Instruction Sheet
2– and 3– Wire Tel–Splice Connectors 408–3109
LOC B
1 of 2
E
2004 T yco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
AMP and Tyco are trademarks. *T rademark
Other products, logos, and company names used are the property of their respective owners.
TOOLING ASSISTANCE CENTER 1–800–722–1 11 1
F AX/PRODUCT INFO 1–800–522–6752
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www.tycoelectronics.com
This controlled document is subject to change.
For latest revision, call the FAX/PRODUCT INFO number.
12 JUL 04 Rev B
(Loose–Piece)
Figure 1
Upper
Housing
Contact
Wire Size
Range Marking
Wire Hole
Lower
Housing
1. INTRODUCTION
These instructions cover domestic, international, and
flame retardant (sealed and unsealed) 2–wire (for
example, part numbers 552795–[ ] and 553395–[ ]),
shown in Figure 1, and 3–wire (for example, part
numbers 552678–[ ] and 553759–[ ]) loose–piece
Tel–Splice connectors. The connectors terminate
wires by using the insulation displacement technique.
Dimensions in this instruction sheet are in metric
units [with U.S. customary units in brackets].
Figures are not drawn to scale.
PRO–CRIMPER* II Hand Tool Assembly 58610–1
(instruction sheet 408–4235) or Economy Hand Tool
231839–1 (408–3183) can be used to terminate these
connectors.
Industry–standard tools having parallel–action
jaws can be used to terminate these connectors;
however, as with any tool used, the terminated
connector must be gaged periodically to ensure
proper wire insertion depth.
Crimp Height Gage 230495–1 (included with the
connectors) is used to check the crimp height (wire
insertion depth) of the connector after termination.
For detailed application requirements for the
connectors, refer to Application Specification
114–6010.
Reasons for reissue of this instruction sheet are
provided in Section 5, REVISION SUMMARY.
2. DESCRIPTION
These connectors will accept any combination of solid
copper wire sizes 26 through 19 AWG with an
insulation diameter range of 0.51 through 2.0 mm
[.020 through .080 in.]. Wire insulation must be filled,
foam skin, or air core plastic for domestic and
international connectors and paper pulp or air core
plastic for flame retardant connectors.
Attached to the upper housing is a U–shaped contact
or two blades. The lower housing contains 2 or 3 wire
holes or a wire hole and a wire slot. Each hole or slot
accepts only one wire. The contact has 4 or 6 wire
contact slots—2 for each wire. The lower housing
contains a wire stuffer which forces the wires into the
contact slots when the housings are pressed together
for termination.
3. TERMINATING PROCEDURE
Make sure that the wire size matches the wire size
marking on the connector being terminated, and
proceed as follows:
1. Cut the wires evenly to length; except for 2–wire
half–tap connectors, cut the tap wire to length and
leave the through wire uncut (wires must not be
stripped).
2. Insert the wires into the wire holes until the
wires bottom in the lower housing (refer to
Figure 2, Detail A); except for half–tap connectors,
insert the wires into the wire hole and wire slot
making sure that the through wire is fully contained
in the wire slot and extends past the housing (see
Figure 2, Detail B).
3. Press the upper housing and lower housing
together for pre–crimp, and hold the wires in place.
4. Position the connector in the tool according to
the instructions packaged with the tool.
5. Holding the wires in place, actuate the tool.
Figure 2
Wires Bottomed in
Lower Housing
Wire Bottomed in
Lower Housing
Through Wire Fully
Contained in Wire Slot and
Extends Past Housing
Detail B
Detail A
NOTE
NOTE
NOTE
408–3109
2– and 3– Wire Tel–Splice Connectors (Loose–Piece)
Rev B2 of 2
6. Refer to Figure 3 and using the gage, check the
crimp height of the connector as follows:
a. Slide the connector into the gage slot marked
with the wire size used. Make sure that the
contact is aligned with the gage members.
b. Slide the gage off of the connector. If the
connector slides off easily with little or no drag,
the connector is properly terminated. If the
connector sticks in the gage, the connector is
not properly terminated.
If the connector sticks in the gage, terminate and
gage a few sample connectors. If the sample
connectors also stick in the gage, re–terminate
the connectors with another hand tool. If these
connectors still stick in the gage, replace the
connectors.
Figure 3
Contact Aligned
with Gage Members
Gage
Slot
Wire Size Range
Marking Matches
Wire Size Used
4. REPLACEMENT AND REPAIR
The connectors are not repairable. DO NOT use
damaged connectors or connectors that are
improperly terminated. DO NOT re–use terminated
connectors by removing the wires.
5. REVISION SUMMARY
Revisions to this instruction sheet per EC
0990–0890–04 include:
S
Updated document to corporate requirements
S
Added Connectors 553395–[ ] and 553759–[ ]
S
Added Tool 231839–1
S
Added reference to 114–6010
S
Modified Section 3
S
Added Section 4
NOTE
