ApplicationSpecificationPre-InsulatedDiamondGrip(PIDG*)114--2157 ... - PDF document

ApplicationSpecificationPre-InsulatedDiamondGrip(PIDG*)114--2157 of14LOCB2011TycoElectronicsCorporation,aTEConnectivityLtd.CompanyAllRightsReserved*TrademarkTEConnectivity,TEconnectivity(logo),andTE(logo)aretrademarks.Otherlogos,productand/orCompanynamesmaybetrademarksoftheirrespectiveowners.TOOLINGASSISTANCECENTER1--800--722--1111PRODUCTINFORMATION1--800--522--6752Thiscontrolleddocumentissubjecttochange.ForlatestrevisionandRegionalCustomerService,visitourwebsiteatwww.te.comTerminals,Splices,andEndCaps 03MAY11RevGAllnumericalvaluesareinmetricunits[withU.S.customaryunitsinbrackets].Dimensionsareinmillimeters[andinches].Unlessotherwisespecified,dimensionshaveatoleranceof+ 0.13[+ .005]andangleshaveatoleranceof+ Figuresandillustrationsareforidentificationonlyandarenotdrawntoscale.1.INTRODUCTIONThisspecificationcoverstherequirementsforapplicationofPIDGterminals,splices,andendcapsinvariousoperatingenvironments.Eachconsistsofaprecision--formedmetalwirebarrelandacoppersleeveencasedininsulatingmaterialmadeofnylon,polyvinylchloride(PVC)orpolyvinylfluoride(PVF).Theinsulationiscolor In--LineRingTongueIn--LineRectangularTongueOffsetRingTongueKnifeConnect/DisconnectHookTongueSpringSpadeTongueFlangedSpadeTongue CopperSleeve Insulation Terminal TongueWireBarrel 114-2157 Revof14 Figure1(End) WindowOpaqueInsulationWireBarrelCopperSleeve TransparentInsulationWindowEndCapInsulation ButtSplice2.REFERENCEMATERIAL2.1.RevisionSummaryRevisionstothisapplicationspecificationinclude:Changedcompanylogo2.2.CustomerAssistanceReferenceProductBasePartNumber51864andProductCode3022arerepresentativeofPIDGterminals,splices,andendcaps.Useofthesenumberswillidentifytheproductlineandexpediteyourinquiriesthroughaservicenetworkestablishedtohelpyouobtainproductandtoolinginformation.SuchinformationcanbeobtainedthroughalocalRepresentativeor,afterpurchase,bycallingPRODUCTINFORMATIONatthenumberatthebottomofpage1.2.3.DrawingsCustomerDrawingsforproductpartnumbersareavailablefromtheservicenetwork.IfthereisaconflictbetweentheinformationcontainedintheCustomerDrawingsandthisspecificationorwithanyothertechnicaldocumentationsupplied,callPRODUCTINFORMATIONatthenumberatthebottomofpage1.2.4.SpecificationsProductSpecification108--11023providestestandperformanceresultsforinsulatedterminalsandsplicesforClass1ENuclearapplications.2.5.InstructionalMaterialInstructionSheets(408--series)provideproductassemblyinstructionsortoolingsetupandoperationproceduresandCustomerManuals(409--series)providemachinesetupandoperationprocedures.Documentsavailablewhichpertaintothisproductare:408--1261HandCrimpingTools59239--4and59287--2408--1559HandCrimpingTools46121,47386,and47387408--1610“T”--HeadCrimpingTools59250and59275408--1632TerminalandSpliceCrimpingDies69344,47806--2,47807--1,47808--5,and47808--6408--2095HandCrimpingTool69710--1408--2423CrimpingDieAssembliesforTape--MountedPIDGTerminalsandSplices408--2498CrimpingHeadCrossReferenceforPneumaticTools408--2822CrimpingDieAssemblies59826--1,59827--1,and59828--1408--2823TETRA--CRIMP*HandCrimpingTool59824--1408--3295Preparing(Reel--Wrap)ReelofContactsforApplicatorTooling408--4099PneumaticTETRA--CRIMPAdapter679305--1408--4105StraightActionCrimper217200--[]408--7424CheckingTerminalCrimpHeightorGagingDieClosure408--8044MiniatureQuick--ChangeApplicatorforTape--MountedClosedBarrelTerminals408--8053MiniatureQuick--ChangeApplicators 114-2157 Revof14408--8082MiniatureQuick--ChangeApplicators(Side--FeedType)withAirFeed408--9252PRO--CRIMPER*IIIHandCrimpingTool58433--3408--9586PneumaticCrimpingHeads314269--1,314270--3,and314537--1408--9640CrimpQualityMonitorApplicatorsforSide--FeedandEnd--FeedApplications408--9816HandlingofReeledProducts409--1993AMP--TAPETRONIC*Machine69875409--5842AMP--O--LECTRIC*Model“G”TerminatingMachine354500--1409--5862626PneumaticToolingAssemblies189721--[]409--5878AMPOMATOR*CLSIV+Lead--MakingMachines356500--[]2.6.StandardsandPublicationsMilitaryspecificationsprovideindustrytestandperformancerequirements.Documentsavailablewhichpertaintothisproductare:MIL--T7928/1,“Terminal,LugandSplices,Conductor,CrimpStyle,CopperTerminal,Lug,CrimpStyle,Copper,Insulated,RingTongue,forThinWallWire,TypeII,ClassIfor105CTotalConductorTemperature”MIL--T7928/4,“Terminals,LugandSplices,Conductor,CrimpStyle,CopperTerminal,Lug,Insulated,RingTongue,Bell--MountedTypeII,ClassIfor150CTotalConductorTemperature”MIL--T7928/5,“Terminals,LugandSplices,Conductor,CrimpStyle”MIL--T7928/6,“Terminals,LugandSplices,Conductor,CrimpStyle,Splice,Electric,(Permanent,TypeII,Class1)for150CTotalConductorTemperature”MS17182,“Terminal,Lug,CrimpStyle,Copper,Insulated(ServoComponents),TypeII,ClassIfor125TotalConductorTemperature”MS25036,“Terminal,Lug,CrimpStyle,Copper,Insulated,RingTongue,BellMouthed,TypeII,Class1forCTotalConductorTemperature”MS25274,“Cap,Electrical(WireEnd,CrimpStyle,TypeII,Class1)for105CTotalConductorTemperature”3.REQUIREMENTS3.1.LimitationTheseterminalsandendcapsaresuitablefor300voltsmaximum,andthesplicesaresuitablefor600voltsmaximum.Theterminals,splices,andendcapshavingthefollowinginsulationcanwithstandthefollowingtemperaturerange:nylon--40to105C[--40to221PVC--10to90C[14to194--65to150C[--149to3023.2.StorageA.UltravioletLightProlongedexposuretoultravioletlightmaydeterioratethechemicalcompositionusedintheinsulation.B.ReelStorageTape--mountedreeledproductshouldbestoredhorizontallytopreventsaggingandpossiblestretchingordistortionoftheplastictapewhichcouldadverselyaffectfeedingoftheproductthroughthetooling.C.ShelfLifeTheproductshouldremainintheshippingcontainersuntilreadyforusetopreventinadvertentdamage.Theproductshouldbeusedonafirstin,firstoutbasistoavoidstoragecontaminationthatcouldadverselyaffectsignaltransmissions. 114-2157 Revof14D.ChemicalExposureDonotstoreproductnearchemicalslistedbelow.Theycouldcausestresscorrosioncrackingofproduct.AlkaliesAmmoniaCitratesPhosphatesCitratesSulfurCompoundsAminesCarbonatesNitritesSulfurNitritesTartrates3.3.WireSelectionandPreparationTerminalsandsplicesacceptsolidand/orstrandedwiresizes26through10AWGandendcapsacceptsolidand/orstrandedwiresizes22through10AWG.Thewiresizeusedmustbewithintherangestampedontheundersideoftheterminaltongueoronthecenterofthespliceorendcap.Generally,thestriplengthofthewireshouldbeequaltothewirebarrellengthplus0.76[.030].SpecificstriplengthsaregiveninFigure2.Conductor(StrandedShown)Note:NottoScale StripLength(SeeTable)Insulation WIRE TERMINAL,SPLICE, WIRESTRIPLENGTH SIZE(AWG) DIAMETERRANGE ORENDCAPINSULATIONCOLOR TERMINAL SPLICE ENDCAP 0.66--1.40[.026--.055] Yellow/Black 6.35--7.14[.250--.281] — 26--24 Multiple Yellow 5.16--5.94[.203--.234] 4.37--5.16[.172--.203] 26--22 Multiple Yellow 3.96--4.78[.156--.188] 4.37--5.16[.172--.203] 4.78--5.56[.188--.219] — 0.79--1.40[.031--.055] Blue 6.35--7.14[.188--.281] — 2 4 2 0 M u l t i p l e White 24--20 Multiple Natural/White 4.78--5.56[.188--.219 5.56--6.35[.219--.250] 0.97--2.79[.038--.110] Red/Green 6.35--7.13[.250--.281] — 2 2 1 6 M u l t i p l e Red 7.95--8.74[.313--.344] 22--16 Multiple Natural/Red 5.16--5.94[.203--.234 6.35--7.13[.250--.281] 1.17--2.79[.046--.110] Red/Red 6.35--7.13[.250--.281] — 1.42--2.79[.056--.110] Red/White 6.35--7.13[.250--.281] — 1.60--3.30[.063--.130] Blue/Blue 6.35--7.13[.250--.281] — 1 6 1 4 M u l t i p l e Natural/Blue 16--14 Multiple Blue 5.16--5.94[.203--.234 6.35--7.13[.250--.281] 7.95--8.74[.313--.344] 16--14 Multiple Yellow/Black 7.93--8.71[.312--.343] — 1.98--3.30[.078--.130] Blue/Green 6.35--7.13[.250--.281] — 1 2 1 0 M u l t i p l e Natural/Yellow 12--10 Multiple Yellow 7.93--8.71[.312--.343 8.71--9.53[.343--.375] 8.74--9.53[.344--.375] 2.41--5.08[.095--.200] Yellow/Yellow 9.53--10.31[.375--.406] — 3.02--5.08[.119--.200] Yellow/Brown 9.53--10.31[.375--.406] — ContactPRODUCTINFORMATIONatthenumberonpage1foracceptableinsulationdiameterrangesangesLargesleeveterminaldesignedforClassIENuclearapplicationsForusewithheavy--dutyterminalshavinganinsulationthicknessof1.02--1.27[.040--.050]Figure2 114-2157 Revof14Thewireconductor(s)mustnotbenicked,scraped,orcutduringthestrippingoperation.3.4.WirePlacementThestrippedwiremustbeinsertedintothewirebarreluntilthewireinsulationisagainstthewirebarrelbutnotinsideit.Thewireinsulationmustbeinsidethemetalsleeve.Agapbetweenthewireinsulationandwirebarrelisallowed,butnottoexceedthedimensiongiveninFigure3. Figure3WireBarrel WireInsulationMayButtAgainst,ButNotEnter,WireBarrel 1.59[.062]MaximumGapWireInsulationMustBeInsideMetalSleeveSpliceInsulation TransparentInsulationWindowButtSpliceShown MetalSleeve 3.5.CrimpRequirementsA.CrimpHeightThespring--backoftheterminal,splice,orendcapinsulationpreventsanaccuratedirectmeasurementofcrimpheight.However,crimpingaslugofsolder(60%tinand40%lead)withadiameterslightlylargerthantheconductoroutsidediametercanverifypropertermination.Thecrimpheightoftheresultingsolderslugcanbecheckedwithastandardmicrometerorcomparator.Themeasurementmustbemadeoverthemostcompressedareaofthesolderslug.SeeFigure4.Sometoolingwithmultiplecrimpingchambersformanembosseddotcodeintheterminal,splice,orendcapinsulationthatindicateswhichcrimpingchamberwasused.Thisdotcodecanbeusedasavisualinspectiontoensurethatthecorrectwiresizeandcrimpingchamberwereused.Theresilienceofthespliceinsulationpreventsaccuratedirectmeasurementofcrimpheight.Crimpheightcanbeobtainedbymeasuringacrimpedsolderslug(60%tinand40%lead)withadiametercomparabletothewiresize.Theslugmustbemeasuredoverthemostcompressedareaoftheslugwithastandardmicrometerorcrimpheightcomparator(referto408--7424forspecificinstructions).ThesolderslugdiameterandcrimpheightmustbewithinthedimensionsprovidedinFigure4.B.WireBarrelCrimpProfileandLocationThewirebarrelcrimpproducedbythetooling(dies,heads,handtools,pneumatictools,ormachines)mustbeeitheraconfinedcrescentcrimpwhichappearsasadepressedovalshapeoraflatrectangularcrimpoverthecenterofthewirebarrel.Thecrimpmustbeevenlyformed.RefertoFigures4,5,and11.Crescentcrimptoolingproducesthecrescentcrimp,andTETRA--CRIMPtoolingproducestheflatrectangularcrimp.Foratooling--to--crimpprofilecross--reference,refertoFigure10.C.DotCodeThedotcodeontheinsulationmustbewellformedandcorrespondwiththewiresizeorcolorcodemarkingonthecrimpingchamberofthetoolingused.SeeFigures4and5.D.BellmouthsThereshallbenorearbellmouth.ThefrontbellmouthshallbeevidentonthetopandbottomofthewirebarrelasshowninFigure5.AlsoseeFigure11. 114-2157 Revof14 MicrometerorComparatorCrescentCrimp(DepressedOvalShape)FlatRectangularCrimp CenterofMostCompressedArea(RefertoTableforCrimpHeight) DotCode(1DotShown) SolderSlugProducedbyCrescentCrimpToolingProducedbyTETRA--CRIMPTooling r i m p I n s n U s i n g M i c r o m ete r a r a i r e B a r r e l C r i m p P r a n dLoc i o n DotCode(1DotShown) CrimpEvenlyFormedOverCenterofWireBarrel SOLDERSLUG WIRESIZE TERMINAL,SPLICE, CRIMPHEIGHT (AWG) INSULATIONCOLOR DIAMETER CRESCENTCRIMP FLATRECTANGULAR (DepressedOvalShape) CRIMP Yellow/Black 26--24 Yellow 26--22 Yellow 1Dot 3.18[.125 1.60--1.75[.063--.069] Yellow/Blue White 24--20 Natural/White 2Dots 3.18[.125 2.26--2.41[.089--.095] Red/Green 1Dot Red 22--16 Natural/Red 1Dot 3.18[.125 2.77--2.92[.109--.115] 1.98--2.18[.078--.086 Red/Red 1Dot Red/White 1Dot Blue/Blue 2Dots 3.18[.125 3.02--3.18[.119--.125] 2.34--2.54[.092--.100 Blue 16--14 Natural/Blue 2Dots 4.76[.187] 3.02--3.18[.119--.125] 2.34--2.54[.092--.100] Blue/Green 2Dots 16--14 Yellow/Black 1Dot Yellow/Yellow 1Dot Yellow 6.35[.250] 4.29--4.45[.169--.175] 3.25--3.45[.128--.136] 12--10 Natural/Yellow 1Dot Yellow/Brown 1Dot Forusewithheavydutyterminalshavinganinsulationthicknessrangeof1.02--1.27[.040--.050].Figure4 114-2157 Revof14Figure5WireSizeMarkingMatchesWireSize OverstressMarksNotApparentonInsulation WireConductor(s)VisibleWithinThisArea(ExceptSpliceandEndCap,SeeDetailAandDetailB) FrontBellmouthEvident(TopandBottomofWireBarrel)DotCode(1DotShown)isWellFormedandCorrespondsWithCrimpingChamberofToolingUsed WireInsulationInsideMetalSleeveButNotInsideWireBarrel NoFlashinThisArea WireBottomedinEndCapCutawayShowforClarity NoRearBellmouth WireFlushtoEndofWireBarrelorBottomedonStopInsideCenterofSplice Note:TerminalShown—SameAppliestoSpliceandEndCapDetailB—EndCapDetailA—Splice E.FlashThereshallbenoflashorextrudedinsulationmaterialvisibleinthemostcompressedareaofthewirecrimp.SeeFigure5.F.Terminal,Splice,orEndCapInsulationTheinsulationoftheterminal,splice,orendcapmustnotbecutorshowunevenstressmarksorhighlightedmarksontheinsulation.SeeFigure5.G.WireLocation1.TerminalsshallhavethewireendsflushorextendedslightlybeyondtheendofthewirebarrelasshowninFigure5.2.Splicesshallhavetheendofthewirelocatedagainstthewirestopinsidethecenterofthesplice.3.Endcapsshallhavetheendofthewirebottomedintheendcap.H.InsulationCrimpCheckTheinsulationcrimpmustcapturethewireinsulation.Thewireinsulationmustnotbecrimpedinsidethewirebarreloftheterminal,splice,orendcap.Thewireinsulationmustbeinsidethemetalsleevetoprovidestrainreliefforthewire.SeeFigure5.Theholdoftheinsulationcrimpcanbetestedbyusingthebendtestwhich,ifsuccessful,indicatesthattheholdisnottooloose.Thebendtestmustbeperformedasfollows:1.Usinganunstrippedwire,makeatestcrimp 2.Holdtheterminal,splice,orendcapinonehand.Usethesideofonefingerontheotherhandatapproximately76[3]topushthewireup90anddown180,onetimeeach.RefertoFigure6.Ifthewireinsulationcomesoutduringthebendtest,theinsulationcrimpisnottightenough,andthetoolingmustbeadjustedtoproduceatighterinsulationcrimp.Figure8,DetailAshowsacrimpthatistooloose,providinglittleornosupportforthewire. 114-2157 Revof14Ifthecrimppassesthebendtest,theinsulationcrimpmustbetestedbypullingthewirefromtheterminal,splice,orendcap.Ifthewireinsulationisonlyslightlydeformed,thecrimpiscorrect.Figure8,DetailBshowsadesiredcrimp,providingadequatesupportwithoutdamagetoeithertheinsulationorthewireconductor(s).Ifthereisvisibledamage,suchastearingorpiercingoftheinsulation,thecrimpistootight,andthetoolingmustbeadjustedtoproducealooserinsulationcrimp.Figure8,DetailCshowsacrimpthatistootight,damagingtheinsulationandpossiblybreakingwireconductor(s)orreducingcircularmilarea(CMA)bywireextrusion.Figure6 HoldHere Note:NottoScaleBendTest(TestCrimpUsingUnstrippedWire) 76.2[3](Approx) 1stPush 2ndPush 3.6.TensileStrengthCrimpedterminals,splices,orendcapsshouldholdthewireconductor(s)firmlyandhaveapull--testtensilevaluemeetingthatspecifiedinthetableinFigure7.Adjusttensiletestingmachineforheadtravelof25.4[1.0]perminute.Directlyandgraduallyapplyforcefor1minute.WIRESIZE TENSILEFORCE(PullTest)Newtons[lb--force] (AWG) COMMERCIALREQUIREMENTS MILITARYREQUIREMENTS 13.4[3] 31.1[7] 22.3[5] 44.5[10] 35.6[8] 66.7[15] 57.9[13] 84.5[19] 89.0[20] 169.0[38] 133.5[30] 222.5[50] 222.5[50] 311.5[70] 311.5[70] 489.3[110] 356.0[80] 667.2[150] Figure7 114-2157 Revof14Figure8 DetailA—TooLooseDetailB—CorrectDetailC—TooTight MetalSleeveTerminal,Splice,orEndCapInsulationWireInsulation Cross-SectionofInsulationCrimpatWireEndofTerminal,Splice,orEndCap(IllustrationsRepresentUppermostWireInsulationRangeofTerminal,Splice,orEndCap(ThinnerWireInsulationMayAppearSlightlyDifferent,ButWillPerformtheSame,RefertoFigure2) 3.7.BendAllowanceUpwardanddownwardbendoftheterminatedterminal,splice,orendcapmustbewithinthetoleranceprovidedinFigure9.Figure9 TerminalSpliceDatumLineDatumLineCenterofSplice EndCap DatumLine CenterofCrimp CenterofCrimp 3.8.RepairDamagedordefectiveterminal,splice,orendcapmustnotbeused.Ifdamageisevident,theterminal,splice,orendcapshouldbecutfromthewireandreplacedwithanewone.Crimpedterminals,splices,orendcapsMUSTNOTbere--terminatedorre--usedbyremovingthewire. 114-2157 Revof144.QUALIFICATIONSMost,butnotall,PIDGterminals,splices,andendcapsareListedbyUnderwritersLaboratoriesInc.(UL)inFileE13288andCertifiedbyCSAInternationalinFileLR7189.Todeterminewhetheraterminal,splice,orendcap(identifiedbypartnumber)meetstherequirementsofanagency,contactPRODUCTINFORMATIONatthenumberatthebottomofpage1.5.TOOLINGHandtoolsformanualapplicationofloosepieceterminals,splices,orendcaps,andautomaticandsemi--automaticmachinesforpowerassistedapplicationoftape--mountedterminals,splices,orendcapsareavailabletocoverthefullwiresizerange.ToolingpartnumbersandinstructionalmaterialpackagedwiththetoolingareshowninFigure10.Selectionoftoolingwilldependontheterminal,splice,orendcaprequirementssuchasquantityofterminations,operatortrainingandskill,andtheavailablesupportequipment(electrical,pneumatic,etc.)intheworkarea.Modifieddesignsandadditionaltoolingconceptsmaybeavailabletomeetotherproductionrequirements.Foradditionalinformation,contactoneoftheservicegroupsatthebottomofpage1.5.1.HandToolsHandtoolsconsistingofahandleassemblywithintegralfixedjawsordiesandhandtoolsthatacceptvariousdieassembliesareavailableforloosepieceterminals,splices,orendcaps.Bothtypesfeaturearatchettoensurefullcrimpingpressureisappliedtotheterminal,splice,orendcap.5.2.DieAssembliesDieassembliesareprecisiontoolsthatformthewirebarreloftheterminal,splice,orendcapontotheconductor(s)ofthewireandformtheoptimumcrimpheight.Thedieassembliesconsistofstationaryandmovablediesthataredesignedforaspecificwiresizeandterminal,splice,orendcap.A.LoosePieceTerminal,Splice,orEndCapThesedieassembliescanbeusedineithermanualorpowerassisttools.B.Tape-MountedTerminal,Splice,orEndCapThesedieassembliesaredesignedforuseinapplicatorsinstalledinpowerunits.5.3.ApplicatorsApplicatorsareusedinpowerunitsforlargeproductionapplications.Theyfeatureanautomaticfeedmechanism,adjustablecrimpheightpads,andprecisioncrimpingdies.Theyhavebeendesignedtosimplifytoolingchangesandavoidunnecessaryduplicationofpowerunits.5.4.626PneumaticToolingSystemThispneumaticallyoperatedtoolingsystemwillcrimpthefullwiresizerangeoftheterminal,splice,orendcap.Thesystemisapneumaticpowerunitavailablewithalogiccontrolforfootpedaloperationorwithoutfootpedalforhandoperation.Itisdesignedtoacceptvarioustypesofcrimpingheads,includingthosethatwillacceptdieassembliesforloosepieceterminals,splices,orendcaps.5.5.PowerUnitsPowerunitsprovidetheforceneededtooperatetheapplicator.A.Bench-MountedAMP--O--LECTRICModel“G”terminatingmachineandAMP--TAPETRONICmachinearedesignedtoaccepthand--fedpre--strippedwires.B.FloorStandingTheAMPOMATORCLSIV+lead--makingmachinecanbesetuptoautomaticallycutthewiretolengthandterminateitatahighrateofspeed. 114-2157 Revof14 PneumaticCrimpingHeads(RefertoTable)(408--9586) StraightActionCrimper217200--[](AcceptsAllDieAssembliesListedinTable)(408--4105) TETRA--CRIMPHandCrimpingTool(408--2823)PRO--CRIMPERIIIHandCrimpingTool(408--9252)HandToolsandDieAssemblies(RefertoTableforPartNumbers)“T”--HeadHandTools(T--HDHT)(408--1610)DoubleActionHandTools(DAHT)(408--1559)626PneumaticToolingSystemTerminalandSpliceDieAssemblies(408--1632)HeavyHeadHandTools(HHHT)(408--1261) HandCrimpingTool69710--1(AcceptsAllDieAssembliesListedinTable)(408--2095) TETRA--CRIMPPneumaticAdapter(RefertoTable)(408--4099) 626PneumaticToolingAssemblies189721--[](409--5862)ToolHolderAssembly189766--[](Small) P i r m i n a l , r E n ToolHolderAssembly189928--1(StraightAction)ToolHolderAssembly189767--[](Large) HANDTOOL PNEUMATICTOOLING WIRESIZE(AWG) T--HDHT TETRA--CRIMPHandTool PRO--CRIMPERHandTool CrimpingHead TETRA--CRIMPAdapter DIEASSEMBLY 26--22 46121 59275 — — 314537--1 0----0 22--18 — — — — — 22--16 47386 59250 59824--1 58433--3 314270--3 47806--2 16--14 59250 59824--1 58433--3 314269--1 47807--1 16--14and12--10 — 59824--1 58433--3 59239--4or59287--2 — 679305--1 47808--6or47808--5 Forusewithterminalshavinganinsulationthicknessrangeof0.51--0.84[.020--.033].Forusewithheavydutyterminalshavinganinsulationthicknessof1.02--1.27[.040--.050].Forusewithwirehavingamaximuminsulationdiameterof7.62[.300].roducesCrescentCrimpProducesFlatRectangularCrimpForusewithTool69710--1orCrimper217200--[]Figure10(Cont’d) 114-2157 Revof14DieAssemblies69872,69873,69874,69877,and69897(408--2423)DieAssemblies59826--1,59827--1,and59828--1(408--2822)AMP--TAPETRONICMachine69875(409--1993) AMPOMATORCLSIV+Lead--MakingMachine356500--[](409--5878) AMP--O--LECTRICModel“G”TerminatingMachine354500--1(409--5842) MiniatureQuick--ChangeApplicator567200--3(408--8082)MiniatureQuick--ChangeApplicator687658--1(408--8044) Tape-MountedTerminal,Splice,orEndCapPowerUnitsDieAssembliesandApplicators APPLICATOR WIRESIZE(AWG) DIEASSEMBLY AMP--TAPETRONICMachine AMP--O--LECTRICModel“G”TerminatingMachine AMPOMATORCLSIV+Lead--MakingMachine 26--22 69877 22--16 or59826--1 16--14 or59827--1 IncludedwithMachine 567200--3 687658--1 16--14and12--10 59828--1or69897 Forusewithterminalshavinganinsulationthicknessrangeof0.51--0.84[.020--.033].Forusewithheavydutyterminalshavinganinsulationthicknessof1.02--1.27[.040--.050].Forusewithwirehavingamaximuminsulationdiameterof7.62[.300].ProducesCrescentCrimpProducesFlatRectangularCrimpFigure10(End) 114-2157 Revof146.VISUALAIDFigure11showsatypicalapplicationofPIDGterminals,splices,andendcaps.Thisillustrationshouldbeusedbyproductionpersonneltoensureacorrectlyappliedterminal,splice,orendcap.ApplicationswhichDONOTappearcorrectshouldbeinspectedusingtheinformationintheprecedingpagesofthisspecificationandintheinstructionalmaterialshippedwiththeproductortooling.FIGURE11.VISUALAID(CONT’D) ENDOFTERMINAL,SPLICE,ORENDCAPMUSTNOTBEBENTORDEFORMED CRIMPMUSTBEEVENLYFORMEDACROSSCENTEROFWIREBARREL INSULATIONOFTERMINAL,SPLICE,ORENDCAPMUSTBEFORMEDOVERWIREINSULATION WIREMUSTBEVISIBLEATENDOFWIREBARRELIFAPPLICABLE,DOTCODEMUSTBEWELLFORMEDANDCORRESPONDWITHWIRESIZEMARKINGONTOOLINGTERMINAL,SPLICE,ORENDCAPMUSTBESTRAIGHTANDNOTTWISTEDALONGAXISINSULATIONOFTERMINAL,SPLICE,ORENDCAPMUSTBEEVENLYFORMEDWITHOUTOVERSTRESSMARKS WIREINSULATIONMUSTBEINSIDEMETALSLEEVEOFTERMINAL,SPLICE,ORENDCAPINSULATIONOFTERMINAL,SPLICE,ORENDCAPMUSTNOTBECUTORTORN FRONTBELLMOUTHMUSTBEEVIDENT WIREMUSTBEBOTTOMEDINENDCAP EACHWIREMUSTBEFLUSHTOENDOFWIREBARRELORBOTTOMEDONSTOP 114-2157 Revof14FIGURE11.VISUALAID(END) PROPERCRIMPCRIMPCENTEREDONWIREBARREL FRONTBELLMOUTHONTOPOFINSULATION FRONTBELLMOUTHONTOPANDBOTTOMOFWIREBARRELSMALLAMOUNTOFSPACEBETWEENWIRECONDUCTOR(S)ANDWIREBARREL DetailADetailB(InsulationandMetalSleeveRemoved)IMPROPERCRIMPCRIMPTOOFARFRONTONWIREBARREL NOBELLMOUTHONTOPOFWIREBARRELNOSPACEBETWEENWIRECONDUCTOR(S)ANDWIREBARREL FRONTBELLMOUTHONTOPOFINSULATIONTOOLARGE NOBELLMOUTHONBOTTOMOFWIREBARRELTOOMUCHSPACEBETWEENWIRECONDUCTOR(S)ANDWIREBARRELCRIMPTOOFARBACKONWIREBARREL DetailADetailB(InsulationandMetalSleeveRemoved)DetailADetailB(InsulationandMetalSleeveRemoved) NOBELLMOUTHONTOPOFINSULATION