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Radiation Resistant/150°C Pre-Insulated Terminals and Splices The line of Tyco Electronics radiation resistant/150°C pre-insulated terminals and splices includes terminals and splices of the well-known PIDG and PLASTI-GRIP terminal designs. Radiation resistant terminals are made of fine grade, high conductivity copper with either bright tin-lead or matte tin-plating and feature polyvinylidene fluoride (PVF2) insulation for high resistance to radiation and solvents. PIDG terminals meet the performance requirements of SAE-AS7928. They are also tested by Tyco Electronics and an independent test facility and have fulfilled all requirements including radiation testing to 200 megarads and operating temperature range from -40°C to +150°C. One outstanding quality of the standard Tyco Electronics terminals, such as tapered entry ramps, help eliminate bent wire strands and insulation support for stronger, more reliable connections. Serrated or dimpled wire barrels provide maximum contact and tensile strength after crimping, and color coded insulation with wire size stamped on the terminal tongue identifies the product and assists in proper terminal-wire match. The radiation resistant/150°C terminals are designed and engineered to successfully withstand extreme vibration, shock and structural stresses, and other conditions which can adversely affect the critical circuit requirements in complex equipment. The matching Tyco Electronics tooling precisely crimps all terminations. This uniformity increases reliability and also serves as a built-in quality control factor. Radiation Resistant/150°C Pre-Insulated Terminals and Splices Ring Tongue Terminals Material and Finish: • Terminal body : copper per ASTM-B152 with bright tin/lead (93/7) {3% MIN lead content} plating per ASTM-B545 • Insulation support sleeve : copper per ASTM-B152 with bright tin/lead (93/7) {3% MIN lead content} plating per ASTM-B545 Catalog 82038 Issue Date : 7.2009 PIDG Terminals - Whisker Mitigating (Contains 3% Minimum Lead Content in Plating) Wire Range AWG 26-24 CMA [mm2] 202-509 [.10-.26] Tongue Thickness Maximun Wire Ins. Diameter Maximum .029 .74 .082 2.09 Stripe Color Code Yellow • Insulation sleeve : PVF2, natural with colored stripe 24-20 22-16 320-1,290 [.16-.65] 509-3,250 [.26-1.65] .025 .64 .033 .84 .100 2.54 .125 3.18 White Red Related Product Data • Application tooling pages 8-11 • Technical documents page 8 16-14 2,050-5,180 [1.04-2.62] .033 .84 .150 3.81 Blue Stud Size Dimensions Part Numbers Tin Plate W C1 MIN. E MAX. L MAX. Loose Tape 2 M2 .203 5.16 .211 5.35 .632 16.06 .736 18.70 53400-1 _ 4 .203 5.16 .211 5.35 .632 16.06 .736 18.70 53401-1 _ 6 M3.5 .250 6.35 .243 6.17 .664 16.87 .792 20.12 53402-1 _ 8 M4 .281 7.13 .250 6.35 .671 17.05 .814 20.68 53403-1 _ 10 .312 7.92 .281 7.13 .702 17.84 .861 21.87 53404-1 _ 6 M3.5 .281 7.13 .250 6.35 .631 16.03 .774 19.66 53809-2 _ 4 .218 5.54 .156 3.96 .560 14.23 .672 17.02 53405-1 _ 6 M3.5 .218 5.54 .156 3.96 .560 14.23 .672 17.07 53406-1 _ 6 M3.5 .250 6.35 .250 6.35 .654 16.62 .782 19.87 53407-1 53407-2 8 M4 .312 7.91 .281 7.13 .685 17.4 .844 21.44 53408-1 53408-2 10 .312 7.92 .281 7.13 .685 17.4 .844 21.44 53409-1 _ 1/4 M6 .469 11.91 .437 11.09 .841 21.37 1.078 27.39 53410-1 53410-2 5/16 M8 .469 11.91 .437 11.09 .841 21.37 1.078 27.39 53411-1 _ 3/8 .531 13.49 .546 13.86 .950 24.13 1.218 30.94 53412-1 _ 1/2 M12 .713 18.11 .530 13.46 .934 24.13 1.293 32.85 53413-1 _ 4 .250 6.35 .171 4.34 .575 14.61 .703 17.86 53414-1 _ 6 M3.5 .250 6.35 .171 4.34 .575 14.61 .703 17.86 53415-1 _ 6 M3.5 .312 7.92 .281 7.13 .685 17.4 .844 21.44 53416-1 53416-2 8 M4 .312 7.92 .281 7.13 .685 17.4 .844 21.44 53417-1 53417-2 10 .312 7.92 .281 7.13 .685 17.4 .844 21.44 53418-1 53418-2 1/4 M6 .469 11.91 .437 11.09 .841 21.37 1.078 27.39 53419-1 _ 5/16 M8 .469 11.91 .437 11.09 .841 21.37 1.078 27.39 53420-1 _ 3/8 .531 13.49 .546 13.86 .950 24.13 1.218 30.94 53421-1 _ 1/2 M12 .713 18.11 .530 13.46 .934 23.73 1.293 32.85 53422-1 _ 1-Dimension applies from edge of metal wire barrel to center of stud hole. 2 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support Canada: 1-905-475-6222 USA: 1-800-522-6752 Mexico: 01-800-733-8926 www.tycoelectronics.com Radiation Resistant/150°C Pre-Insulated Terminals and Splices Ring Tongue Terminals (continued) Catalog 82038 Issue Date : 7.2009 PIDG Terminals - Whisker Mitigating (Contains 3% Minimum Lead Content in Plating) Wire Range CMA [mm2] AWG 16-14 Heavy Duty Tongue Thickness Maximun .050 1.3 2,050-5,180 [1.04-2.62] 5,18013,100 [2.62-6.64] 12-10 Wire Ins. Diameter Maximum .230 5.84 .042 1.07 .230 5.84 Stripe Color Code Black Yellow Stud Size Dimensions Part Numbers Tin Plate W C1 MIN. E MAX. L MAX. Loose Tape 4 .281 7.14 .219 5.56 .810 20.57 .955 24.26 53963-1 _ 6 M3.5 .343 8.71 .281 7.13 .872 22.15 1.046 26.57 53964-1 _ 8 M4 .343 8.71 .281 7.13 .872 22.15 1.046 26.57 53982-1 _ 10 .343 8.71 .281 7.13 .872 22.15 1.046 26.57 53983-1 _ 1/4 M6 .531 13.49 .437 11.09 1.028 26.12 1.296 32.92 53984-1 _ 6 M3.5 .219 5.56 .250 6.35 .810 20.57 .938 23.83 54593-1 _ 6 M3.5 .375 9.53 .302 7.67 .893 22.69 1.083 27.51 53423-1 _ 8 M4 .375 9.53 .302 7.67 .893 22.69 1.083 27.51 53424-1 _ 10 .375 9.53 .302 7.67 .893 22.69 1.083 27.51 53425-1 _ 1/4 M6 .531 13.48 .468 11.88 1.054 26.78 1.322 33.58 53426-1 _ 5/16 M8 .531 13.48 .468 11.88 1.054 26.78 1.322 33.58 53427-1 _ 3/8 .593 15.06 .531 13.48 1.115 28.33 1.414 35.92 53428-1 _ 1/2 M12 .715 18.16 .474 12.04 1.054 26.77 1.414 35.92 53429-1 _ 1-Dimension applies from edge of metal wire barrel to center of stud hole. Butt Splices Material and Finish: • Splice body : copper per ASTM-B152 with bright tin/lead (93/7) {3% MIN lead content} plating per ASTM-B545 • Insulation support sleeve : copper per ASTM-B152 with bright tin/lead (93/7) {3% MIN lead content} plating per ASTM-B545 • Insulation sleeve : PVF2, natural with colored stripe PIDG Splices - Whisker Mitigating (Contains 3% Minimum Lead Content in Plating) Wire Range Barrel I.D. Minimum Stripe Color Code Wire Ins. Diameter Maximum Dimension Length Maximum AWG CMA [mm2] 26-22 202-810 [.10-.41] .029 .73 Yellow .082 2.09 24-20 320-1,290 [.16-.65] .043 1.09 White 22-16 509-3,250 [.26-1.65] .061 1.54 16-14 2,050-5,180 [1.04-2.62] 12-10 5,180-13,000 [2.62-6.64] Part Numbers Tin Plate Loose Tape .890 22.61 53546-1 - .100 2.54 1.035 26.29 53547-1 - Red .125 3.18 1.265 32.14 53548-1 53548-2 .085 2.15 Blue .150 3.81 1.265 32.14 53549-1 - .129 3.27 Yellow .220 5.59 .220 42.07 53550-1 - Related Product Data • Application tooling pages 8-11 • Technical documents page 8 3 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support Canada: 1-905-475-6222 USA: 1-800-522-6752 Mexico: 01-800-733-8926 www.tycoelectronics.com Radiation Resistant/150°C Pre-Insulated Terminals and Splices Ring Tongue Terminals Material and Finish: • Terminal body : copper per ASTM-B152 with bright tin/lead (93/7) {3% MIN lead content} plating per ASTM-B545 PLASTI-GRIP Terminals - Whisker Mitigating (Contains 3% Minimum Lead Content in Plating) Wire Range AWG • Insulation sleeve : PVF2, natural with colored stripe 8 6 Related Product Data • Application tooling pages 8-11 Catalog 82038 Issue Date : 7.2009 4 CMA [mm2] 13,100-20,800 [6.64-10.5] 20,800-33,100 [10.5-16.8] 33,100-52,600 [16.8-26.7] Tongue Thickness Maximun Wire Ins. Diameter Maximum .043 1.1 .048 1.22 .051 1.3 .380 9.66 .436 11.08 .515 13.09 Stripe Color Code Red Blue Yellow • Technical documents page 8 2 52,600-83,700 [26.7-42.4] .060 1.53 .560 14.23 Red Dimensions Part Numbers Stud Size Max. Washer Rad. W E MAX. L MAX. Loose 10 .437 11.1 .431 10.95 1.344 34.13 1.562 39.68 53978-1 1/4 M6 .437 11.1 .478 12.14 1.344 34.14 1.586 40.29 53943-1 5/16 M8 .500 12.7 .587 14.91 1.402 35.62 1.702 43.24 54947-1 3/8 .500 12.7 .587 14.91 1.406 35.72 1.702 43.24 53944-1 1/2 M12 .500 12.70 .875 22.23 1.406 35.72 1.846 46.89 53945-1 10 .421 10.7 .468 11.89 1.482 37.65 1.719 43.67 53975-1 1/4 M6 .421 10.7 .500 12.7 1.622 41.2 1.898 46.42 53946-1 3/8 .515 13.09 .625 15.88 1.591 40.42 1.905 48.42 53947-1 10 .531 13.49 .546 13.87 1.672 42.47 1.948 49.48 53949-1 1/4 M6 .531 13.49 .546 13.87 1.672 42.47 1.948 49.48 53980-1 3/8 .531 13.49 .546 13.87 1.672 42.47 2.014 51.16 53950-1 1/2 M12 .531 13.49 .679 17.25 1.672 42.47 2.014 51.16 53951-1 1/4 M6 .578 14.69 .675 17.15 1.731 43.97 2.071 52.60 53977-1 3/8 .578 14.69 .711 18.06 1.731 43.97 2.089 53.07 53953-1 1/2 M12 .578 14.69 .855 21.72 1.731 43.97 2.161 54.9 53954-1 4 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support Canada: 1-905-475-6222 USA: 1-800-522-6752 Mexico: 01-800-733-8926 www.tycoelectronics.com Radiation Resistant/150°C Pre-Insulated Terminals and Splices Catalog 82038 Issue Date : 7.2009 PIDG PVF2 Wire Pins - RoHS Compliant Wire Pins Material and Finish: • Terminal body : copper per ASTM-B152 with bright tin {99.5% MIN tin content} plating per ASTM-B545 • Insulation support sleeve : copper per ASTM-B152 with bright tin {99.5% MIN tin content} plating per ASTM-B545 • Insulation sleeve : PVF2, natural with colored stripe Bright Tin Plated Wire Range Tongue Thickness Maximun Wire Ins. Diameter Maximum Stripe Color Code AWG CMA [mm2] 22-16 493-3,158 [.25-1.6] .033 .84 .013 3.30 16-14 1,973-5,131 [1.0-2.60] .033 .84 12-10 5,131-13,025 [2.6-6.6] Dimensions Part Numbers Tin Plate Loose Tape W X MIN. L MAX. Red .071 1.80 .390 9.90 .903 22.93 737049-1 _ .154 3.90 Blue .071 1.80 .390 9.90 .903 22.93 737051-1 _ .042 1.07 .236 6.00 Yellow .102 1.80 .390 9.90 1.128 28.65 737053-1 _ Tongue Thickness Maximun Wire Ins. Diameter Maximum Stripe Color Code Matte Tin Plated Wire Pins Material and Finish: Wire Range • Terminal body : copper per ASTM-B152 with matte tin {99.5% MIN tin content} plating per ASTM-B545 • Insulation support sleeve : copper per ASTM-B152 with matte tin {99.5% MIN tin content} plating per ASTM-B545 AWG CMA [mm2] 22-16 509-3,250 [.26-1.65] .033 .84 .014 3.56 16-14 3,260-5,180 [1.04-2.62] .033 .84 12-10 5,180-13,100 [2.62-6.64] .041 1.04 Dimensions Part Numbers Tin Plate Loose Tape W X MIN. L MAX. Red .070 1.78 .390 9.91 .918 23.32 1958191-1 _ .170 4.32 Blue .070 1.78 .390 9.91 .933 23.70 1958192-1 _ .250 6.35 Yellow .102 2.59 .390 9.91 1.148 29.16 1958193-1 _ • Insulation sleeve : PVF2, natural with colored stripe W X L 5 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support Canada: 1-905-475-6222 USA: 1-800-522-6752 Mexico: 01-800-733-8926 www.tycoelectronics.com Radiation Resistant/150°C Pre-Insulated Terminals and Splices Ring Tongue Terminals Catalog 82038 Issue Date : 7.2009 PIDG PVF2 Rings - RoHS Compliant Material and Finish: • Terminal body: copper per ASTM-B152 with matte tin {99.5% MIN tin content} plating per ASTM-B545 • Insulation support sleeve : copper per ASTM-B152 with matte tin {99.5% MIN tin content} plating per ASTM-B545 Wire Range AWG 26-24 CMA [mm2] 202-509 [.10-.26] Tongue Thickness Maximun .029 .74 Wire Insulation OD MAX .082 2.09 Stripe Color Code Yellow • Insulation sleeve : PVF2, natural with colored stripe 24-20 320-1,290 [.16-.65] .025 .64 .100 2.54 White Related Product Data • Application tooling pages 8-11 22-16 509-3,250 [.26-1.65] .033 .84 .125 3.18 Red • Technical documents page 8 16-14 2,050-5,180 [1.04-2.62] .033 .84 .150 3.81 Blue Stud Size Dimensions Part Numbers Tin Plate W C1 MIN E MAX L MAX Loose Tape 2 M2 .203 5.16 .211 5.36 .632 16.05 .741 18.82 696420-1 _ 4 .203 5.16 .211 5.36 .632 16.05 .741 18.82 696420-2 _ 6 M3.5 .250 6.35 .243 6.17 .644 16.87 .797 20.24 696420-3 _ 8 M4 .281 7.14 .250 6.35 .671 17.04 .819 20.80 696420-5 _ 10 .312 7.92 .281 7.14 .702 17.83 .866 22.00 696420-6 _ 4 .281 7.14 .250 6.35 .631 16.03 .779 19.79 696421-1 696421-3 6 M3.5 .281 7.14 .250 6.35 .631 16.03 .779 19.79 696421-2 696421-4 8 M4 .312 7.92 .281 7.14 .662 16.81 .826 20.98 696421-5 696421-7 10 .312 7.92 .281 7.14 .662 16.81 .826 20.98 696421-6 696421-8 4 .218 5.54 .156 .396 .560 14.22 .677 17.20 696422-2 _ 6 M3.5 .218 5.54 .156 3.96 .560 14.22 .677 17.20 696422-3 _ 6 M3.5 .250 6.35 .250 6.35 .654 16.61 .787 19.99 696422-4 _ 8 M4 .312 7.92 .281 7.14 .685 17.40 .849 21.56 696422-5 _ 10 .312 7.92 .281 7.14 .685 17.40 .849 21.56 696422-6 _ 1/4” M6 .469 11.91 .437 11.10 .841 21.36 1.083 27.51 696422-7 _ 5/16” M8 .469 11.91 .437 11.10 .841 21.36 1.083 27.51 696422-8 _ 3/8” .531 13.49 .546 13.87 .950 24.13 1.223 27.51 696422-9 _ 1/2” M12 .713 18.11 .530 13.46 .934 23.72 1.298 32.97 1-696422-0 _ 4 .250 6.35 .171 4.34 .575 14.61 .708 17.98 696423-2 _ 6 M3.5 .250 6.35 .171 4.34 .575 14.61 .708 17.98 696423-3 _ 6 M3.5 .312 7.92 .281 7.14 .685 17.40 .849 21.56 696423-4 _ 8 M4 .312 7.92 .281 7.14 .685 17.40 .849 21.56 696423-5 _ 10 .312 7.92 .281 7.14 .685 14.40 .849 21.56 696423-6 _ 1/4” M6 .469 11.91 .437 11.10 .841 21.36 1.083 27.51 696423-7 _ 5/16” M8 .469 11.91 .437 11.10 .841 21.36 1.083 27.51 696423-8 _ 3/8” .531 13.49 .546 13.87 .950 24.13 1.223 31.06 696423-9 _ 1/2” M12 .713 18.11 .530 13.46 .934 23.72 1.298 32.97 1-696423-0 _ 1-Dimension applies from edge of metal wire barrel to center of stud hole. 6 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support Canada: 1-905-475-6222 USA: 1-800-522-6752 Mexico: 01-800-733-8926 www.tycoelectronics.com Radiation Resistant/150°C Pre-Insulated Terminals and Splices Ring Tongue Terminals (continued) Catalog 82038 Issue Date : 7.2009 PIDG PVF2 Rings - RoHS Compliant Wire Range CMA [mm2] AWG 16-14 Heavy Duty 12-10 Tongue Thickness Maximun 2,0505,180 [1.04-2.62] Wire Insulation OD MAX .050 1.27 5,18013,000 [2.62-6.64] .041 1.04 .230 5.84 Stripe Color Code Stud Size Part Numbers Tin Plate W C1 MIN E MAX L MAX Loose Tape 4 .281 7.14 .219 5.59 .815 20.70 .960 24.38 696430-2 _ 6 M3.5 .343 8.71 .281 7.14 .877 22.28 1.051 26.70 696430-4 _ 8 M4 .343 8.71 .281 7.14 .877 22.28 1.051 26.70 696430-5 _ 10 .343 8.71 .281 7.14 .877 22.28 1.051 26.70 696430-6 _ 1/4” M6 .531 13.49 .437 11.10 1.033 26.24 1.301 33.05 696430-7 _ 5/16” M8 .531 13.49 .437 11.10 1.033 26.24 1.301 33.05 696430-8 _ 3/8” .531 13.49 .437 11.10 1.033 26.24 1.301 33.05 696430-9 _ 1/2” M12 .750 19.05 .625 15.88 1.221 31.01 1.599 40.61 1-696430-0 _ 6 M3.5 .375 9.53 .302 7.67 .893 22.68 1.088 27.64 696424-4 _ 8 M4 .375 9.53 .302 7.67 .893 22.68 1.088 27.64 696424-5 _ 10 .375 9.53 .302 7.67 .893 22.68 1.088 27.64 696424-6 _ 1/4” M6 .531 13.49 .468 11.89 1.054 26.77 1.327 33.71 696424-7 _ 5/16” M8 .531 13.49 .468 11.89 1.054 26.77 1.327 33.71 696424-8 _ 3/8” .593 15.06 .531 13.49 1.115 26.77 1.419 36.04 363424-9 _ 1/2” M12 .715 18.16 .474 12.04 1.054 26.77 1.419 36.04 1-696424-0 _ Yellow .230 5.84 Dimensions Yellow 1-Dimension applies from edge of metal wire barrel to center of stud hole. Butt Splices PIDG PVF2 Splices - RoHS Compliant Material and Finish: • Splice body: copper per ASTM-B152 with matte tin {99.5% MIN Tin content} plating per ASTM-B545 • Insulation support sleeve : copper per ASTM-B152 with matte tin {99.5% MIN tin content} plating per ASTM-B545 • Insulation sleeve : PVF2, natural with colored stripe Wire Range Wire Insulation OD MAX Stripe Color Code L MAX AWG CMA [mm2] 26-22 202-810 [.10-.26] .082 2.08 Yellow 24-20 320-1,290 [.16-.65] .100 2.54 22-16 509-3,250 [.26-1.65] 16-14 12-10 Part Numbers Tin Plate Loose Tape .082 22.61 696425-1 _ White 1.035 26.29 696426-1 _ .125 3.18 Red 1.265 32.13 696427-1 _ 2,050-5,180 [1.04-2.62] .150 3.81 Blue 1.265 32.13 696428-1 _ 5,180-13,000 [2.62-6.64] .220 5.59 Yellow 1.656 42.06 696429-1 _ Related Product Data • Application tooling pages 8-11 • Technical documents page 8 7 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support Canada: 1-905-475-6222 USA: 1-800-522-6752 Mexico: 01-800-733-8926 www.tycoelectronics.com Radiation Resistant/150°C Pre-Insulated Terminals and Splices PIDG PVF2 Wire Pins Catalog 82038 Issue Date : 7.2009 Application Tooling Material and Finish: Loose form terminal and splice tooling for wire range 26-10 AWG [0.12-6.0 mm2] Wire Range AWG 24-20 Hand Tools mm .16-.65 Technical Documents Instruction Sheets : • 408-1559 CERTI-CRIMP hand crimp tools • 408-1724 crimping dies for 8-2/0 AWG connectors 26-22 Style Part Number DAHT 47907-1 T-HEAD Tool 59275 T-HEAD Tool 59300 DAHT 46121 T-HEAD Tool 59275 DAHT 47386 59250 2 .1-.4 26-24 & 22-16 .1-.2 & .26-1.65 T-HEAD Tool T-HEAD Tool 59300 22-16 .26-1.65 DAHT 69151-1 16-14 1.04-2.62 16-14 HD 12-10 DAHT 47387 T-HEAD Tool 59250 1.04-2.62 Heavy Head 59239-4 2.62-6.64 Heavy Head 59239-4 CERTI-CRIMP Hand Tools DAHT Heavy Head Hand Tool T-HEAD Tool Battery Crimp Tool Kit Take automatic crimping away from the bench to the product, with this convenient, portable, battery operated tool. It’s at home in the factory or in the field. It performs approximately 100 crimps per charge. Request catalog 1773381 for more information. 626 Pneumatic Tool System This versatile system provides the ultimate in wire range flexibility for higher volume operation. It’s available with hand-or-foot operated configurations. Request catalog 124208 for more information. 8 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support Canada: 1-905-475-6222 USA: 1-800-522-6752 Mexico: 01-800-733-8926 www.tycoelectronics.com Radiation Resistant/150°C Pre-Insulated Terminals and Splices Tooling for loose form terminals, wire range 8-2 AWG [6.64-42.4 mm2] Ordering Information: To insure that all applicable Tyco Electronics part numbers are specified in your order we recommend that you make note of the following information: 1. Select either Electric Hydraulic Tool 1804700-1, -2, Foot Operated Tool 1583659-1 or Hand Pump 1583661-1. 2. Powered systems require a pump, hand or foot control, hose, crimp head and die. 3. The portable battery pump, 1804111-1, includes a hand control Application Tooling (continued) Tyco Electronics continues the quality tradition of AMP crimping tools with a new line of industry-standard 10,000 psi (68,950 kPa) hydraulic compression crimp heads, pumps and interchangeable U-dies. A new battery-powered pump and tool options provide unprecedented portability for any crimping application. Electric/Hydraulic Power Unit : AWG [6.64-42.4 mm2]. Heads and dies are listed in the table below. Part Numbers : Power Unit Only (Includes pressure release on unit) • 115 Volts 60 Hz—1804700-1 (10,000 psi) • 230 Volts 60 Hz—1804700-2 (10,000 psi) Portable, Battery/Hydraulic Power Unit (Kit includes Hand Controller, 10,000 psi)—1804111-1 Hydraulic Hand Tool 1490749-1 is also available Crimping Heads, Hand Tools or Dies 4. Manual systems require hand tools and the battery hand tool requires only dies. 5. Refer to matrix for die, head and hand tool options. Accessory Power Controls and Hoses • Control and hose accessories must be ordered separately. • If electric hydraulic tool is to be used in portable applications, a handle control and hose assembly should be used. • For stationary applications, a foot switch assembly and hose assembly will be necessary. Catalog 82038 Issue Date : 7.2009 Hydraulic Crimping Tooling 10,000 psi Operating Pressure Hand-Tool Hydraulic Head Hydraulic Heads 1490749-1 1490746-1, 1976230-1 Wire Size in AWG (mm2) 1752877-1 1752787-1 U-Dies U-Dies 8 [7-8.5] 1490749-1 1490746-1, 1976230-1 1752877-1 1752787-1 6 [13-15] 1490534-1 1490534-1 48858-1 48858-1 4 [21] 1490535-1 1490536-1 48860-1 48860-1 2 [34-35] 1490410-1 1490410-1 48861-1 48861-1 Shank Dies Accessories For use with Power Unit No. 1804700-1 1804700-2 1804700-1 1804700-2 Accessory Description Accessory Part Number 7 ft. [2.13 m] handle control assembly - hose and cord 1901775-1 15 ft. [4.57 m] handle control assembly - hose and cord 1901776-1 21 ft. [6.4 m] handle control assembly - hose and cord 1901777-1 Remarks _ 15 ft. [4.57] foot switch assembly 68284-1 need hose assembly 6 ft. [0.91 m] hose assembly 1583662-1 68284-1 foot switch 10 ft. [2.13 m] hose assembly 1583662-2 assembly needed 20 ft. [4.57 m] hose assembly 1583662-3 with hose 3-way multi-directional valve (manual) 1901782-1 _ • Multidirectional valves are used when more than one crimping head is permanently attached to the tool. 9 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support Canada: 1-905-475-6222 USA: 1-800-522-6752 Mexico: 01-800-733-8926 www.tycoelectronics.com Radiation Resistant/150°C Pre-Insulated Terminals and Splices DYNA-CRIMP Tooling for loose form terminals. Wire range 8-2/0 AWG [7-70 mm2] Ordering Information: To insure that all applicable AMP part numbers are specified in your order, we recommend that you make your selection in four (4) steps: Catalog 82038 Issue Date : 7.2009 Application Tooling (continued) Electric/Hydraulic Power Unit : This unit provides crimping for terminals in the wire range of 8-2/0 AWG [7-70 mm2]. Heads and dies are listed in the table below. Part Numbers : Power Unit Only (Includes pressure release on unit) 115 Volts 60 Hz : 69120 230 Volts 60 Hz : 69120-2 1. Select either Electric Hydraulic Tool 69120. Foot Operated Tool 69325-3 or Hand Tool 59974-1. 2. Select a head if using either the Electric Hydraulic or Foot Operated Tools. 3. Select dies from the table on this page. 4. Select control and hose mechanism from accessories list below when using 69120. Crimping Heads and Dies for Tools 69120-1, 69325-3 and 59974-1 Wire Range PLASTI-GRIP Style Terminals AWG mm2 Dies for Head 69066 Dies for Head 69051 and 59974-1 8 7-8 48858-1 48752-1 47820* 6 18-15 48859-1 48753-1* 47821* 4 21 48860-1 48754-1 47822* 2 34-35 48861-1 47239-1** 48755-1 47823* *No insulation crimp. **Large expansion. Accessory Power Controls and Hoses • Control and hose accessories must be ordered separately. • If electric hydraulic tool is to be used in portable applications, a handle control and hose assembly should be used. • For stationary applications, a foot switch assembly and hose assembly will be necessary. • Multidirectional valves are used when more than one crimping head is permanently attached to the tool. Accessories For use with Power Unit No. 69120-1 69120-2 Accessory Description Accessory Part Number 7 ft. [2.13 m] handle control assembly - hose and cord 59907-7 15 ft. [4.57 m] handle control assembly - hose and cord 1-59907-5 15 ft. [4.57 m] handle control assembly - cord (less hose) 1-59908-5 Remarks _ _ _ _ 21 ft. [6.4 m] handle control assembly - hose and cord 2-59907-1 21 ft. [6.4 m] handle control assembly - cord (less hose) 2-59908-1 28 ft. [8.53 m] handle control assembly - hose and cord 2-59907-8 _ 15 ft. [4.57] foot switch assembly 68284-1 need hose assembly 3 ft. [0.91 m] hose assembly 59909-3 68284-1 foot switch 7 ft. [2.13 m] hose assembly 59909-7 assembly needed 15 ft. [4.57 m] hose assembly 1-59909-5 with these hose 21 ft. [6.4 m] hose assembly 2-59909-1 3-way multi-directional valve 6-way multi-directional valve 59220 59221 assemblies _ 69120-1 69120-2 _ foot switch only 10 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support Canada: 1-905-475-6222 USA: 1-800-522-6752 Mexico: 01-800-733-8926 www.tycoelectronics.com Radiation Resistant/150°C Pre-Insulated Terminals and Splices Hydraulic Hand Tool for Wire Range 8-2 AWG [7-35 mm2] Catalog 82038 Issue Date : 7.2009 Application Tooling (continued) Hydraulic Hand Tool Part No. 1490749-1 Dies for this tool are listed in the table on page 9. Hydraulic Hand Tool Part No. 59974-1 Dies for this tool are listed in the table on page 10 under head No. 69051. Tape Form Terminal and Splice Tooling for Wire Range 24-10 AWG [0.2-6 mm2] Model G Terminating Machine TAPETRONIC Machine Part No. 354500-1 Part No. 69875 Applicator : 567200-3 Requires dies. No applicator required. Tyco Electonics application tools are designed to produce a carefully controlled, uniform pressure crimp, whether manually or pneumatically powered. All tools feature matching dies that fully “bottom” at the completion of the crimp, resulting in a proper crimp height. These dies are color coded to aid in matching tool to wire size. Dies for Tape Mounted Terminals Wire Range Dies AWG mm2 22-16 0.3 - 1.4 69872 16-14 1.25 - 2.0 69873 12-10 3.0 - 6.0 69874 For AMP-O-LECTRIC Machine 565435-5, use aplicator 567200-2 11 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support Canada: 1-905-475-6222 USA: 1-800-522-6752 Mexico: 01-800-733-8926 www.tycoelectronics.com Radiation Resistant/150°C Pre-Insulated Terminals and Splices Catalog 82038 Issue Date : 7.2009 Part Number Index Part No. Page RoHS Code Part No. Page RoHS Code 53400-1 2 L 53401-1 2 L Part No. Page RoHS Code 53809-2 2 53943-1 4 L 696422-9 6 R L 1-696422-0 6 R 53402-1 2 L 53944-1 4 L 696423-2 6 R 53403-1 2 L 53945-1 4 L 696423-3 6 R 53404-1 2 L 53946-1 4 L 696423-4 6 R 53405-1 2 L 53947-1 4 L 696423-5 6 R 53406-1 2 L 53949-1 4 L 696423-6 6 R 53407-1 2 L 53950-1 4 L 696423-7 6 R 53407-2 2 L 53951-1 4 L 696423-8 6 R 53408-1 2 L 53953-1 4 L 696423-9 6 R 53408-2 2 L 53954-1 4 L 1-696423-0 6 R 53409-1 2 L 53963-1 3 L 696424-4 7 R 53410-1 2 L 53964-1 3 L 696424-5 7 R 53410-2 2 L 53975-1 4 L 696424-6 7 R 53411-1 2 L 53977-1 4 L 696424-7 7 R 53412-1 2 L 53978-1 4 L 696424-8 7 R 53413-1 2 L 53980-1 4 L 696424-9 7 R 53414-1 2 L 53982-1 3 L 1-696424-0 7 R 53415-1 2 L 53983-1 3 L 696425-1 7 R 53416-1 2 L 53984-1 3 L 696426-1 7 R 53416-2 2 L 54593-1 3 L 696427-1 7 R 53417-1 2 L 54947-1 4 L 696428-1 7 R 53417-2 2 L 696420-1 6 R 696429-1 7 R 53418-1 2 L 696420-2 6 R 696430-2 7 R 53418-2 2 L 696420-3 6 R 696430-4 7 R 53419-1 2 L 696420-5 6 R 696430-5 7 R 53420-1 2 L 696420-6 6 R 696430-6 7 R 53421-1 2 L 696421-1 6 R 696430-7 7 R 53422-1 2 L 696421-2 6 R 696430-8 7 R 53423-1 3 L 696421-3 6 R 696430-9 7 R 53424-1 3 L 696421-4 6 R 1-696430-0 7 R 53425-1 3 L 696421-5 6 R 737049-1 5 R 53426-1 3 L 696421-6 6 R 737051-1 5 R 53427-1 3 L 696421-7 6 R 737053-1 5 R 53428-1 3 L 696421-8 6 R 1958191-1 5 R 53429-1 3 L 696422-2 6 R 1958192-1 5 R 53546-1 3 L 696422-3 6 R 1958193-1 5 R 53547-1 3 L 696422-4 6 R 53548-1 3 L 696422-5 6 R 53548-2 3 L 696422-6 6 R 53549-1 3 L 696422-7 6 R 53550-1 3 L 696422-8 6 R 12 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support Canada: 1-905-475-6222 USA: 1-800-522-6752 Mexico: 01-800-733-8926 www.tycoelectronics.com Radiation Resistant/150°C Pre-Insulated Terminals and Splices Global Contacts Americas Argentina (Buenos Aires) Phone: +54-11-4733-2200 Fax: +54-11-4733-2211 Brasil (São Paulo) Phone: +55-11-2103-6000 Fax: +55-11-2103-6030 Chile (Santiago) Phone: +56-2-345-0361 Fax: +56-2-223-1477 Canada (Toronto) Phone: +905-475-6222 Fax: +905-474-5520 Product Information Center: Phone: +905-470-4425 Fax: +905-474-5525 Colombia (Bogota) Phone: +57-1-319-8959 Fax: +57-1-319-8960 Mexico (Mexico City) Phone: +52-55-1106-0800 +01-800-733-8926 Fax: +52-55-1106-0901 For Latin/South American (Countries not shown) Phone: +54-11-4733-2015 Fax: +54-11-4733-2083 United States (Harrisburg, PA) Phone: +1-717-564-0100 Fax: +1-717-986-7575 Product Information Center: Phone: +1-800-522-6752 Fax: +1-717-986-7575 (Troy, MI) Phone: +1-248-273-3359 Fax: +1-248-273-3322 Asia/Pacific Australia (Sydney) Phone: 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+39-011-4031-116 Product Information Center: Phone: +39-011-4012-428 Fax: +39-011-40-287-428 Norway (Nesbru) Phone: +47-66-77-88-50 Fax: +47-66-77-88-55 Poland (Warsaw) Phone: +48-22-4576-700 Fax: +48-22-4576-720 Product Information Center: Phone: +48-22-4576-704 Fax: +48-22-4576-720 Romania (Bucharest) Phone: +40-21-311-3479/3596 Fax: +40-21-312-0574 Russia (Moscow) Phone: +7-495-790-7902 Fax: +7-495-721-1893 Product Information Center: Phone: +7-495-790-7902-404 Fax: +7-495-790-7902-401 Russia (St. Petersburg) Phone: +7-812-718-8192 Fax: +7-812-718-8193 Spain (Barcelona) Phone: +34-93-291-0330 Fax: +34-93-201-7879 Switzerland (Steinach) Phone: +41-71-447-0447 Fax: +41-71-447-0444 Turkey (Istanbul) Phone: +90-212-281-8181/2/3 +90-212-282-5130/5430 Fax: +90-212-281-8184 Ukraine (Kiev) Phone: +380-44-206-2265 Fax: +380-44-206-2264 Product Information Center: Phone: +380-44-206-2265 Fax: +380-44-206-2264 United Kingdom (Stanmore, Middlesex) Phone: +44-8706-080208 Fax: +44-208-954-6234 Product Information Center: Freephone (UK only): +0800-267-666 Phone: +44-8706-080208 Fax: +44-208-420-8095 Slovenia (Ljubljana) Phone: +386-1561-3270 Fax: +386-1561-3240 13 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support Canada: 1-905-475-6222 USA: 1-800-522-6752 Mexico: 01-800-733-8926 www.tycoelectronics.com Tyco Electronics Corporation Harrisburg, PA www.tycoelectronics.com © 2009 Tyco Electronics Corporation. All Rights Reserved. 82038 CIS PDF 7/2009 AMP, CERTI-CRIMP, PIDG, PLASTI-GRIP, T-HEAD, TE logo and Tyco Electronics are trademarks. Other products, logos and company names mentioned herein may be trademarks of their respective owners. While Tyco Electronics has made every reasonable effort to ensure the accuracy of the information in this catalog, Tyco Electronics does not guarantee that it is error-free, nor does Tyco Electronics make any other representation, warranty or guarantee that the information is accurate, correct, reliable or current. Tyco Electronics reserves the right to make any adjustments to the information contained herein at any time without notice. Tyco Electronics expressly disclaims all implied warranties regarding the information contained herein, including, but not limited to, any implied warranties of merchantability or fitness for a particular purpose. The dimensions in this catalog are for reference purposes only and are subject to change without notice. Specifications are subject to change without notice. Consult Tyco Electronics for the latest dimensions and design specifications.