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114-2161
2. REFERENCE MATERIAL
2.1. Revision Summary
Updated document to corporate requirements
Added NOTE to Paragraph 2.4 and deleted most reference documentation
Added text to Section 4, QUALIFICATION
Added NOTE to Section 5, and deleted reference tooling
2.2. Customer Assistance
Reference Product Base Part Number 32945 and Product Code 3040 are representative of PLASTI-GRIP
terminals and splices. Use of these numbers will identify the product line and help you to obtain product and
tooling information when visiting
www.te.com
or calling the number at the bottom of page 1.
2.3. Drawings
Customer drawings for product part numbers are available from
www.te.com.
Information contained in the
customer drawing takes priority.
2.4. Instructional Material
Instruction sheets (408-series) provide product assembly instructions or tooling setup and operation
procedures.
NOTE
Because of the large amount of dies, hand tools, applicators, and power units used to terminate this product line, it is not
feasible to list all the related tooling documents in this section. Related tooling documents are available through the service
network and are also shipped with the specific application tooling.
Some documents which pertain to this product are:
408-7424
408-9816
Checking Terminal Crimp Height or Gaging Die Closure
Handling of Reeled Products
3. REQUIREMENTS
3.1. Safety
Do not stack product shipping containers so high that the containers buckle or deform.
3.2. Special Characteristics
Terminals with an open-ended tongue, such as spade terminals, can be installed and removed without
complete removal of the mounting screw. The terminal flat sides provide a locking feature against lateral stress;
flanged ends reduce possibility of terminal separation. The snap feature on spring spade terminals increases
resistance to axial loads if the mounting screw becomes loosened. The closed-end tongue, in terminals such as
ring tongue terminals, provides maximum protection against separation; these terminals are well suited for high
vibration environments.
3.3. Material
The terminal body and splice body is made of copper plated with tin-except the spring spade terminal is made
of phosphor bronze plated with tin or brass plated with tin, and the .093-Series plug terminal is made of brass.
Rivets on the 3-way link terminal and tube cap assembly are made of brass and the tube cap on the tube cap
assembly is made of copper zinc alloy. The insulation is made of vinyl or PVF
2
(polyvinylidene fluoride). The
vinyl insulation is highly resistant to abrasion. The PVF
2
insulation is highly resistant to radiation and solvents.
3.4. Storage
A. Ultraviolet Light
Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the product
material.
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B. Shelf Life
The product should remain in the shipping containers until ready for use to prevent deformation to
components. The product should be used on a first in, first out basis to avoid storage contamination that
could adversely affect performance.
C. Reeled Terminals and Splices
When using tape-mounted reeled terminals or splices, care must be taken to prevent stretching, sagging,
or other distortion that would prevent smooth feeding of the tape through automatic machine feed
mechanisms. Store coil wound reels horizontally and traverse wound reels vertically.
D. Chemical Exposure
Do not store product near any chemical listed below as they may cause stress corrosion cracking in the
material.
Alkalies
Amines
Ammonia
Carbonates
Citrates
Nitrites
Phosphates Citrates
Sulfur Nitrites
Sulfur Compounds
Tartrates
3.5. Wire Selection and Preparation
The terminals and splices will accept solid or stranded copper wire sizes 26 through 1/0 AWG and stranded
wire sizes 8 through 2/0 AWG (509 through 150,500 circular mil area) with an insulation diameter range of
1.27 through 19.69 mm [.050 through .775 in.]. Proper strip length is necessary to properly insert the wire into
the terminal or splice. The strip length of the wire is shown in Figure 2.
CAUTION
Reasonable care must be taken not to nick, scrape, or cut any strands during the stripping operation.
3.6. Wire Placement
Stranded wire conductors must be inside the terminal or splice wire barrel. No strands can be folded back over
the wire insulation. Conductor ends must be bottomed in the wire barrel. The wire insulation must be inside the
insulation of the terminal or splice, but must not enter the wire barrel, to provide strain relief for the wire.
3.7. Crimp Requirements
The terminal or splice must be crimped to the wire according to instructions packaged with applicable tooling.
A. Wire Barrel Crimp
The crimp applied to the wire barrel portion of the terminal or splice is the most compressed area and is
most critical in ensuring optimum electrical and mechanical performance of the crimped terminal or splice.
The crimped area must be symmetrical on both sides of the wire barrel of the terminal or splice. The crimp
may be off center on the wire barrel but not off the end of the wire barrel. See Figure 3.
B. Crimp Dot Code
Some tools with multiple crimping chambers will emboss a crimp dot code onto the terminal or splice
insulation when crimped. The crimp dot code must be fully formed on the insulation to indicate that the
correct product and tooling combination was used. The crimp dot code must correspond with the wire size
marking on the tooling. See Figure 3.
C. Wire Conductor and Insulation Location
After crimping, all conductors must be held firmly inside the wire barrel. No strands can be folded back
over the wire insulation. The wire insulation must be inside the insulation barrel of the terminal or splice,
but must not enter the wire barrel. Conductor ends must be flush with, or extend slightly beyond, the end
of the wire barrel; or, in splices with a wire stop inside the center of the splice, conductor ends must butt
against the wire stop. See Figure 3.
CAUTION
Wire insulation shall NOT be cut or broken during the crimping operation. Reasonable care should be taken to provide
undamaged wire terminations.
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Stranded Wire
Solid Wire
Strip Length
Conductor
TERMINAL OR SPLICE
INSULATION
SIZE
COLOR
26-22
24-20
22-16
20-16 HD
16-14
Yellow
White
Red
Natural/Red
Black
Natural/Green
Blue
Natural/Blue
Black
Yellow/Black
Black
Yellow
Natural/Yellow
Black
Red
8
Natural/Red
Blue
6
Natural/Blue
Yellow
4
Natural/Yellow
Red
2
Natural/Red
1/0
2/0
Natural/Yellow
Blue
Yellow
---
---
1.27-13.08
[.050-.515]
---
12.19-14.22
[.480-.560]
---
---
16.00-19.68
[.630-.775]
---
---
Strip Length
Insulation
WIRE
INSULATION
DIA RANGE
1.27-2.03
[.050-.080]
2.03-3.18
[.080-.125]
---
---
---
2.92-4.32
[.115-.170]
---
---
---
---
---
---
---
---
---
WIRE STRIP LENGTH
TERMINAL
---
4.75-5.54
[.187-.218]
5.16-5.94
[.203-.234]
5.16-5.94
[.203-.234]
5.16-5.94
[.203-.234]
7.92-8.71
[.312-.343]
7.92-8.71
[.312-.343]
11.51-12.29
[.453-.484]
8.33-9.12
[.328-.359]
15.47-16.26
[.609-.640]
9.93-10.72
[.609-.640]
15.47-16.26
[.609-.640]
9.93-10.72
[.609-.640]
11.51-12.29
[.453-.484]
11.51-12.29
[.453-.484]
18.67-21.82
[.735-.859]
18.67-21.82
[.735-.859]
18.67-21.82
[.735-.859]
Figure 2
BUTT SPLICE
4.34-5.16
[.171-.203]
---
6.35-7.14
[.250-.281]
---
6.35-7.14
[.250-.281]
---
7.92-8.71
[.312-.343]
8.33-9.12
[.328-.359]
---
9.93-10.72
[.391-.422]
---
---
---
---
---
---
---
---
PARALLEL
SPLICE
---
---
7.87-8.64
[.310-.340]
---
7.87-8.64
[.310-.340]
---
7.92-8.71
[.312-.343]
---
13,100-20,800
---
---
20,800-33,100
---
---
33,100-52,600
---
---
52,600-83,700
---
---
---
119,500-150,500
---
83,700-119,500
WIRE CIRCULAR
MILL AREA
(CMA)
202-810
320-1,290
509-3,260
810-3,260
2,050-5,180
16-14 HD
2,050-5,180
12-10
5,180-13,100
D. Terminal or Splice Insulation
The terminal or splice insulation must not be deformed, cut, or show uneven stress marks. See Figure 3.
E. Bellmouth
There shall be no rear bellmouth. The front bellmouth shall be evident as shown in Figure 3.
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114-2161
Terminal
Wire Conductor Location
Front Bellmouth Must Be Visible
End of Conductors Must
Be Flush with, or
Extend Slightly Beyond
End of Wire Barrel
Wire Insulation
Location
Plug Terminal
Front Bellmouth
Must Be Visible
Crimp Dot Code (Ref)
Crimp Centered on Wire Barrel
(Crimp May Be Off Center, but
Not Off End of Wire Barrel)
Splice
Wire Conductor Location
Wire Insulation
Location
Wire Conductor Location
Wire Insulation
Location
Crimp Centered on Wire Barrel (Crimp May Be
Off Center, But Not Off End of Wire Barrel)
TERMINAL OR SPLICE SIZE
26-22
24-20
22-16
20-16 HD
16-14
16-14 HD
12-10
8
6
4
2
1/0
2/0
SOLDER SLUG
CRIMP HEIGHT RANGE (See Notes)
CRIMP PRODUCED BY
CRESCENT CRIMP
TETRA-CRIMP* TOOLING
1.60-1.75 [.063-.069]
---
2.26-2.41 [.089-.095]
2.77-2.92 [.109-.115]
1.98-2.18 [.078-.086]
3.02-3.18 [.119-.125]
4.29-4.44 [.169-.175]
5.11-5.26 [.201-.207]
6.02-6.17 [.237-.243]
6.83-6.98 [.269-.275]
8.10-8.26 [.319-.325]
10.19-10.34 [.401-.407]
10.67-12.83 [.499-.505]
2.34-2.54 [.092-.100]
3.25-3.45 [.128-.136]
---
---
---
---
---
---
DIAMETER
3.18 [.125]
3.18 [.125]
4.76 [.188]
6.35 [.250]
6.35 [.250]
6.35 [.250]
9.53 [.375]
9.53 [.375]
12.70 [.500]
12.70 [.500]
NOTE
The resilience of the terminal and 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
Instruction Sheet
408-7424
for specific instructions). The solder slug diameter and crimp height must be within the dimensions
provided.
NOTE
Each crimp dimension represents the functional range of a wire/terminal or splice combination. There are tool designs
available to meet various application requirements. The developed crimp configuration is unique for each tool design and is
acceptable provided the crimp height is within the functional range. For crimp dimensions of a specific tool, refer to instruction
sheet packaged with manual tools and applicator log packaged with power tools.
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