Application Specification
114--2161
LOC B
1of 19
E2009 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
PLASTI- GRIP* Terminals and Splices 31 JUL 09 Rev E
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.
Figure 1
Ring Tongue
Terminal
3--Way Link
Terminal
Slotted Ring Tongue
Terminal
Plug Terminal
Rectangular Tongue
Terminal
Long Spring Spade
Terminal
Short Spring Spade
Terminal
Multi Stud Ring
Terminal
Ring Tongue 90_
Bend Terminal
Hook Tongue
Terminal
Ring Tongue Flag
Terminal
Butt SpliceParallel Splice
Tube Cap Terminal
Assembly
Flanged Spade
Terminal
NOTE
i
114- 2161PLASTI- GRIP Terminals and Splices
Rev E2 of 19 Tyco Electronics Corporation
2. REFERENCE MATERIAL
2.1. Revision Summary
Revisions to this application specification include:
SRemoved 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 Checking Terminal Crimp Height or Gaging Die Closure
408--9816 Handling of Reeled Products
B. Tooling
408--1256 Hand Crimping Tool 59270
408--1261 Hand Crimping Tool 59239--4
408--1263 Hand Crimping Tools 59489 and 59287--1
408--1310 Pneumatic Tool 69015
408--1502 Hand Crimping Tools 45160 and 45575--1
408--1548 Hand Crimping Tools 45449 and 45450
408--1559 Hand Crimping Tools 46121, 47386, and 47387
408--1570 Hand Crimping Tools 48040 and 48049
408--1610 “T”--HEAD* Crimping Tools 59250 and 59170
408--1632 Crimping Dies 47806--2, 47807--1, and 47808--6
408--1724 Crimping Dies 48858--1, 48859--1, 48861--1, and 47238--1
408--1729 Crimping Dies 47820, 47821, 47822, and 47823
408--1758 Crimping Dies 48752--1, 48753--1, 48754--1, and 48755--1
408--2095 Hand Crimping Tool 69710--1
408--2423 Crimping Die Assemblies 69877, 69878, 69872, 69873, and 68116--1
408--2434 Hand Crimping Tool 69959
408--2450 Hydraulic Crimping Head 69051
408--2453 Hydraulic Crimping Head 69066
408--2498 Crimping Head Cross--Reference for Pneumatic Tools
408--2567 Tool and Die Selection Chart
408--2575 Tool and Die Selection Chart for AMP* Terminals and Splices
408--2592 Crimping Die Assemblies 68247--1 and 68248--1
408--2667 Crimping Die Assembly 69893
408--2822 Crimping Die Assemblies 59826--1, 59827--1, 59828--1, and 69874
408--2823 TETRA--CRIMP* Hand Crimping Tool 59824--1
408--4071 Pneumatic Crimping Head 679300--1
408--4099 Pneumatic TETRA--CRIMP Adapter 679305--1
114- 2161
PLASTI- GRIP Terminals and Splices
Rev E 3 of 19Tyco Electronics Corporation
408--4105 Straight Action Crimper 217200--1
408--4190 C--Head Pneumatic Adapter (Crimper) 318161--1
408--4198 Pneumatic Crimping Head Assembly 314991--1
408--4303 Pneumatic CERTI--CRIMP* Tool Holder Assemblies 356303--1 (Small) and 356302--1 (Large)
408--4321 Straight Action Tool Holder Assembly 356304--1 (Logic)
408--6757 Hydraulic Hand Crimping Tool 59974--1
408--6764 CERTI--LOK* Hand Tool Frame Assembly 169400
408--6765 Crimping Die Assembly 169404
408--8044 Miniature Quick--Change Applicator 687658--1 (Side--Feed with Mechanical Feed System)
408--8082 Miniature Quick--Change Applicators 567200--2 and --3 (Side--Feed with Air Feed System)
408--9177 Crimping Dies 47378--1, 48756--1, and 48757--1
408--9252 PRO--CRIMPER* III Hand Crimping Tool 58433--3
408--9535 Hydraulic Crimping Head 58422--1
408--9586 Pneumatic Crimping Heads 314269--1 and 314270--3
408--9684 Inspection and Servicing of Hydraulic Crimping Heads 69051, 58422--1, and 69066
408--9775 Pneumatic Crimping Heads 314868--1 and 314869--1
409--1950 Hydraulic Power Units 69120--1 and 69120--2
409--1993 AMP--TAPETRONIC* Machine 69875
409--2586 AMP--TAPETRONIC Machine 68250--1
409--2761 Pneudraulic Wiring Terminating Machine 68354--1
409--5128 Basic AMP--O--LECTRIC* Model “K” Terminating Machine 471273--[ ]
409--5842 AMP--O--LECTRIC Model “G” Terminating Machine 354500--[ ]
409--5852 AMPOMATOR* CLS III--G Lead--Making Machine 122500--[ ]
409--5860 Hydraulic Hand Pump 314979--1
409--5862 626 Pneumatic Tooling Assemblies 189721--[ ] and 189722--[ ]
409--5878 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 PVF2insulation 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.
114- 2161PLASTI- GRIP Terminals and Splices
Rev E4 of 19 Tyco Electronics Corporation
3.4. Chemical Exposure
Do not store terminals or splices near any chemical listed below as they may cause stress corrosion
cracking in the terminal or splices.
Alkalies Ammonia Citrates Phosphates Citrates Sulfur Compounds
Amines Carbonates Nitrites Sulfur Nitrites 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.
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.
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.
CAUTION
!
CAUTION
!
114- 2161
PLASTI- GRIP Terminals and Splices
Rev E 5 of 19Tyco Electronics Corporation
St
r
a
n
ded W
i
r
eSo
l
i
dW
i
r
e
Strip Length
Conductor Insulation
Strip Length
TERMINAL OR SPLICE WIRE WIRE STRIP LENGTH WIRE
SIZE INSULATION
COLOR
W
I
R
E
INSULATION
DIA RANGE TERMINAL BUTT SPLICE PARALLEL
SPLICE
W
I
R
E
CIRCULAR MIL AREA
(CMA)
26--22 Yellow 1.27--2.03
[.050--.080] —4.34--5.16
[.171--.203] —202--810
24--20 White 2.03--3.18
[.080--.125]
4.75--5.54
[.187--.218] — — 320--1,290
Red —
5
1
6
5
9
4
6
3
5
7
1
4
7
8
7
8
6
4
22--16 Natural/Red —5.16--5.94
[
2
0
3
--
2
3
4
]
6.35--7.14
[
2
5
0
--
2
8
1
]
7.87--8.64
[
3
1
0
--
3
4
0
]
509--3,260
6
Black —
[
.
2
0
3
-- .
2
3
4
]
[
.
2
5
0
-- .
2
8
1
]
[
.
3
1
0
-- .
3
4
0
]
5
0
9
3
,
6
0
20--16 HD Natural/Green 2.92--4.32
[.115--.170]
5.16--5.94
[.203--.234] — — 810--3,260
Blue —
5
1
6
5
9
4
6
3
5
7
1
4
7
8
7
8
6
4
16--14 Natural/Blue —5.16--5.94
[
2
0
3
--
2
3
4
]
6.35--7.14
[
2
5
0
--
2
8
1
]
7.87--8.64
[
3
1
0
--
3
4
0
]
2,050--5,180
6
Black —
[
.
2
0
3
-- .
2
3
4
]
[
.
2
5
0
-- .
2
8
1
]
[
.
3
1
0
-- .
3
4
0
]
,
0
5
0
5
,
8
0
1
6
1
4
H
D
Yellow/Black —7.92--8.71
2
0
5
0
5
1
8
0
16--14
H
D
Black —
7
.
9
2
8
.
7
1
[.312--.343]
—
—
2,050--5,180
Yellow —
7
9
2
8
7
1
7
9
2
8
7
1
7
9
2
8
7
1
12--10 Natural/Yellow —7.92--8.71
[
3
1
2
--
3
4
3
]
7.92--8.71
[
3
1
2
--
3
4
3
]
7.92--8.71
[
3
1
2
--
3
4
3
]
5,180--13,100
0
Black —
[
.
3
1
2
-- .
3
4
3
]
[
.
3
1
2
-- .
3
4
3
]
[
.
3
1
2
-- .
3
4
3
]
5
,
8
0
3
,
0
0
R
e
d
11.51--12.29 8.33--9.12
8
R
e
d
—
1
1
.
5
1
1
2
.
2
9
[.453--.484]
8
.
3
3
9
.
1
2
[.328--.359]
—
1
3
1
0
0
2
0
8
0
0
8
Natural/Red —8.33--9.12
[.328--.359] — —
13,100--20,800
6
Blue —15.47--16.26
[.609--.640]
9.93--10.72
[.391--.422] —
2
0
8
0
0
3
3
1
0
0
6
Natural/Blue —9.93--10.72
[.391--.422] — —
20,800--33,100
4
Yellow —15.47--16.26
[.609--.640] — —
3
3
1
0
0
5
2
6
0
0
4
Natural/Yellow 1.27--13.08
[.050--.515]
9.93--10.72
[.391--.422] — —
33,100--52,600
2
Red —11.51--12.29
[.453--.484] — —
5
2
6
0
0
8
3
7
0
0
2
Natural/Red 12.19--14.22
[.480--.560]
11.51--12.29
[.453--.484] — —
52,600--83,700
1/0 Blue —18.67--21.82
[.735--.859] — — 83,700--119,500
2
/
0
Yellow —18.67--21.82
[.735--.859] — —
1
1
9
5
0
0
1
5
0
5
0
0
2
/
0
Natural/Yellow 16.00--19.68
[.630--.775]
18.67--21.82
[.735--.859] — —
119,500--150,500
Figure 2
114- 2161PLASTI- GRIP Terminals and Splices
Rev E6 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
OffCenter,ButNotOffEndofWireBarrel)
Wire Insulation
Location
Wire Conductor Location
Wire Insulation
Location
Wire Conductor Location
Crimp Dot Code (Ref)
Front Bellmouth Must Be Visible
End of Conductors
Must Be Flush With, or
Extend Slightly Beyond
EndofWireBarrel
Terminal Plug Terminal
Splice
Front Bellmouth
Must Be Visible
SOLDER SLUG
TERMINAL OR SPLICE CRIMP HEIGHT RANGE (See Notes)
O
S
C
SIZE DIAMETER CRESCENT CRIMP CRIMP PRODUCED BY
TETRA--CRIMP TOOLING
26--22
3
1
8
[
1
2
5
]
1.60--1.75 [.063--.069] —
24--20 3.18 [.125] 2.26--2.41 [.089--.095] —
22--16 3.18 [.125] 2.77--2.92 [.109--.115] 1.98--2.18 [.078--.086]
20--16 HD
4
7
6
[
1
8
8
]
3
0
2
3
1
8
[
1
1
9
1
2
5
]
2
3
4
2
5
4
[
0
9
2
1
0
0
]
16--14 4.76 [.188] 3.02--3.18 [.119--.125
]
2.34--2.54 [.092--.100
]
16--14 HD
6
3
5
[
2
5
0
]
4
2
9
4
4
4
[
1
6
9
1
7
5
]
3
2
5
3
4
5
[
1
2
8
1
3
6
]
12--10 6.35 [.250] 4.29--4.44 [.169--.175
]
3.25--3.45 [.128--.136
]
86.35 [.250] 5.11--5.26 [.201--.207] —
66.35 [.250] 6.02--6.17 [.237--.243] —
49.53 [.375] 6.83--6.98 [.269--.275] —
29.53 [.375] 8.10--8.26 [.319--.325] —
1/0 12.70 [.500] 10.19--10.34 [.401--.407] —
2/0 15.88 [.625] 10.67--12.83 [.499--.505] —
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
114- 2161
PLASTI- GRIP Terminals and Splices
Rev E 7 of 19Tyco Electronics Corporation
F. Tensile Strength
Crimped terminals or splices must hold the wire firmly and have a crimp pull--out test value meeting that
specified in Figure 4.
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) TENSILE FORCE
(N [lb]) Min
26 13.4 [3]
24 22.3 [5]
22 35.6 [8]
20 57.9 [13]
18 89.0 [20]
16 133.5 [30]
14 222.5 [50]
12 311.5 [70]
10 356.0 [80]
8400.5 [90]
6445.0 [100]
4623.0 [140]
2801.0 [180]
1/0 1112.5 [250]
2/0 1235.0 [300]
F
i
gu
r
e4
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.
NOTE
i
114- 2161PLASTI- GRIP Terminals and Splices
Rev E8 of 19 Tyco Electronics Corporation
Figure 5
UpandDownBend
Side- to- Side Bend
Datum Line
11_
11_
Datum Line
11_
11_
Datum Line
11_
11_
11_
11_
Datum Line
Datum Line
11_
11_
11_
11_
11_
11_
Datum Line
11_
11_
Terminal
Plug Terminal
Splice
Terminal
Plug Terminal
Splice
114- 2161
PLASTI- GRIP Terminals and Splices
Rev E 9 of 19Tyco Electronics Corporation
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 6.
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.
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.
NOTE
i
114- 2161PLASTI- GRIP Terminals and Splices
Rev E10 of 19 Tyco Electronics Corporation
Hand Crimping Tools
46121, 47386, 47387
(408--1559)
45160, 45575--1 (408--1502)
45449, 45450 (408--1548)
“T”--HEAD Crimping
Tools 59250, 59170
(408--1610)
TETRA--CRIMP Hand
Crimping Tool 59824--1
(408--2823)
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)
PRO--CRIMPER Hand
Crimping Tool 58433--3
(408--9252)
Hydraulic Hand Crimping
Tool 59974--1 (408--6757)
Figure 6 (Cont’d)
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)
114- 2161
PLASTI- GRIP Terminals and Splices
Rev E11 of 19Tyco Electronics Corporation
626 Pneumatic Tooling
Assemblies 189721--[ ],
189722--[ ] (409--5862)
C--Head Pneumatic
Adapter (Crimper)
318161--1 (408--4190)
Straight Action Crimper
217200--1 (408--4105)
Straight Action Tool Holder Assembly
189928--1 (Non--Logic) (409--5862)
356304--1 (Logic) (408--4321)
Large Tool Holder Assembly
189767--1 (Non--Logic) (409--5862)
356302--1 (Logic) (408--4303)
Pneumatic TETRA--CRIMP
Adapter 679305--1
(408--4099)
Pneumatic Crimping Head
679300--1 (408--4071)
Hydraulic Crimping Head
69051 (408--2450)
58422--1 (408--9535)
69066 (408--2453)
Pneumatic Tool
69015 (408--1310)
Pneumatic Crimping
Head Assembly
314991--1 (408--4198)
CERTI--CRIMP (Small) Tool
Holder Assembly 189766--1
(Non--Logic) (409--5862)
356303--1 (Logic) (408--4303)
Pneumatic Crimping Heads
314868--1, 314869--1 (408--9775)
314269--1 , 314270--3 (408--9586)
Figure 6 (Cont’d)
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)
114- 2161PLASTI- GRIP Terminals and Splices
Rev E12 of 19 Tyco Electronics Corporation
AMPOMATOR CLS III--G
Lead--Making Machines
122500--[ ] (409--5852)
AMPOMATOR CLS IV+
Lead--Making Machines
356500--[ ] (409--5878)
AMP--O--LECTRIC Model “G”
Terminating Machines 354500--1
(409--5842)
Hydraulic Power Units
69120--1, 69120--2
(409--1950)
Hydraulic Hand Pump
314979--1 (409--5860)
AMP--TAPETRONIC Machine
68250--1 (409--2586)
69875 (409--1993)
Pneudraulic Wire
Terminating Machine
68354--1 (409--2761)
Figure 6 (Cont’d)
AMP--O--LECTRIC Model “K”
Terminating Machine 1--471273--3
or 565435--5 (Modified)
No Longer Manufactured New
(409--5128)
114- 2161
PLASTI- GRIP Terminals and Splices
Rev E13 of 19Tyco Electronics Corporation
PRODUCT
TYPE
WIRE SIZE
(AWG)
CRIMPING
DIE HAND TOOL
TOOL
HOLDER
ASSEMBLY
HEAD OR
ADAPTER APPLICATOR POWER UNIT
24--20 69878 — — — 567200--2 or
567200--3 69875 or d
—59250 — — — —
—59170 — — — —
—47386 — — — —
—59824--1 — — — —
47806--2 189721--1 or
189722--1
189928--1 or
356304--1 217200--1 — —
47806--2 189721--2 or
189722--2
189928--1 or
356304--1 318161--1 — —
Terminals:
Flag
M
l
t
i
S
t
d
—189721--1 or
189722--1
189767--1 or
356302--1 679305--1 — —
g
Multi Stud
Ring
S
p
ade 22--16 —189721--1 or
189722--1
189766--1 or
356303--1 314270--3 — —
S
p
a
d
e
Tube Cap
W
i
r
e
P
i
n
169404 169400 — — — —
W
i
re
P
i
n
59826--1,
69872, or
69893
— — — 687658--1 c
59826--1,
69872, or
69893
— — — — 69875
59826--1 or
69872 — — — 567200--3 d
59826--1 or
69872 — — — 567200--2
1--471273--2
or 565435--5
(Modified)
20--16 HD —48040 — — — —
c122500--2, 122500--3, 356500--1, 356500--2
d354500--1
Figure 6 (Cont’d)
114- 2161PLASTI- GRIP Terminals and Splices
Rev E14 of 19 Tyco Electronics Corporation
PRODUCT
TYPE
WIRE SIZE
(AWG)
CRIMPING
DIE HAND TOOL
TOOL
HOLDER
ASSEMBLY
HEAD OR
ADAPTER APPLICATOR POWER UNIT
—59250 — — — —
—59170 — — — —
—47387 — — — —
—59824--1 — — — —
47807--1 189721--1 or
189722--1
189928--1 or
356304--1 217200--1 — —
47807--1 189721--2 or
189722--2
189928--1 or
356304--1 318161--1 — —
1
6
1
4
—189721--1 or
189722--1
189767--1 or
356302--1 679305--1 — —
16--14
—189721--1 or
189722--1
189766--1 or
356303--1 314269--1 — —
169404 169400 — — — —
Terminals:
F
l
a
g
59827--1 or
69873 — — — 687658--1 c
F
l
a
g
Hook
Multi Stud
R
i
n
g
59827--1 or
69873 — — — — 69875
Ring
Spade
3--Way Link
59827--1 or
69873 — — — 567200--3 d
3
W
a
y
L
i
n
k
Wire Pin 59827--1 or
69873 — — — 567200--2 354500--1
—189721--1 or
189722--1
189767--1 or
356302--1
679300--1 or
679305--1 — —
47808--6 189721--1 or
189722--1
189928--1 or
356304--1 217200--1 — —
47808--6 189721--2 or
189722--2
189928--1 or
356304--1 318161--1 — —
16--14 HD 47808--6 69710--1 — — — —
6
169404 169400 — — — —
—59824--1 — — — —
—58433--3 — — — —
—48049 — — — —
—59239--4 — — — —
c122500--2, 122500--3, 356500--1, 356500--2
d354500--1
Figure 6 (Cont’d)
114- 2161
PLASTI- GRIP Terminals and Splices
Rev E15 of 19Tyco Electronics Corporation
PRODUCT
TYPE
WIRE SIZE
(AWG)
CRIMPING
DIE HAND TOOL
TOOL
HOLDER
ASSEMBLY
HEAD OR
ADAPTER APPLICATOR POWER UNIT
—59239--4 — — — —
—59824--1 — — — —
—58433--3 — — — —
—48049 — — — —
—189721--1 or
189722--1
189767--1 or
356302--1
679300--1 or
67305--1 — —
Terminals:
F
l
a
g
47808--6 189721--1 or
189722--1
189928--1 or
356304--1 217200--1 — —
Flag
Ring
Spade
12--10 47808--6 189721--2 or
189722--2
189928--1 or
356304--1 318161--1 — —
S
p
a
d
e
Wire Pin 169404 169400 — — — —
59828--1 or
69874 — — — 687658--1 c
59828--1 — — — — 69875
59828--1 or
69874 — — — 567200--3 d
59828--1 or
69874 — — — 567200--2 354500--1
—69959 — — — —
47820 or
48752--1 59974--1 — — — —
T
e
r
m
i
n
a
l
s
:
47820 or
48752--1 — — 69051 —
T
erm
i
na
l
s:
Ring 8
48858--1 — — 58422--1 or
69066 —e
68247--1 — — — — 68250--1
68116--1 — — — — 69875
68355--1 — — — — 68354--1
c122500--2, 122500--3, 356500--1, 356500--2
d354500--1
e69120--1, 69120--2, or 314979--1
Figure 6 (Cont’d)
114- 2161PLASTI- GRIP Terminals and Splices
Rev E16 of 19 Tyco Electronics Corporation
PRODUCT
TYPE
WIRE SIZE
(AWG)
CRIMPING
DIE HAND TOOL
TOOL
HOLDER
ASSEMBLY
HEAD OR
ADAPTER APPLICATOR POWER UNIT
47821 or
48753--1 59974--1 — — —
47821 — — 69051 —e
48859--1 — — 58422--1 or
69066 —314979--1
648753--1 — — 69051 —e
48859--1 — — 58422--1 or
69066 —e
68248--1 — — — — 68250--1
68356--1 — — — — 68354--1
47822 or
48754--1 59974--1 — — — —
T
i
l
—69015 —314991--1 — —
Terminals:
Ring 447822 or
48754--1 — — 69051 —e
47238--1 — — 58422--1 or
69066 —e
47823 or
48755--1 59974--1 — — — —
247823 or
48755--1 — — 69051 —e
48861--1 — — 69066 or
58422--1 —e
1
/
0
47378--1 or
48756--1 — — 69066 or
58422--1 —e
1
/
0
48861--1 — — 58422--1 —e
2/0 48757--1 — — 58422--1 or
69066 —e
e69120--1, 69120--2, or 314979--1
Figure 6 (Cont’d)
114- 2161
PLASTI- GRIP Terminals and Splices
Rev E17 of 19Tyco Electronics Corporation
PRODUCT
TYPE
WIRE SIZE
(AWG)
CRIMPING
DIE HAND TOOL
TOOL
HOLDER
ASSEMBLY
HEAD OR
ADAPTER APPLICATOR POWER UNIT
—45160 — — — —
22--16 —189721--1 or
189722--1
189766--1 or
356303--1 314868--1 — —
—59250 — — — —
—47387 — — — —
—189721--1 or
189722--1
189766--1 or
356303--1 314269--1 — —
47807--1 189721--1 or
189722--1
189928--1 or
356304--1 — — —
S
H
U
R
P
L
U
G
*
—189721--1 or
189722--1
189767--1 or
356302--1 679305--1 — —
SHUR--PLUG
*
Terminals —59824--1 — — — —
T
e
r
m
i
n
a
l
s
16--14 —58433--3 — — — —
1
6
1
4
169404 169400 — — — —
59827--1 or
69873 — — — 687658--1 c
59827--1 or
69873 — — — — 69875
59827--1 or
69873 — — — 567200--3 d
59827--1 or
69873 — — — 567200--2
1--471273--2
or 565435--5
(Modified)
c122500--2, 122500--3, 356500--1, 356500--2
d354500--1
Figure 6 (Cont’d)
114- 2161PLASTI- GRIP Terminals and Splices
Rev E18 of 19 Tyco Electronics Corporation
PRODUCT
TYPE
WIRE SIZE
(AWG)
CRIMPING
DIE HAND TOOL
TOOL
HOLDER
ASSEMBLY
HEAD OR
ADAPTER APPLICATOR POWER UNIT
—46121 — — — —
69877 — — — 687658--1 c
26--22 69877 — — — — 69875
69877 — — — 567200--3 d
69877 — — — 567200--2 354500--1
—45160 — — — —
—58433--3 — — — —
—189721--1 or
189722--1
189766--1 or
356303--1 314868--1 — —
22--16 69872 — — — 687658--1 c
69872 — — — — 69875
69872 — — — 567200--3 d
B
u
t
t
S
p
l
i
c
e
69872 — — — 567200--2 354500--1
B
utt
S
p
l
i
ce
—45575--1 — — — —
—58433--3 — — — —
1
6
--
1
4
—189721--1 or
189722--1
189766--1 or
356303--1 314869--1 — —
1
6
--
1
4
69873 — — — — 69875
69873 — — — 567200--3 d
69873 — — — 567200--2 354500--1
—59287--1 — — — —
—59489 — — — —
1
2
1
0
—58433--3 — — — —
12--10 69874 — — — 687658--1 c
69874 — — — 567200--3 d
69874 — — — — 69875
22--16 —45449 — — — —
Parallel Splice 16--14 —45450 — — — —
p
12--10 —59270 — — — —
c122500--2, 122500--3, 356500--1, 356500--2
d354500--1
Figure 6 (End)
114- 2161
PLASTI- GRIP Terminals and Splices
Rev E19 of 19Tyco Electronics Corporation
6. VISUAL AID
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.
FIGURE 7. VISUAL AID
WIRE INSULATION
MUST BE UNDAMAGED
CRIMP DOT CODE
MUST BE FORMED
WHEN USING TOOL
WITH COLOR CODING
WIRE INSULATION MUST BE INSIDE INSULATION
BARREL BUT MUST NOT ENTER WIRE BARREL
INSULATION BARREL MUST
BE IN FIRM CONTACT WITH
WIRE INSULATION
WIRE SIZE MUST BE SAME
AS WIRE SIZE STAMPED
ON TERMINAL
THEREMUSTBENO
NICKED OR MISSING
CONDUCTOR STRANDS
WIRE MUST BE
FULLY INSERTED
END OF CONDUCTORS MUST BE
FLUSH WITH, OR EXTEND SLIGHTLY
BEYOND END OF WIRE BARREL
END OF CONDUCTORS MUST
BE AGAINST WIRE STOP OR
MUST BE FLUSH WITH, OR
EXTEND SLIGHTLY BEYOND,
END OF WIRE BARREL
ALL CONDUCTORS MUST BE HELD
FIRMLY INSIDE WIRE BARREL
TERMINAL MUST NOT BE BENT
OR DEFORMED IN ANY WAY
CRIMP DOT CODE MUST BE
FORMED WHEN USING TOOL
WITH COLOR CODING
SPLICE MUST NOT BE
BENT OR DEFORMED
IN ANY WAY
SPLICE INSULATION MUST
BE IN FIRM CONTACT WITH
WIRE INSULATION
