TE CONNECTIVITY 53409-3

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 (PVF ) insulation for high resistance to radiation and 2 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 Catalog 82038 Pre-Insulated Terminals and Splices Issue Date : 7.2009 Ring Tongue Terminals PIDG Terminals - Whisker Mitigating (Contains 3% Minimum Lead Content in Plating) Material and Finish: Wire Range Dimensions Part Numbers • Terminal body : Tongue Wire Ins. Stripe Stud copper per ASTM-B152 Thickness Diameter Color Size 1 Tin Plate CMA C E L Maximun Maximum Code with bright tin/lead (93/7) AWG W 2 [mm ] MIN. MAX. MAX. {3% MIN lead content} Loose Tape plating per ASTM-B545 2 .203 .211 .632 .736 _ 53400-1 M2 5.16 5.35 16.06 18.70 • Insulation support sleeve : copper per .203 .211 .632 .736 _ 4 53401-1 ASTM-B152 with bright 5.16 5.35 16.06 18.70 tin/lead (93/7) {3% MIN 202-509 .029 .082 6 .250 .243 .664 .792 _ 26-24 Yellow 53402-1 lead content} plating [.10-.26] .74 2.09 M3.5 6.35 6.17 16.87 20.12 per ASTM-B545 8 .281 .250 .671 .814 _ 53403-1 • Insulation sleeve : M4 7.13 6.35 17.05 20.68 PVF , natural with 2 .312 .281 .702 .861 _ 10 53404-1 colored stripe 7.92 7.13 17.84 21.87 320-1,290 .025 .100 6 .281 .250 .631 .774 _ 24-20 White 53809-2 [.16-.65] .64 2.54 M3.5 7.13 6.35 16.03 19.66 .218 .156 .560 .672 _ 4 53405-1 5.54 3.96 14.23 17.02 6 .218 .156 .560 .672 _ 53406-1 M3.5 5.54 3.96 14.23 17.07 6 .250 .250 .654 .782 53407-1 53407-2 M3.5 6.35 6.35 16.62 19.87 8 .312 .281 .685 .844 53408-1 53408-2 M4 7.91 7.13 17.4 21.44 509-3,250 .033 .125 .312 .281 .685 .844 _ 22-16 Red 10 53409-1 7.92 7.13 17.4 21.44 [.26-1.65] .84 3.18 1/4 .469 .437 .841 1.078 53410-1 53410-2 M6 11.91 11.09 21.37 27.39 5/16 .469 .437 .841 1.078 _ 53411-1 M8 11.91 11.09 21.37 27.39 Related Product Data .531 .546 .950 1.218 _ • Application tooling 3/8 53412-1 13.49 13.86 24.13 30.94 pages 8-11 1/2 .713 .530 .934 1.293 _ • Technical documents 53413-1 M12 18.11 13.46 24.13 32.85 page 8 .250 .171 .575 .703 _ 4 53414-1 6.35 4.34 14.61 17.86 6 .250 .171 .575 .703 _ 53415-1 M3.5 6.35 4.34 14.61 17.86 6 .312 .281 .685 .844 53416-1 53416-2 M3.5 7.92 7.13 17.4 21.44 8 .312 .281 .685 .844 53417-1 53417-2 M4 7.92 7.13 17.4 21.44 2,050-5,180 .033 .150 .312 .281 .685 .844 16-14 Blue 10 53418-1 53418-2 7.92 7.13 17.4 21.44 [1.04-2.62] .84 3.81 1/4 .469 .437 .841 1.078 _ 53419-1 M6 11.91 11.09 21.37 27.39 5/16 .469 .437 .841 1.078 _ 53420-1 M8 11.91 11.09 21.37 27.39 .531 .546 .950 1.218 _ 3/8 53421-1 13.49 13.86 24.13 30.94 1/2 .713 .530 .934 1.293 _ 53422-1 M12 18.11 13.46 23.73 32.85 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 Technical Support Canada: 1-905-475-6222 www.tycoelectronics.com equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Mexico: 01-800-733-8926 Radiation Resistant/150°C Catalog 82038 Pre-Insulated Terminals and Splices Issue Date : 7.2009 Ring Tongue Terminals PIDG Terminals - Whisker Mitigating (continued) (Contains 3% Minimum Lead Content in Plating) Wire Range Dimensions Part Numbers Tongue Wire Ins. Stripe Stud Thickness Diameter Color Size 1 Tin Plate CMA C E L Maximun Maximum Code AWG W 2 [mm ] MIN. MAX. MAX. Loose Tape .281 .219 .810 .955 _ 4 53963-1 7.14 5.56 20.57 24.26 6 .343 .281 .872 1.046 _ 53964-1 M3.5 8.71 7.13 22.15 26.57 16-14 2,050-5,180 .050 .230 8 .343 .281 .872 1.046 _ Heavy Black 53982-1 [1.04-2.62] 1.3 5.84 M4 8.71 7.13 22.15 26.57 Duty .343 .281 .872 1.046 _ 10 53983-1 8.71 7.13 22.15 26.57 1/4 .531 .437 1.028 1.296 _ 53984-1 M6 13.49 11.09 26.12 32.92 6 .219 .250 .810 .938 _ 54593-1 M3.5 5.56 6.35 20.57 23.83 6 .375 .302 .893 1.083 _ 53423-1 M3.5 9.53 7.67 22.69 27.51 8 .375 .302 .893 1.083 _ 53424-1 M4 9.53 7.67 22.69 27.51 .375 .302 .893 1.083 _ 10 53425-1 9.53 7.67 22.69 27.51 5,180- .042 .230 1/4 .531 .468 1.054 1.322 _ 12-10 13,100 Yellow 53426-1 1.07 5.84 M6 13.48 11.88 26.78 33.58 [2.62-6.64] 5/16 .531 .468 1.054 1.322 _ 53427-1 M8 13.48 11.88 26.78 33.58 .593 .531 1.115 1.414 _ 3/8 53428-1 15.06 13.48 28.33 35.92 1/2 .715 .474 1.054 1.414 _ 53429-1 M12 18.16 12.04 26.77 35.92 1-Dimension applies from edge of metal wire barrel to center of stud hole. Butt Splices PIDG Splices - Whisker Mitigating (Contains 3% Minimum Lead Content in Plating) Material and Finish: Wire Range Part Numbers Stripe Wire Ins. Dimension • Splice body : Barrel I.D. Color Diameter Length copper per ASTM-B152 Minimum Tin Plate CMA Code Maximum Maximum AWG with bright tin/lead (93/7) 2 [mm ] Loose Tape {3% MIN lead content} plating per ASTM-B545 202-810 .029 .082 .890 26-22 Yellow 53546-1 - [.10-.41] .73 2.09 22.61 • Insulation support sleeve : copper per 320-1,290 .043 .100 1.035 24-20 White 53547-1 - ASTM-B152 with bright [.16-.65] 1.09 2.54 26.29 tin/lead (93/7) {3% MIN lead content} plating 509-3,250 .061 .125 1.265 22-16 Red 53548-1 53548-2 32.14 per ASTM-B545 [.26-1.65] 1.54 3.18 • Insulation sleeve : 2,050-5,180 .085 .150 1.265 16-14 Blue 53549-1 - PVF , natural with 2 [1.04-2.62] 2.15 3.81 32.14 colored stripe 5,180-13,000 .129 .220 .220 12-10 Yellow 53550-1 - [2.62-6.64] 3.27 5.59 42.07 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 Technical Support Canada: 1-905-475-6222 www.tycoelectronics.com equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Mexico: 01-800-733-8926 Radiation Resistant/150°C Catalog 82038 Pre-Insulated Terminals and Splices Issue Date : 7.2009 Ring Tongue Terminals PLASTI-GRIP Terminals - Whisker Mitigating (Contains 3% Minimum Lead Content in Plating) Material and Finish: Wire Range Dimensions Part Numbers • Terminal body : Tongue Wire Ins. Stripe Max. Stud copper per ASTM-B152 Thickness Diameter Color Washer Size CMA E L Maximun Maximum Code Rad. with bright tin/lead (93/7) AWG W Loose 2 [mm ] MAX. MAX. {3% MIN lead content} plating per ASTM-B545 .437 .431 1.344 1.562 10 53978-1 11.1 10.95 34.13 39.68 • Insulation sleeve : PVF , natural with 1/4 .437 .478 1.344 1.586 2 53943-1 M6 11.1 12.14 34.14 40.29 colored stripe 13,100-20,800 .043 .380 5/16 .500 .587 1.402 1.702 8 Red 54947-1 [6.64-10.5] 1.1 9.66 M8 12.7 14.91 35.62 43.24 .500 .587 1.406 1.702 3/8 53944-1 12.7 14.91 35.72 43.24 1/2 .500 .875 1.406 1.846 53945-1 M12 12.70 22.23 35.72 46.89 .421 .468 1.482 1.719 10 53975-1 10.7 11.89 37.65 43.67 20,800-33,100 .048 .436 1/4 .421 .500 1.622 1.898 6 Blue 53946-1 [10.5-16.8] 1.22 11.08 M6 10.7 12.7 41.2 46.42 .515 .625 1.591 1.905 3/8 53947-1 13.09 15.88 40.42 48.42 .531 .546 1.672 1.948 10 53949-1 13.49 13.87 42.47 49.48 1/4 .531 .546 1.672 1.948 53980-1 Related Product Data M6 13.49 13.87 42.47 49.48 33,100-52,600 .051 .515 4 Yellow • Application tooling [16.8-26.7] 1.3 13.09 .531 .546 1.672 2.014 3/8 53950-1 pages 8-11 13.49 13.87 42.47 51.16 • Technical documents 1/2 .531 .679 1.672 2.014 53951-1 page 8 M12 13.49 17.25 42.47 51.16 1/4 .578 .675 1.731 2.071 53977-1 M6 14.69 17.15 43.97 52.60 52,600-83,700 .060 .560 .578 .711 1.731 2.089 2 Red 3/8 53953-1 [26.7-42.4] 1.53 14.23 14.69 18.06 43.97 53.07 1/2 .578 .855 1.731 2.161 53954-1 M12 14.69 21.72 43.97 54.9 4 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric Technical Support Canada: 1-905-475-6222 www.tycoelectronics.com equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Mexico: 01-800-733-8926 Radiation Resistant/150°C Catalog 82038 Pre-Insulated Terminals and Splices Issue Date : 7.2009 Wire Pins PIDG PVF Wire Pins - RoHS Compliant 2 Material and Finish: Bright Tin Plated • Terminal body : copper per ASTM-B152 with bright tin {99.5% Wire Range Dimensions Part Numbers Tongue Wire Ins. Stripe Color MIN tin content} plating Thickness Diameter Code Tin Plate CMA X L per ASTM-B545 Maximun Maximum AWG W 2 [mm ] MIN. MAX. Loose Tape • Insulation support sleeve : copper per 493-3,158 .033 .013 .071 .390 .903 _ 22-16 Red 737049-1 .84 1.80 9.90 22.93 ASTM-B152 with bright tin [.25-1.6] 3.30 {99.5% MIN tin content} 1,973-5,131 .033 .154 .071 .390 .903 _ plating per ASTM-B545 16-14 Blue 737051-1 [1.0-2.60] .84 3.90 1.80 9.90 22.93 • Insulation sleeve : PVF , natural with colored 5,131-13,025 .042 .236 .102 .390 1.128 _ 2 12-10 Yellow 737053-1 [2.6-6.6] 1.07 6.00 1.80 9.90 28.65 stripe Wire Pins Matte Tin Plated Material and Finish: Wire Range Dimensions Part Numbers Tongue Wire Ins. Stripe Color • Terminal body : Thickness Diameter Code Tin Plate CMA X L Maximun Maximum copper per ASTM-B152 AWG W 2 [mm ] MIN. MAX. Loose Tape with matte tin {99.5% MIN tin content} plating 509-3,250 .014 .033 .070 .390 .918 _ 22-16 Red 1958191-1 per ASTM-B545 [.26-1.65] .84 3.56 1.78 9.91 23.32 • Insulation support 3,260-5,180 .033 .170 .070 .390 .933 _ sleeve : copper per 16-14 Blue 1958192-1 [1.04-2.62] .84 4.32 1.78 9.91 23.70 ASTM-B152 with matte tin {99.5% MIN tin content} 5,180-13,100 .041 .250 .102 .390 1.148 _ 12-10 Yellow 1958193-1 plating per ASTM-B545 [2.62-6.64] 1.04 6.35 2.59 9.91 29.16 • Insulation sleeve : PVF , natural with 2 colored stripe W X L 5 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric Technical Support Canada: 1-905-475-6222 www.tycoelectronics.com equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Mexico: 01-800-733-8926 Radiation Resistant/150°C Catalog 82038 Pre-Insulated Terminals and Splices Issue Date : 7.2009 Ring Tongue Terminals PIDG PVF Rings - RoHS Compliant 2 Material and Finish: Wire Range Dimensions Part Numbers • Terminal body: Tongue Wire Stripe Stud copper per ASTM-B152 Thickness Insulation Color Size 1 Tin Plate CMA C E L Maximun OD MAX Code with matte tin {99.5% AWG W 2 [mm ] MIN MAX MAX Loose Tape MIN tin content} plating per ASTM-B545 2 .203 .211 .632 .741 _ 696420-1 M2 5.16 5.36 16.05 18.82 • Insulation .203 .211 .632 .741 _ support sleeve : copper 4 696420-2 5.16 5.36 16.05 18.82 per ASTM-B152 with matte tin {99.5% MIN 202-509 .029 .082 6 .250 .243 .644 .797 _ 26-24 Yellow 696420-3 [.10-.26] .74 2.09 M3.5 6.35 6.17 16.87 20.24 tin content} plating per ASTM-B545 8 .281 .250 .671 .819 _ 696420-5 M4 7.14 6.35 17.04 20.80 • Insulation sleeve : .312 .281 .702 .866 _ PVF , natural with 2 10 696420-6 7.92 7.14 17.83 22.00 colored stripe .281 .250 .631 .779 696421-3 4 696421-1 7.14 6.35 16.03 19.79 6 .281 .250 .631 .779 696421-2 696421-4 M3.5 7.14 6.35 16.03 19.79 320-1,290 .025 .100 24-20 White [.16-.65] .64 2.54 8 .312 .281 .662 .826 696421-5 696421-7 M4 7.92 7.14 16.81 20.98 .312 .281 .662 .826 10 696421-6 696421-8 7.92 7.14 16.81 20.98 .218 .156 .560 .677 _ 4 696422-2 5.54 .396 14.22 17.20 6 .218 .156 .560 .677 _ 696422-3 M3.5 5.54 3.96 14.22 17.20 6 .250 .250 .654 .787 _ 696422-4 M3.5 6.35 6.35 16.61 19.99 8 .312 .281 .685 .849 _ 696422-5 Related Product Data M4 7.92 7.14 17.40 21.56 • Application tooling 509-3,250 .033 .125 .312 .281 .685 .849 _ 22-16 Red 10 696422-6 pages 8-11 [.26-1.65] .84 3.18 7.92 7.14 17.40 21.56 • Technical documents 1/4” .469 .437 .841 1.083 _ 696422-7 page 8 M6 11.91 11.10 21.36 27.51 5/16” .469 .437 .841 1.083 _ 696422-8 M8 11.91 11.10 21.36 27.51 .531 .546 .950 1.223 _ 3/8” 696422-9 13.49 13.87 24.13 27.51 1/2” .713 .530 .934 1.298 _ 1-696422-0 M12 18.11 13.46 23.72 32.97 .250 .171 .575 .708 _ 4 696423-2 6.35 4.34 14.61 17.98 6 .250 .171 .575 .708 _ 696423-3 M3.5 6.35 4.34 14.61 17.98 6 .312 .281 .685 .849 _ 696423-4 M3.5 7.92 7.14 17.40 21.56 8 .312 .281 .685 .849 _ 696423-5 M4 7.92 7.14 17.40 21.56 2,050-5,180 .033 .150 .312 .281 .685 .849 _ 16-14 Blue 10 696423-6 [1.04-2.62] .84 3.81 7.92 7.14 14.40 21.56 1/4” .469 .437 .841 1.083 _ 696423-7 M6 11.91 11.10 21.36 27.51 5/16” .469 .437 .841 1.083 _ 696423-8 M8 11.91 11.10 21.36 27.51 .531 .546 .950 1.223 _ 3/8” 696423-9 13.49 13.87 24.13 31.06 1/2” .713 .530 .934 1.298 _ 1-696423-0 M12 18.11 13.46 23.72 32.97 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 Technical Support Canada: 1-905-475-6222 www.tycoelectronics.com equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Mexico: 01-800-733-8926 Radiation Resistant/150°C Catalog 82038 Pre-Insulated Terminals and Splices Issue Date : 7.2009 Ring Tongue Terminals PIDG PVF Rings - RoHS Compliant 2 (continued) Wire Range Dimensions Part Numbers Tongue Wire Stripe Stud Thickness Insulation Color Size 1 Tin Plate CMA C E L Maximun OD MAX Code AWG W 2 [mm ] MIN MAX MAX Loose Tape .281 .219 .815 .960 _ 4 696430-2 7.14 5.59 20.70 24.38 6 .343 .281 .877 1.051 _ 696430-4 M3.5 8.71 7.14 22.28 26.70 8 .343 .281 .877 1.051 _ 696430-5 M4 8.71 7.14 22.28 26.70 .343 .281 .877 1.051 _ 10 696430-6 16-14 2,050- 8.71 7.14 22.28 26.70 .050 .230 Heavy 5,180 Yellow 1.27 5.84 1/4” .531 .437 1.033 1.301 _ Duty [1.04-2.62] 696430-7 M6 13.49 11.10 26.24 33.05 5/16” .531 .437 1.033 1.301 _ 696430-8 M8 13.49 11.10 26.24 33.05 .531 .437 1.033 1.301 _ 3/8” 696430-9 13.49 11.10 26.24 33.05 1/2” .750 .625 1.221 1.599 _ 1-696430-0 M12 19.05 15.88 31.01 40.61 6 .375 .302 .893 1.088 _ 696424-4 M3.5 9.53 7.67 22.68 27.64 8 .375 .302 .893 1.088 _ 696424-5 M4 9.53 7.67 22.68 27.64 .375 .302 .893 1.088 _ 10 696424-6 9.53 7.67 22.68 27.64 5,180- .041 .230 1/4” .531 .468 1.054 1.327 _ 12-10 13,000 Yellow 696424-7 1.04 5.84 M6 13.49 11.89 26.77 33.71 [2.62-6.64] 5/16” .531 .468 1.054 1.327 _ 696424-8 M8 13.49 11.89 26.77 33.71 .593 .531 1.115 1.419 _ 3/8” 363424-9 15.06 13.49 26.77 36.04 1/2” .715 .474 1.054 1.419 _ 1-696424-0 M12 18.16 12.04 26.77 36.04 1-Dimension applies from edge of metal wire barrel to center of stud hole. Butt Splices PIDG PVF2 Splices - RoHS Compliant Material and Finish: Wire Range Part Numbers Wire Stripe L Insulation Color • Splice body: MAX Tin Plate CMA OD MAX Code AWG 2 copper per ASTM-B152 [mm ] Loose Tape with matte tin {99.5% MIN Tin content} plating per 202-810 .082 .082 _ 26-22 Yellow 696425-1 [.10-.26] 2.08 22.61 ASTM-B545 • Insulation support 320-1,290 .100 1.035 _ 24-20 White 696426-1 sleeve : copper per [.16-.65] 2.54 26.29 ASTM-B152 with matte tin 509-3,250 .125 1.265 {99.5% MIN tin content} _ 22-16 Red 696427-1 [.26-1.65] 3.18 32.13 plating per ASTM-B545 • Insulation sleeve : 2,050-5,180 .150 1.265 _ 16-14 Blue 696428-1 PVF , natural with [1.04-2.62] 3.81 32.13 2 colored stripe 5,180-13,000 .220 1.656 _ 12-10 Yellow 696429-1 [2.62-6.64] 5.59 42.06 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 Technical Support Canada: 1-905-475-6222 www.tycoelectronics.com equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Mexico: 01-800-733-8926 Radiation Resistant/150°C Catalog 82038 Pre-Insulated Terminals and Splices Issue Date : 7.2009 PIDG PVF Wire Pins 2 Application Tooling Material and Finish: Wire Range Hand Tools Loose form terminal and splice tooling for 2 AWG mm Style Part Number wire range 26-10 AWG DAHT 47907-1 [0.12-6.0 mm2] 24-20 .16-.65 T-HEAD Tool 59275 T-HEAD Tool 59300 Technical Documents DAHT 46121 26-22 .1-.4 Instruction Sheets : T-HEAD Tool 59275 • 408-1559 CERTI-CRIMP DAHT 47386 26-24 .1-.2 hand crimp tools & & T-HEAD Tool 59250 • 408-1724 crimping 22-16 .26-1.65 T-HEAD Tool 59300 dies for 8-2/0 AWG connectors 22-16 .26-1.65 DAHT 69151-1 DAHT 47387 16-14 1.04-2.62 T-HEAD Tool 59250 16-14 1.04-2.62 Heavy Head 59239-4 HD 12-10 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 Technical Support Canada: 1-905-475-6222 www.tycoelectronics.com equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Mexico: 01-800-733-8926 Radiation Resistant/150°C Catalog 82038 Pre-Insulated Terminals and Splices Issue Date : 7.2009 Tooling for loose form Application Tooling (continued) terminals, wire range 8-2 AWG [6.64-42.4 Tyco Electronics continues the quality tradition mm2] of AMP crimping tools with a new line of industry-standard 10,000 psi (68,950 kPa) hydraulic compression crimp heads, pumps and Ordering Information: interchangeable U-dies. A new battery-powered pump and tool options provide unprecedented To insure that all applicable portability for any crimping application. Tyco Electronics part numbers are specified Electric/Hydraulic Power Unit : in your order we recommend that you AWG [6.64-42.4 mm2]. Heads and dies are listed in make note of the the table below. following information: 1. Select either Electric Part Numbers : Hydraulic Tool 1804700-1, Power Unit Only (Includes pressure release on unit) -2, Foot Operated Tool • 115 Volts 60 Hz—1804700-1 (10,000 psi) 1583659-1 or Hand Pump • 230 Volts 60 Hz—1804700-2 (10,000 psi) 1583661-1. 2. Powered systems Portable, Battery/Hydraulic Power Unit require a pump, hand or foot control, hose, crimp (Kit includes Hand Controller, 10,000 psi)—1804111-1 head and die. Hydraulic Hand Tool 1490749-1 is also available 3. The portable battery pump, 1804111-1, includes a hand control Crimping Heads, Hand Tools or Dies 4. Manual systems require Hydraulic Crimping Tooling 10,000 psi Operating Pressure hand tools and the battery hand tool requires only Hand-Tool Hydraulic Head Hydraulic Heads dies. 5. Refer to matrix for 1490749-1 1490746-1, 1976230-1 1752877-1 1752787-1 die, head and hand tool Wire Size options. U-Dies U-Dies Shank Dies 2 in AWG (mm ) 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 Accessory Power Accessories Controls and Hoses For use with Accessory Accessory Description Remarks Power Unit No. Part Number • Control and hose _ 7 ft. [2.13 m] handle control assembly - hose and cord 1901775-1 accessories must be ordered separately. 15 ft. [4.57 m] handle control assembly - hose and cord 1901776-1 • If electric hydraulic 21 ft. [6.4 m] handle control assembly - hose and cord 1901777-1 1804700-1 tool is to be used in 15 ft. [4.57] foot switch assembly 68284-1 need hose assembly 1804700-2 portable applications, a 6 ft. [0.91 m] hose assembly 1583662-1 68284-1 foot switch handle control and hose 10 ft. [2.13 m] hose assembly 1583662-2 assembly needed assembly should be used. 20 ft. [4.57 m] hose assembly 1583662-3 with hose • For stationary applications, a foot 1804700-1 _ 3-way multi-directional valve (manual) 1901782-1 switch assembly and 1804700-2 hose assembly will be necessary. • 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 Technical Support Canada: 1-905-475-6222 www.tycoelectronics.com equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Mexico: 01-800-733-8926 Radia Radiation R tion Resis esistant/ tant/150°C 150°C Catalog 82038 Pr Pre-Insula e-Insulat ted T ed Terminals and Splic erminals and Splices es Issue Date : 7.2009 DYNA-CRIMP Tooling for Application Tooling (continued) loose form terminals. Wire range 8-2/0 AWG Electric/Hydraulic Power Unit : [7-70 mm2] This unit provides crimping for terminals in the wire 2 range of 8-2/0 AWG [7-70 mm ]. Heads and dies are listed in the table below. Ordering Information: To insure that all applicable Part Numbers : AMP part numbers are Power Unit Only (Includes pressure release on unit) specified in your order, we 115 Volts 60 Hz : 69120 recommend that you make 230 Volts 60 Hz : 69120-2 your selection in four (4) steps: 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 Crimping Heads and Dies for Tools 69120-1, 69325-3 and 59974-1 on this page. 4. Select control and hose Wire Range PLASTI-GRIP Style Terminals mechanism from accessories list below when using 69120. Dies for Head Dies for Head 2 AWG mm 69066 69051 and 59974-1 48752-1 8 7-8 48858-1 47820* 48753-1* 6 18-15 48859-1 47821* 48754-1 4 21 48860-1 47822* 48861-1 48755-1 2 34-35 47239-1** 47823* *No insulation crimp. **Large expansion. Accessory Power Accessories Controls and Hoses For use with Accessory Accessory Description Remarks Power Unit No. Part Number • Control and hose _ 7 ft. [2.13 m] handle control assembly - hose and cord 59907-7 accessories must be _ ordered separately. 15 ft. [4.57 m] handle control assembly - hose and cord 1-59907-5 _ • If electric hydraulic tool 15 ft. [4.57 m] handle control assembly - cord (less hose) 1-59908-5 is to be used in portable _ 21 ft. [6.4 m] handle control assembly - hose and cord 2-59907-1 applications, a handle _ 21 ft. [6.4 m] handle control assembly - cord (less hose) 2-59908-1 control and hose assembly 69120-1 _ should be used. 28 ft. [8.53 m] handle control assembly - hose and cord 2-59907-8 69120-2 • For stationary applications, 15 ft. [4.57] foot switch assembly 68284-1 need hose assembly a foot switch assembly 3 ft. [0.91 m] hose assembly 59909-3 68284-1 foot switch and hose assembly will be 7 ft. [2.13 m] hose assembly 59909-7 assembly needed necessary. 15 ft. [4.57 m] hose assembly 1-59909-5 with these hose • Multidirectional valves 21 ft. [6.4 m] hose assembly 2-59909-1 assemblies are used when more _ than one crimping head 3-way multi-directional valve 59220 69120-1 is permanently attached 69120-2 6-way multi-directional valve 59221 foot switch only to the tool. 10 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric Technical Support Canada: 1-905-475-6222 www.tycoelectronics.com equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Mexico: 01-800-733-8926 Radia Radiation R tion Resis esistant/ tant/150°C 150°C Catalog 82038 Pr Pre-Insula e-Insulat ted T ed Terminals and Splic erminals and Splices es Issue Date : 7.2009 Hydraulic Hand Tool for Application Tooling (continued) Wire Range 8-2 AWG [7-35 mm2] 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. Model G Terminating Machine TAPETRONIC Machine Tape Form Terminal and Splice Tooling for Part No. 354500-1 Part No. 69875 Wire Range 24-10 AWG Applicator : 567200-3 Requires dies. No applicator required. [0.2-6 mm2] 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 2 AWG mm 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 Technical Support Canada: 1-905-475-6222 www.tycoelectronics.com equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Mexico: 01-800-733-8926 Radiation Resistant/150°C Catalog 82038 Pre-Insulated Terminals and Splices Issue Date : 7.2009 Part Number Index Part No. Page RoHS Code Part No. Page RoHS Code Part No. Page RoHS Code 53400-1 2 L 53809-2 2 L 696422-9 6 R 53401-1 2 L 53943-1 4 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 Technical Support Canada: 1-905-475-6222 www.tycoelectronics.com equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. 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(Ljubljana) Phone: +39-011-4012-428 Phone: +386-1561-3270 Fax: +39-011-40-287-428 Fax: +386-1561-3240 13 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric Technical Support Canada: 1-905-475-6222 www.tycoelectronics.com equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Mexico: 01-800-733-8926 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.