Application Specification
Pre-Insulated Diamond Grip (PIDG*) 114-2157
LOC B
1
of 14
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
Terminals, Splices, and End Caps
09 SEP 08 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 PIDG terminals, splices, and end caps in various
operating environments. Each consists of a precision–formed metal wire barrel and a copper sleeve encased in
insulating material made of nylon, polyvinyl chloride (PVC) or polyvinyl fluoride (PVF2). The insulation is color
coded (solid primary color or a primary color with a color stripe) to correspond with a specific wire size or wire
size range. The terminals, splices, and end caps accept a combination of solid and stranded wire. The wire
barrel contains serrations that provide maximum contact and tensile strength after crimping the terminal, splice,
or end cap onto the wire. The terminals are available with a variety of tongue lengths and configurations; and
the terminals, splices, and end caps are available with various wire barrel lengths and diameters to
accommodate different wire sizes, wire types, and combination of wire sizes.
The terminals, splices, and end caps are available in loose piece form to be terminated with manual and
pneumatically–powered hand held tools and tape mounted to be terminated with bench mount semi–automatic
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.
Right Angle Ring Tongue
Right-Angle Rectangular Tongue
Multiple Stud Hole
Figure 1 (Cont’d)
In-Line Ring Tongue
In-Line Rectangular Tongue
Offset Ring Tongue
Knife Connect/Disconnect
Hook Tongue
Spring Spade Tongue
Flanged Spade Tongue
Copper
Sleeve
Insulation
Terminal
Tongue
Wire Barrel
NOTE
i
PIDG Terminals, Splices, and End Caps 114-2157
Rev
E2
of 14 Tyco Electronics Corporation
Figure 1 (End)
Window
Opaque Insulation
Wire Barrel
Copper
Sleeve
Transparent Insulation Window
End Cap
Insulation
Butt Splice
2. REFERENCE MATERIAL
2.1. Revision Summary
Revisions to this application specification include:
S
Updated document to corporate requirements
S
Added NOTE to Paragraph 3.5, I
S
Added specifications to Paragraph 2.6
S
Removed Applicator 818057–2 and Machine 818380–1
2.2. Customer Assistance
Reference Product Base Part Number 51864 and Product Code 3022 are representative of PIDG terminals,
splices, and end 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. Specifications
Product Specification 108–11023 provides test and performance results for insulated terminals and splices for
Class 1 E Nuclear applications.
2.5. 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:
408–1261 Hand Crimping Tools 59239–4 and 59287–2
408–1559 Hand Crimping Tools 46121, 47386, and 47387
408–1610 “T”–Head Crimping Tools 59250 and 59275
408–1632 Terminal and Splice Crimping Dies 69344, 47806–2, 47807–1, 47808–5, and 47808–6
408–2095 Hand Crimping Tool 69710–1
408–2423 Crimping Die Assemblies for Tape–Mounted PIDG Terminals and Splices
408–2498 Crimping Head Cross Reference for Pneumatic Tools
408–2822 Crimping Die Assemblies 59826–1, 59827–1, and 59828–1
408–2823 TETRA–CRIMP* Hand Crimping Tool 59824–1
408–3295 Preparing (Reel–Wrap) Reel of Contacts for Applicator Tooling
408–4099 Pneumatic TETRA–CRIMP Adapter 679305–1
408–4105 Straight Action Crimper 217200–[ ]
PIDG Terminals, Splices, and End Caps 114-2157
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Tyco Electronics Corporation
408–7424 Checking Terminal Crimp Height or Gaging Die Closure
408–8044 Miniature Quick–Change Applicator for Tape–Mounted Closed Barrel Terminals
408–8053 Miniature Quick–Change Applicators
408–8082 Miniature Quick–Change Applicators (Side–Feed Type) with Air Feed
408–9252 PRO–CRIMPER* III Hand Crimping Tool 58433–3
408–9586 Pneumatic Crimping Heads 314269–1, 314270–3, and 314537–1
408–9640 Crimp Quality Monitor Applicators for Side–Feed and End–Feed Applications
408–9816 Handling of Reeled Products
409–1993 AMP–TAPETRONIC* Machine 69875
409–5842 AMP–O–LECTRIC* Model “G” Terminating Machine 354500–1
409–5862 626 Pneumatic Tooling Assemblies 189721–[ ]
409–5878 AMPOMATOR* CLS IV+ Lead–Making Machines 356500–[ ]
2.6. Standards and Publications
Military specifications provide industry test and performance requirements. Documents available which pertain
to this product are:
MIL–T 7928/1, “Terminal, Lug and Splices, Conductor, Crimp Style, Copper Terminal, Lug, Crimp Style,
Copper, Insulated, Ring Tongue, for Thin Wall Wire, Type II, Class I for 105
_
C Total Conductor
Temperature”
MIL–T 7928/4, “Terminals, Lug and Splices, Conductor, Crimp Style, Copper Terminal, Lug, Insulated, Ring
Tongue, Bell–Mounted Type II, Class I for 150
_
C Total Conductor Temperature”
MIL–T 7928/5, “Terminals, Lug and Splices, Conductor, Crimp Style”
MIL–T 7928/6, “Terminals, Lug and Splices, Conductor, Crimp Style, Splice, Electric, (Permanent, Type II,
Class 1) for 150
_
C Total Conductor Temperature”
MS 17182, “Terminal, Lug, Crimp Style, Copper, Insulated (Servo Components), Type II, Class I for 125
_
C
Total Conductor Temperature”
MS 25036, “Terminal, Lug, Crimp Style, Copper, Insulated, Ring Tongue, Bell Mouthed, Type II, Class 1 for
105
_
C Total Conductor Temperature”
MS 25274, “Cap, Electrical (Wire End, Crimp Style, Type II, Class 1) for 105
_
C Total Conductor
Temperature”
3. REQUIREMENTS
3.1. Limitation
These terminals and end caps are suitable for 300 volts maximum, and the splices are suitable for 600 volts
maximum.
The terminals, splices, and end caps having the following insulation can withstand the following temperature
range:
nylon –40 to 105
_
C [–40 to 221
_
F]
PVC –10 to 90
_
C [14 to 194
_
F]
PVF2–65 to 150
_
C [–149 to 302
_
F]
3.2. Storage
A. Ultraviolet Light
Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the insulation.
B. Reel Storage
Tape–mounted reeled product should be stored horizontally to prevent sagging and possible stretching or
distortion of the plastic tape which could adversely affect feeding of the product through the tooling.
C. Shelf Life
The product should remain in the shipping containers until ready for use to prevent inadvertent damage.
The product should be used on a first in, first out basis to avoid storage contamination that could adversely
affect signal transmissions.
PIDG Terminals, Splices, and End Caps 114-2157
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of 14 Tyco Electronics Corporation
D. Chemical Exposure
Do not store product near chemicals listed below. They could cause stress corrosion cracking of product.
Alkalies Ammonia Citrates Phosphates Citrates Sulfur Compounds
Amines Carbonates Nitrites Sulfur Nitrites Tartrates
3.3. Wire Selection and Preparation
Terminals and splices accept solid and/or stranded wire sizes 26 through 10 AWG and end caps accept solid
and/or stranded wire sizes 22 through 10 AWG. The wire size used must be within the range stamped on the
underside of the terminal tongue or on the center of the splice or end cap. Generally, the strip length of the wire
should be equal to the wire barrel length plus 0.76 [.030]. Specific strip lengths are given in Figure 2.
Conductor
(Stranded Shown)
Note:
Not to Scale Strip Length
(See Table) Insulation
WIRE TERMINAL, SPLICE,
OR END CAP
WIRE STRIP LENGTH
SIZE (AWG) DIAMETER RANGE
OR END CAP
INSULATION COLOR TERMINAL SPLICE END CAP
26 0.66-1.40 [.026-.055] Yellow/Black 6.35-7.14 [.250-.281] Ċ Ċ
26-24 Multiple
H
Yellow 5.16-5.94 [.203-.234] 4.37-5.16 [.172-.203] Ċ
26-22 Multiple
H
Yellow 3.96-4.78 [.156-.188] 4.37-5.16 [.172-.203] Ċ
24
0 79 1 40 [ 031 055]
Yellow/Blue
4.78-5.56 [.188-.219] Ċ Ċ
[
24
[
0
.
79
-
1
.
40 [
.
031
-.
055]
Yellow/Blue
6.35-7.14 [.188-.281] Ċ Ċ
24 20
Multiple
H
White
4 78 5 56 [ 188 219]
5 56 6 35 [ 219 250]
24
-
20
Multiple
H
Natural/White
4
.
78
-
5
.
56 [
.
188
-.
219]
5
.
56
-
6
.
35 [
.
219
-.
250]
Ċ
22 0.97-2.79 [.038-.110] Red/Green 6.35-7.13 [.250-.281] Ċ Ċ
22 16
Multiple
H
Red
5 16 5 94 [ 203 234]
6 35 7 13 [ 250 281]
7.95-8.74 [.313-.344]
22
-
16
Multiple
H
Natural/Red
5
.
16
-
5
.
94 [
.
203
-.
234]
6
.
35
-
7
.
13 [
.
250
-.
281]
Ċ
20 1.17-2.79 [.046-.110] Red/Red 6.35-7.13 [.250-.281] Ċ Ċ
18 1.42-2.79 [.056-.110] Red/White 6.35-7.13 [.250-.281] Ċ Ċ
16 1.60-3.30 [.063-.130] Blue/Blue 6.35-7.13 [.250-.281] Ċ Ċ
16 14
Multiple
H
Natural/Blue
5 16 5 94 [ 203 234]
6 35 7 13 [ 250 281]
Ċ
16
-
14
Multiple
H
Blue
5
.
16
-
5
.
94 [
.
203
-.
234]
6
.
35
-
7
.
13 [
.
250
-.
281]
7.95-8.74 [.313-.344]
D
16-14
D
Multiple
H
Yellow/Black 7.93-8.71 [.312-.343] Ċ Ċ
14 1.98-3.30 [.078-.130] Blue/Green 6.35-7.13 [.250-.281] Ċ Ċ
12 10
Multiple
H
Natural/Yellow
7 93 8 71 [ 312 343]
8 71 9 53 [ 343 375]
Ċ
12
-
10
Multiple
H
Yellow
7
.
93
-
8
.
71 [
.
312
-.
343]
8
.
71
-
9
.
53 [
.
343
-.
375]
8.74-9.53 [.344-.375]
12 2.41-5.08 [.095-.200] Yellow/Yellow 9.53-10.31 [.375-.406] Ċ Ċ
10 3.02-5.08 [.119-.200] Yellow/Brown 9.53-10.31 [.375-.406] Ċ Ċ
H
Contact PRODUCT INFORMATION at the number on page 1 for acceptable insulation diameter ranges
[
Large sleeve terminal designed for Class I E Nuclear applications
D
For use with heavy–duty terminals having an insulation thickness of 1.02–1.27 [.040–.050]
Figure 2
PIDG Terminals, Splices, and End Caps 114-2157
Rev
E 5
of 14
Tyco Electronics Corporation
The wire conductor(s) must not be nicked, scraped, or cut during the stripping operation.
3.4. Wire Placement
The stripped wire must be inserted into the wire barrel until the wire insulation is against the wire barrel but not
inside it. The wire insulation must be inside the metal sleeve. A gap between the wire insulation and wire barrel
is allowed, but not to exceed the dimension given in Figure 3.
Figure 3
Wire Barrel Wire Insulation May Butt Against,
But Not Enter, Wire Barrel
1.59 [.062]
Maximum Gap
Wire Insulation Must Be
Inside Metal Sleeve
Splice
Insulation
Transparent Insulation Window Butt Splice Shown
Metal Sleeve
3.5. Crimp Requirements
A. Crimp Height
The spring–back of the terminal, splice, or end cap insulation prevents an accurate direct measurement of
crimp height. However, crimping a slug of solder (60% tin and 40% lead) with a diameter slightly larger
than the conductor outside diameter can verify proper termination. The crimp height of the resulting solder
slug can be checked with a standard micrometer or comparator. The measurement must be made over
the most compressed area of the solder slug. See Figure 4.
Some tooling with multiple crimping chambers form an embossed dot code in the terminal, splice, or end cap
insulation that indicates which crimping chamber was used. This dot code can be used as a visual inspection to ensure
that the correct wire size and crimping chamber were used.
The resilience of the 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 408-7424 for specific instructions). The solder slug diameter and crimp height must be within the
dimensions provided in Figure 4.
B. Wire Barrel Crimp Profile and Location
The wire barrel crimp produced by the tooling (dies, heads, hand tools, pneumatic tools, or machines)
must be either a confined crescent crimp which appears as a depressed oval shape or a flat rectangular
crimp over the center of the wire barrel. The crimp must be evenly formed. Refer to Figures 4, 5, and 11.
Crescent crimp tooling produces the crescent crimp, and TETRA–CRIMP tooling produces the flat
rectangular crimp. For a tooling–to–crimp profile cross–reference, refer to Figure 10.
C. Dot Code
The dot code on the insulation must be well formed and correspond with the wire size or color code
marking on the crimping chamber of the tooling used. See Figures 4 and 5.
D. Bellmouths
There shall be no rear bellmouth. The front bellmouth shall be evident on the top and bottom of the wire
barrel as shown in Figure 5. Also see Figure 11.
NOTE
i
NOTE
i
NOTE
i
PIDG Terminals, Splices, and End Caps 114-2157
'6
E6
0( 8%0 -'%420/+%3 02102#4+0/
+%20.'4'2 02
0.1#2#402
2'3%'/4 2+.1
'12'33'& 6#- *#1'
-#4 '%4#/)5-#2
2+.1
'/4'2 0( 034
0.12'33'& 2'# '('2
40 #$-' (02 2+.1 '+)*4
04 0&'
04 *07/
0-&'2 -5)
CProduced by Crescent Crimp Tooling
FProduced by TETRA–CRIMP Tooling
Crimp Inspection Using Micrometer or Comparator Wire Barrel Crimp Profile and Location
04 0&'
04 *07/ 2+.1 6'/-8 02.'& 6'2
'/4'2 0( +2' #22'-
TERMINAL SPLICE
SOLDER SLUG
WIRE SIZE
(AWG)
TERMINAL, SPLICE,
OR END CAP
DOT CODE
CRIMP HEIGHT
(AWG)
OR END CAP
INSULATION COLOR
DOT CODE
DIAMETER CRESCENT CRIMP FLAT RECTANGULAR
(Depressed Oval Shape) CRIMP
'--07-#%,
'--07
04
! "
! "
'--07
04
!
"
!
"
:
'--07-5'
*+4'
043
! "
! "
#452#-*+4'
043
!
"
!
"
:
'&2''/ 04
'&
04
! "
! "
! "
#452#-'&
04
!
"
!
"
!
"
'&'& 04
'&*+4' 04
! "
! "
! "
-5'-5' 043
!
"
!
"
!
"
-5'
043
#452#--5'
043
!" !" !"
-5'2''/ 043
D
'--07-#%, 04
'--07 '--07 04
'--07
04
!" !" !"
#452#- '--07
04
'--07207/ 04
D
02 53' 7+4* *'#68 &548 4'2.+/#-3 *#6+/) #/ +/35-#4+0/ 4*+%,/'33 2#/)' 0( !"
Figure 4
PIDG Terminals, Splices, and End Caps 114-2157
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of 14
Tyco Electronics Corporation
Figure 5
Wire Size Marking
Matches Wire Size
Overstress Marks Not
Apparent on Insulation Wire Conductor(s) Visible Within This
Area (Except Splice and End Cap,
See Detail A and Detail B)
Front Bellmouth Evident
(Top and Bottom of Wire Barrel)
Dot Code (1 Dot Shown) is Well Formed and Corresponds
With Crimping Chamber of Tooling Used
Wire Insulation Inside Metal
Sleeve But Not Inside Wire Barrel
No Flash in This Area
Wire Bottomed
in End Cap
Cutaway Show
for Clarity
No Rear Bellmouth
Wire Flush to End of Wire Barrel or
Bottomed on Stop Inside Center of Splice
Note:
Terminal Shown Ċ Same Applies to Splice and End Cap
Detail B Ċ End Cap
Detail A Ċ Splice
E. Flash
There shall be no flash or extruded insulation material visible in the most compressed area of the wire
crimp. See Figure 5.
F. Terminal, Splice, or End Cap Insulation
The insulation of the terminal, splice, or end cap must not be cut or show uneven stress marks or
highlighted marks on the insulation. See Figure 5.
G. Wire Location
1. Terminals shall have the wire ends flush or extended slightly beyond the end of the wire barrel as
shown in Figure 5.
2. Splices shall have the end of the wire located against the wire stop inside the center of the splice.
3. End caps shall have the end of the wire bottomed in the end cap.
H. Insulation Crimp Check
The insulation crimp must capture the wire insulation. The wire insulation must not be crimped inside the
wire barrel of the terminal, splice, or end cap. The wire insulation must be inside the metal sleeve to
provide strain relief for the wire. See Figure 5.
The hold of the insulation crimp can be tested by using the bend test which, if successful, indicates that
the hold is not too loose. The bend test must be performed as follows:
1. Using an
unstripped
wire, make a test crimp.
2. Hold the terminal, splice, or end cap in one hand. Use the side of one finger on the other hand at
approximately 76 [3] to push the wire up 90
_
and down 180
_
, one time each. Refer to Figure 6.
If the wire insulation comes out during the bend test, the insulation crimp is not tight enough, and the
tooling must be adjusted to produce a tighter insulation crimp. Figure 8, Detail A shows a crimp that is too
loose, providing little or no support for the wire.
PIDG Terminals, Splices, and End Caps 114-2157
Rev
E8
of 14 Tyco Electronics Corporation
If the crimp passes the bend test, the insulation crimp must be tested by pulling the wire from the terminal,
splice, or end cap. If the wire insulation is only slightly deformed, the crimp is correct. Figure 8, Detail B
shows a desired crimp, providing adequate support without damage to either the insulation or the wire
conductor(s). If there is visible damage, such as tearing or piercing of the insulation, the crimp is too tight,
and the tooling must be adjusted to produce a looser insulation crimp. Figure 8, Detail C shows a crimp
that is too tight, damaging the insulation and possibly breaking wire conductor(s) or reducing circular mil
area (CMA) by wire extrusion.
Figure 6
Hold Here
Note:
Not to Scale
Bend Test
(Test Crimp Using Unstripped Wire)
76.2 [3] (Approx)
90
°
1st Push 180
°
2nd Push
3.6. Tensile Strength
Crimped terminals, splices, or end caps should hold the wire conductor(s) firmly and have a pull–test tensile
value meeting that specified in the table in Figure 7.
Adjust tensile testing machine for head travel of 25.4 [1.0] per minute. Directly and gradually apply force for 1 minute.
WIRE SIZE TENSILE FORCE (Pull Test) Newtons [lb-force]
(AWG) COMMERCIAL REQUIREMENTS MILITARY REQUIREMENTS
26 13.4 [3] 31.1 [7]
24 22.3 [5] 44.5 [10]
22 35.6 [8] 66.7 [15]
20 57.9 [13] 84.5 [19]
18 89.0 [20] 169.0 [38]
16 133.5 [30] 222.5 [50]
14 222.5 [50] 311.5 [70]
12 311.5 [70] 489.3 [110]
10 356.0 [80] 667.2 [150]
Figure 7
NOTE
i
PIDG Terminals, Splices, and End Caps 114-2157
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Tyco Electronics Corporation
Figure 8
Detail A Ċ Too Loose Detail B Ċ Correct DetailCĊTooTight
Metal
Sleeve
Terminal, Splice, or
End Cap Insulation
Wire
Insulation
Cross-Section of Insulation Crimp at Wire End of Terminal, Splice, or End Cap
(Illustrations Represent Uppermost Wire Insulation Range of Terminal, Splice, or End Cap
(Thinner Wire Insulation May Appear Slightly Different, But Will Perform the Same, Refer to Figure 2)
3.7. Bend Allowance
Upward and downward bend of the terminated terminal, splice, or end cap must be within the tolerance
provided in Figure 9.
Figure 9
11
°
11
°
11
°
11
°
11
°
Terminal
Splice
11
°
Datum Line
Datum Line
Center of Splice
End Cap
11
°
11
°
Datum Line
Center of Crimp
Center of Crimp
3.8. Repair
Damaged or defective terminal, splice, or end cap must not be used. If damage is evident, the terminal, splice,
or end cap should be cut from the wire and replaced with a new one. Crimped terminals, splices, or end caps
MUST NOT be re–terminated or re–used by removing the wire.
PIDG Terminals, Splices, and End Caps 114-2157
Rev
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of 14 Tyco Electronics Corporation
4. QUALIFICATIONS
Most, but not all, PIDG terminals, splices, and end caps are Listed by Underwriters Laboratories Inc. (UL) in
File E13288 and Certified by CSA International in File LR7189
To determine whether a terminal, splice, or end cap (identified by part number) meets the requirements of an agency,
contact PRODUCT INFORMATION at the number at the bottom of page 1.
5. TOOLING
Hand tools for manual application of loose piece terminals, splices, or end caps, and automatic and
semi–automatic machines for power assisted application of tape–mounted terminals, splices, or end caps are
available to cover the full wire size range. Tooling part numbers and instructional material packaged with the
tooling are shown in Figure 10.
Selection of tooling will depend on the terminal, splice, or end cap requirements such as quantity of terminations,
operator training and skill, and the available support equipment (electrical, pneumatic, etc.) in the work area. Modified
designs and additional tooling concepts may be available to meet other production requirements. For additional
information, contact one of the service groups at the bottom of page 1.
5.1. Hand Tools
Hand tools consisting of a handle assembly with integral fixed jaws or dies and hand tools that accept various
die assemblies are available for loose piece terminals, splices, or end caps. Both types feature a ratchet to
ensure full crimping pressure is applied to the terminal, splice, or end cap.
5.2. Die Assemblies
Die assemblies are precision tools that form the wire barrel of the terminal, splice, or end cap onto the
conductor(s) of the wire and form the optimum crimp height. The die assemblies consist of stationary and
movable dies that are designed for a specific wire size and terminal, splice, or end cap.
A. Loose Piece Terminal, Splice, or End Cap
These die assemblies can be used in either manual or power assist tools.
B. Tape-Mounted Terminal, Splice, or End Cap
These die assemblies are designed for use in applicators installed in power units.
5.3. Applicators
Applicators are used in power units for large production applications. They feature an automatic feed
mechanism, adjustable crimp height pads, and precision crimping dies. They have been designed to simplify
tooling changes and avoid unnecessary duplication of power units.
5.4. 626 Pneumatic Tooling System
This pneumatically operated tooling system will crimp the full wire size range of the terminal, splice, or end cap.
The system is a pneumatic power unit available with a logic control for foot pedal operation or without foot
pedal for hand operation. It is designed to accept various types of crimping heads, including those that will
accept die assemblies for loose piece terminals, splices, or end caps.
5.5. Power Units
Power units provide the force needed to operate the applicator.
A. Bench-Mounted
AMP–O–LECTRIC Model “G” terminating machine and AMP–TAPETRONIC machine are designed to
accept hand–fed pre–stripped wires.
B. Floor Standing
The AMPOMATOR CLS IV+ lead–making machine can be set up to automatically cut the wire to length
and terminate it at a high rate of speed.
NOTE
i
NOTE
i
PIDG Terminals, Splices, and End Caps 114-2157
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of 14
Tyco Electronics Corporation
Pneumatic Crimping Heads
(Refer to Table)
(408-9586)
Straight Action Crimper
217200-[ ] (Accepts All
Die Assemblies Listed in
Table) (408-4105)
TETRA-CRIMP Hand
Crimping Tool (408-2823) PRO-CRIMPER III Hand
Crimping Tool (408-9252)
Hand Tools and Die Assemblies
(Refer to Table for Part Numbers)
T"-Head Hand Tools
(T-HD HT) (408-1610)
Double Action Hand Tools
(DAHT) (408-1559)
626 Pneumatic Tooling System
Terminal and Splice
Die Assemblies
(408-1632)
Heavy Head Hand Tools
(HHHT) (408-1261) Hand Crimping Tool 69710-1
(Accepts All Die Assemblies
Listed in Table) (408-2095)
TETRA-CRIMP Pneumatic
Adapter (Refer to Table)
(408-4099)
626 Pneumatic Tooling
Assemblies 189721-[ ]
(409-5862) Tool Holder Assembly
189766-[ ] (Small)
Loose Piece Terminal, Splice, or End Cap
Tool Holder Assembly
189928-1 (Straight Action)
Tool Holder Assembly
189767-[ ] (Large)
WIRE SIZE
HAND TOOL PNEUMATIC TOOLING
DIE
WIRE SIZE
(AWG) DAHT
C
T-HD HT
C
TETRA-CRIMP
Hand Tool
F
PRO-CRIMPER
Hand Tool
C
HHHT
C
Crimping
Head
C
TETRA-CRIMP
Adapter
F
DIE
ASSEMBLY
V
C
26-22 46121 59275 Ċ Ċ Ċ 314537-1 Ċ 0-69344-0
22-18 Ċ 59250 Ċ Ċ Ċ Ċ Ċ Ċ
22-16 47386 59250 59824-1 58433-3 Ċ 314270-3 Ċ 47806-2
H
16-14
H
47387 59250 59824-1 58433-3 Ċ 314269-1 Ċ 47807-1
16-14
D
and 12-10 Ċ Ċ 59824-1 58433-3 59239-4 or
59287-2
Z
Ċ 679305-1
D
47808-6 or
47808-5
Z
H
For use with terminals having an insulation thickness range of 0.51-0.84 [.020-.033].
D
For use with heavy duty terminals having an insulation thickness of 1.02-1.27 [.040 -.050].
Z
For use with wire having a maximum insulation diameter of 7.62 [.300].
CP
roduces Crescent Crimp
F
Produces Flat Rectangular Crimp
V
For use with Tool 69710-1 or Crimper 217200-[ ]
Figure 10 (Cont’d)
PIDG Terminals, Splices, and End Caps 114-2157
Rev
E12
of 14 Tyco Electronics Corporation
Die Assemblies 69872, 69873, 69874,
69877, and 69897 (408-2423)
Die Assemblies 59826-1, 59827-1,
and 59828-1 (408-2822)
AMP-TAPETRONIC Machine
69875(409-1993)
AMPOMATOR CLS IV+
Lead-Making Machine 356500-[ ]
(409-5878)
AMP-O-LECTRIC Model G"
Terminating Machine 354500-1
(409-5842)
Miniature Quick-Change Applicator
567200-3 (408-8082)
Miniature Quick-Change Applicator
687658-1 (408-8044 )
Tape-Mounted Terminal, Splice, or End Cap
Power UnitsDie Assemblies and Applicators
WIRE SIZE
APPLICATOR
WIRE SIZE
(AWG) DIE ASSEMBLY AMP-TAPETRONIC
Machine AMP-O-LECTRIC Model G"
Terminating Machine AMPOMATOR CLS IV+
Lead-Making Machine
26-22 69877
C
22-16 69872
C
or 59826-1
F
H
16-14
H
69873
C
or 59827-1
F
Included with Machine 567200-3 687658-1
16-14
D
and 12-10 69874
Z
C
or
59828-1
Z
F
or 69897
C
H
For use with terminals having an insulation thickness range of 0.51–0.84 [.020–.033].
D
For use with heavy duty terminals having an insulation thickness of 1.02–1.27 [.040 –.050].
Z
For use with wire having a maximum insulation diameter of 7.62 [.300].
CProduces Crescent Crimp
FProduces Flat Rectangular Crimp
Figure 10 (End)
PIDG Terminals, Splices, and End Caps 114-2157
Rev
E 13
of 14
Tyco Electronics Corporation
6. VISUAL AID
Figure 11 shows a typical application of PIDG terminals, splices, and end caps. This illustration should be used
by production personnel to ensure a correctly applied terminal, splice, or end cap. 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 11. VISUAL AID (CONT’D)
END OF TERMINAL, SPLICE, OR
END CAP MUST NOT
BE BENT OR DEFORMED
CRIMP MUST BE EVENLY
FORMED ACROSS CENTER
OF WIRE BARREL
INSULATION OF TERMINAL, SPLICE, OR END CAP
MUST BE FORMED OVER WIRE INSULATION
WIRE MUST BE VISIBLE
AT END OF WIRE BARREL
IF APPLICABLE, DOT CODE MUST BE
WELL FORMED AND CORRESPOND
WITH WIRE SIZE MARKING ON TOOLING
TERMINAL, SPLICE, OR END CAP
MUST BE STRAIGHT AND NOT
TWISTED ALONG AXIS
INSULATION OF TERMINAL, SPLICE, OR END CAP
MUST BE EVENLY FORMED WITHOUT
OVERSTRESS MARKS
WIRE INSULATION MUST BE INSIDE
METAL SLEEVE OF TERMINAL,
SPLICE, OR END CAP
INSULATION OF TERMINAL, SPLICE, OR
END CAP MUST NOT BE CUT OR TORN
FRONT BELLMOUTH
MUST BE EVIDENT
WIRE MUST BE BOTTOMED
IN END CAP
EACH WIRE MUST BE FLUSH
TO END OF WIRE BARREL
OR BOTTOMED ON STOP
PIDG Terminals, Splices, and End Caps 114-2157
Rev
E14
of 14 Tyco Electronics Corporation
FIGURE 11. VISUAL AID (END)
PROPER CRIMP
CRIMP CENTERED ON WIRE BARREL
FRONT BELLMOUTH ON
TOP OF INSULATION
FRONT BELLMOUTH
ON TOP AND BOTTOM
OF WIRE BARREL
SMALL AMOUNT OF SPACE
BETWEEN WIRE CONDUCTOR(S)
AND WIRE BARREL
Detail A Detail B (Insulation and Metal Sleeve Removed)
IMPROPER CRIMP
CRIMP TOO FAR FRONT ON WIRE BARREL
NO BELLMOUTH ON
TOP OF WIRE BARREL
NO SPACE
BETWEEN WIRE CONDUCTOR(S)
AND WIRE BARREL
FRONT BELLMOUTH ON
TOP OF INSULATION
TOO LARGE
NO BELLMOUTH ON
BOTTOM OF WIRE BARREL
TOO MUCH SPACE
BETWEEN WIRE CONDUCTOR(S)
AND WIRE BARREL
CRIMP TOO FAR BACK ON WIRE BARREL
Detail A Detail B (Insulation and Metal Sleeve Removed)
Detail A Detail B (Insulation and Metal Sleeve Removed)
NO BELLMOUTH ON
TOP OF INSULATION
