP DOT CODE (OR HASHMARK CODE ON BOTTOM OF TERMINAL) MUST BE FULLY FORMED ON INSULATION OF TERMINAL THERE MUST BE NO HOLES OR THIN SPOTS IN TERMINAL INSULATION FOR POST INSULATED TERMINAL, SLEEVE MUST BE CENTERED OVER WIRE BARREL COLOR CODE, CRIMP DOT OR HASHMARK CODE, AND TOOL COMBINATION MUST MATCH SPARE WIRE CAP THERE MUST BE NO HOLES OR THIN SPOTS IN INSULATION OF SPARE WIRE CAP FULL LENGTH OF RINGS MUST BE CRIMPED THIS RING COLOR CODE MUST MATCH TOOLING COLOR CODE WIRE MUST BE FULLY BOTTOMED IN CAP THIS RING COLOR CODE MUST BE WITHIN WIRE INSULATION DIAMETER RANGE FIGURE 5. VISUAL AID (CONT'D) 18 of 19 Tyco Electronics Corporation Rev C STRATO-THERM Terminals, Splices, and Spare Wire Caps 114-2162 SPLICES WIRE MUST BE FULLY INSERTED AND INSULATION MUST NOT ENTER SPLICE WIRE BARREL CRIMP MUST NOT BE OFF END OF SPLICE WIRE BARREL THERE MUST BE NO NICKED OR MISSING THERE MUST BE NO HOLES CONDUCTOR STANDS OR THIN SPOTS IN SPLICE INSULATION END OF WIRE CONDUCTORS MUST BE WIRE SIZE MUST BE WITHIN FLUSH WITH OR EXTEND SLIGHTLY WIRE SIZE RANGE MARKED BEYOND END OF WIRE BARREL ON SPLICE COLOR CODE, CRIMP DOT OR CRIMP DOT CODE (OR HASHMARK HASHMARK CODE, AND TOOL CODE ON BOTTOM OF SPLICE) COMBINATION MUST MATCH MUST BE FULLY FORMED ON INSULATION OF SPLICE FOR SPLICE WITH INSPECTION HOLE, WIRE CONDUCTOR MUST BE VISIBLE IN INSPECTION HOLE FOR WINDOW BUTT SPLICE, WIRE CONDUCTOR MUST BE VISIBLE IN WINDOW INDENT 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 FOR ALL INSULATED SPLICES, INSULATION BARREL MUST BE IN FIRM CONTACT WITH WIRE FOR POST-INSULATED SPLICE, INSULATION SLEEVE MUST EXTEND SLIGHTLY FROM RING AND BUSHING MUST EXTEND SLIGHTLY FROM SLEEVE 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 POST-INSULATED SPLICE, SLEEVE MUST BE CENTERED OVER SPLICE FIGURE 5. VISUAL AID (END) Rev C Tyco Electronics Corporation 19 of 19