Standard Terminals and Splices

Transcription

1 Standard s and Splices Product Facts MP solderless terminals and splices meet or exceed today s standards for reliable termination in applications ranging from control circuits to heavy duty power wiring This catalog describes only standard terminals and splices accommodating wire sizes from 26 WG through 4/0 WG These terminals are preinsulated and color coded by wire size for easy identification Funnel entry on many terminals allows for easy wire insertion for high speed production Nylon or vinyl insulation provides high dielectric strength The serration or dimple feature inside the terminal barrel provides maximum barrel contact and tensile strength MP s special plating process creates a high resistance to corrosion Use of MP application tooling is designed for uniform high quality terminations UL, CS, Military pproved Need more information? Specifications subject to change. Call the Product Information Center: Copyright 1977, 1980, 1982, 1985, 1986, 1988, 1995 and 2000 by Tyco Electronics Corporation. ll Rights Reserved. The Product Information Center is staffed with specialists well versed in all MP products. The Center can provide you with: Engineering Support Catalogs Technical Documents Product Samples MP uthorized Distributor Locations MP, PIDG, FSTON, PLSTI-GRIP, MPLI-BOND, PLSTI-BOND, TERMINYL, CERTI-SEL, T-HED, UTO-PRO, MP-TPETRONIC, MPOMTOR, MP-O-LECTRIC, TETR-CRIMP, PRO-CRIMPER, DYN-CRIMP Trademarks 1 Dimensions are shown for reference purposes only. Dimensions are in inches and millimeters unless otherwise Specifications subject to change. Technical Support Center

2 Table of Contents Introduction...2, 3 Performance Specifications...4, 5 Stud Hole Sizes...6 PIDG (Pre-Insulated Diamond Grip) s Splices...31, 32 PIDG FSTON s...34, 35 Splices...36 PLSTI-GRIP s Splices MPLI-BOND s PLSTI-BOND...57, 58 s and Tooling...58 TERMINYL s...60, 61 Splices...62 CERTI-SEL...63, 64 Splices and Tooling...64 Class 1 and Class 2 Military pprovals Tooling Numerical Index (Product) Numerical values To convert U.S. customary unit values in this catalog to their metric equivalents, use the following formulas: To convert from to Multiply by inch millimetre (mm) x inch metre (m) x -2 inch centimetre (cm) foot metre (m) x -1 pound-force newton (N) bar pascal (Pa) x 5 pound-force/inch 2 pascal (Pa) x 3 pound-mass kilogram (kg) x -1 ounce-mass kilogram (kg) x -2 To convert wire size (WG) to the equivalent metric value using the circular mil area of the wire, use the following formula: circular mil area (CM)/ = square millimetre (mm 2 ) 2

3 s and Splices PIDG (Pre-insulated Diamond Grip) s and Splices Page 7 ( Restricting s also) PIDG FSTON s and Splices Page 33 ( Restricting s also) PLSTI-GRIP s and Splices Page 37 MPLI-BOND s Page 53 PLSTI-BOND s Page 57 TERMINYL s and Splices Page 59 CERTI-SEL Splices Page 63 3

4 s and Splices Ordering Information This catalog is designed for easy selection of terminal type to meet your needs. ll terminals and splices are cataloged by tongue type and wire size. If the part number is known, refer to the numerical index at the back of this catalog for page location of tabular information. In many instances the part is available in loose piece as well as tape mounted. FSTON terminals are available in strip form. When ordering tape mounted parts, specify the terminal or splice part number, the total quantity of parts required, the part number of the tooling to be used and the type of packaging desired (if applicable). The table shown at top right, lists the wire sizes available and the quantity per package for tape mounted and loose piece. Insulated terminals and splices are color coded to indicate wire range and to help match the terminal with the appropriate tool. The table shown at right identifies the specific wire range insulation color. Standard Packaging Quantities Range WG Packaging Quantity Loose Piece Tape Mounted M/Box 2,500/Reel M/Box 5,000/Reel H.D. 500/Box 2,500/Reel /Box 2,500/Reel 8 thru 4 0/Box 2 thru 4/0 50/Box Note: Package quantities may vary with specific part numbers. Color Code Color Code Range WG Comments Transparent /Black Heavy Duty /0 2/0 3/0 4/0 s and Splices Performance Specifications For detailed test information and product specifications, request appropriate report or refer to the applicable specification listed in the following table. Product Type Test Report Number pplication Specification PIDG s Nylon MIL-T-7928 PIDG Restriction GPR s MIL-T-7928/1 PIDG FSTON s UL3 PLSTI-GRIP s UL486 MPLI-BOND s MIL-T-7928 PLSTI-BOND s TERMINYL s MIL-T-7928 CERTI-SEL s 4

5 s and Splices Performance Specifications (Continued) The many millions of MP terminals and splices that have given ten, fifteen and twenty years of service are ample proof of the testing and research that went into their design and manufacturing. Like all MP solderless wiring devices, they are thoroughly tested to conform to standards of performance under heavy usage. Tests conducted in MP s laboratories and research facilities, some of the best-equipped in their field, indicate that these terminals and splices meet or exceed applicable industrial requirements and military specifications. The result of some of the most popular tests are tabulated h e r e. Upon request, a formal test report will be supplied to support these values and document additional performance requirements not listed. MIL-T-7928 Group III Group VI Tensile Strength fter Tensile Strength fter Wire Spec. Vibration Lb. Corrosion Lb. Size Min. lb. Type Type PIDG PIDG MPLI-BOND TERMINYL MPLI-BOND TERMINYL ,035 1,139 1,136 1/ ,6 1,781 1,605 1,767 2/ ,935 1,787 1,970 1,721 3/ ,430 2,845 2,500 2,880 4/ ,415 3,048 3,465 3,268 MIL-T-7928 Group II Group III Group VI Wire Specification Millivolt Drop fter Millivolt Drop fter Millivolt Drop fter Size Maximum Current Cycling 2 Vibration 2 Corrosion 2 Millivolt Drop 1 Type Type Type PIDG PIDG PIDG MPLI-BOND TERMINYL MPLI-BOND TERMINYL MPLI-BOND TERMINYL / / / / Value is millivolt drop permitted after test plus equal length of wire. 2 Value includes equal length of wire. 5

6 Stud Hole Size Use to Select Proper Size The chart shows sizes and dimensions of various studs and the corresponding terminal stud hole sizes used with MP devices. For example, with stud #5 ( Diameter), use MP device listed for #5 stud (.129 Hole Diameter). stud hole sizes may easily be checked by fitting sample terminal to black circle. Stud Size Minimum Stud Dia. U.S. Cust. Metric Hole Diameter Stud Size U.S. Cust. Metric Stud Dia. Minimum Hole Diameter # # /8" M #2 M # # /4" #5 M3.129 #6 M #8 M /8" M # # # " /4" M /16" M /8" /8" /16" /4" /2" M

7 PIDG (Pre-Insulated Diamond Grip) Product Facts Pre-insulated terminal designed for uniform reliability in most difficult circuit environments PIDG s consist of tin plated copper or tin plated phosphor bronze body for spring spades with a copper sleeve and insulation sleeve fitted over terminal barrel Design of the tool dies and construction of the terminal allows for uniform insulation thickness under crimping pressure, transmitting this pressure evenly to the center of the crimp area The MP Mated Tool/ Concept MP compression crimping produces crimps for a given size wire and terminal that are alike in appearance and p e r f o r m a n c e and crimping tool are designed as uniform matched devices Dies are precisionengineered from the finest hard-metal alloys Crimping pressure is controlled by a ratchet device on the hand tool or a corresponding pre-calibration in the crimping jaws of MP automated crimping machines The Crimp When done properly, crimping pressure can neither overstress nor understress the terminal barrel machined dies fully bottom to the precise crimp height Resulting termination is free of contamination Resistant to shock and critical environments Tensile strength approaches that of the wire itself PIDG s meet or exceed the requirements of MIL-T- 7928, Type II, Class 1 and 2 Refer to MP Qualified Products for Military pplication, Catalog for Military Specification Number to MP Part N u m b e r cross reference Color Coding. insulation is color-coded by wire range to prevent errors during installation. Serrations. Serrations inside barrel provide maximum contact and tensile strength after crimping. Temperature Rating: 5 C Max. MP Wire Range Table of Contents MP PIDG s (Use PIDG Tooling) Listed Solid or Stranded LR7189 Certified Solid or Stranded 300 V Max., 5 C. Max Solid or Stranded Nylon. Nylon sleeve has high dielectric strength. Note: terminals are stamped in accordance with MIL-T UL& CS Nylon Basic. The basic terminal is constructed of fine grade high conductivity copper per STM B-152 and tin-plated per STM B-545. Basic material for Spring Spade Tongue s is phosphor bronze per STM B-139 and tin-plated per STM B-545. MP s special plating process creates durable corrosion resistance to salt spray and most chemical fumes. Copper Sleeve. The specially designed copper sleeve, fitted over the terminal barrel, provides circumferential insulation support to the wire and allows the wire to be bent in any direction, without fraying the wire s insulation or breaking the conductor. Funnel Ramp Entry. Prevents a turned back strand and permits rapid wire insertion during high speed production. Note: Over size expansions are provided in vinyl insulation only. MP PIDG Nylon Butt Window Splice (Use PIDG Tooling) s Ring Tongue Ring Tongue (Vinyl) Ring Tongue ( Restricting) Ring Tongue 90 Bend and Rectangular Tongue 90 Bend ( Restricting) Rectangular Tongue , 20 Rectangular Tongue ( Restricting) and Spade Tongue , 22 Flanged Spade Tongue Short Spring Spade Tongue Long Spring Spade Tongue Slotted Ring Tongue and Hook Tongue Multiple Stud and Offset Ring Tongue Offset Ring Tongue ( Restricting) Shur-Plug and 3-Way Connector Tabs Splices Butt Butt Step Down dapter Inserts and Knife Disconnect MP Wire Range Listed Stranded or Solid LR7189 Certified Stranded or Solid 300 V Max., 5 C. Max Stranded or Solid Note: splices are stamped in accordance with MIL-T

8 Ring Tongue s PIDG (Pre-Insulated Diamond Grip) (Continued) Nylon, UL 94V-2 Body and Metallic Sleeve Copper per STM B-152 pplication Tooling pg. 72 Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted 2 M M [ ] M * * M /Br * * [ ] M * * * M * Natural M Natural Natural Natural , [ ] Natural.0 M M Natural Natural *vailable in small packaging quantities. Note: C dimension applies from edge of metal wire barrel to center of stud hole. Must be crimped with or PIDG (red) Tooling. 8

9 PIDG (Pre-Insulated Diamond Grip) (Continued) Ring Tongue s (Continued) Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted M /Green Black , [ ] M M *vailable in small packaging quantities. 1 Slightly larger than standard #4 stud hole. (.128 in./3.25 mm.) Note: C dimension applies from edge of metal wire barrel to center of stud hole * * * * * * * * * * * * * * * * * * * 32837*

10 Ring Tongue s (Continued) PIDG (Pre-Insulated Diamond Grip) (Continued) Nylon, UL 94V-2 Body and Metallic Sleeve Copper per STM B-152 pplication Tooling pg ,260 [ ] Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted /4 M Black / M / /2 M * * * * * * * 20-16HD , [ ] M * * * * M * * * * * * M * * *vailable in small packaging quantities. 1 Heavy duty for extra mechanical strength. Note: C dimension applies from edge of metal wire barrel to center of stud hole.

11 Ring Tongue s (Continued) PIDG (Pre-Insulated Diamond Grip) (Continued) Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted * * * * / M * Black / * M * / * * / M * /Blk /Blk * M /Blk * /Blk /Blk * M /Blk * /Blk * HD /Blk * /Blk /Blk * /Blk /4 M /Blk /Blk * /16 M /Blk *vailable in small packaging quantities. 1 Heavy duty for extra mechanical strength. Note: C dimension applies from edge of metal wire barrel to center of stud hole. 11

12 Ring Tongue s (Continued) PIDG (Pre-Insulated Diamond Grip) (Continued) Nylon, UL 94V-2 Body and Metallic Sleeve Copper per STM B-152 except where noted. pplication Tooling pg. 72 Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted 3/ /Blk HD 1 /Blk *.050 1/ M /Blk / /Blk * * * M * * * * M * * ,180-13, [ ] * * * * * /4 M * * *vailable in small packaging quantities. 1 Heavy duty for extra mechanical strength. 2 body plating Gold per MIL-G Type II over Nickel per QQ-N body plating Nickel per QQ-N-290. Note: C dimension applies from edge of metal wire barrel to center of stud hole. 12

13 PIDG (Pre-Insulated Diamond Grip) (Continued) Ring Tongue s (Continued) Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted M / * M * * / * ,180-13, [ ] / M * 5/8 M *vailable in small packaging quantities. Note: C dimension applies from edge of metal wire barrel to center of stud hole. Vinyl insulation material 13

14 Ring Tongue s (Vinyl) PIDG (Pre-Insulated Diamond Grip) (Continued) Vinyl, UL 94V-0 Body and Metallic Sleeve Copper per STM B-152 except where noted. pplication Tooling pg ,260 [ ] Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted 6 M M /Blk * 1/ HD 1 /Blk M / /Blk..300 M /2 M /Blk M M mm ,180-13, [ ] / M /16 M / *vailable in small packaging quantities. 1 Heavy duty for extra mechanical strength. 2 body plating Gold per MIL-G Type II over Nickel per QQ-N # stud may be substituted. Note: C dimension applies from edge of metal wire barrel to center of stud hole * * * * *

15 Ring Tongue s ( Restricting) PIDG (Pre-Insulated Diamond Grip) (Continued) Nylon, UL 94V-2 Body Copper per STM B-152 Metallic Sleeve Copper per STM B-152 Plating Nickel per QQ-N-290 or Tin per STM B-545 pplication Tooling pg [0.15] [0.24] [0.38] Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L Color Diameter Loose Tape Max. Min. Max. Max. Solid/Stripe Range Piece Mounted 2 M /Black /Black M /Black /Black M /Black / / M / M / M / / M / M / / M /Green /Green * /Green * M /Green * /Green M * /Green * /4 M /Green /16 M /Green / /Green /2 M /Green *vailable in small packaging quantities. Note: C dimension applies from edge of metal wire barrel to center of stud hole. Must be crimped with or PIDG (red) Tooling. 15

16 Ring Tongue s ( Restricting) (Continued) PIDG (Pre-Insulated Diamond Grip) (Continued) Nylon, UL 94V-2 Body Copper per STM B-152 Metallic Sleeve Copper per STM B-152 Plating Nickel per QQ-N-290 or Tin per STM B-545 pplication Tooling pg ,186 [0.60] 18 1,900 [0.96] 16 2,800 [1.42] Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L Color Diameter Loose Tape Max. Min. Max. Max. Solid/Stripe Range Piece Mounted 2 M / / * / * M / / M * / * 1/4 M / /16 M / / / /2 M / /White * /White * M /White * M /White * /White * /4 M /White /16 M /White / /White /2 M /White / / * M / * M / * / * 1/4 M / / / M / / /2 M / *vailable in small packaging quantities. Note: C dimension applies from edge of metal wire barrel to center of stud hole. 16

17 PIDG (Pre-Insulated Diamond Grip) (Continued) Ring Tongue s ( Restricting) (Continued) 14 4,234 [2.15] 12 6,654 [3.37] 12,066 [6.11] Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L Color Diameter Loose Tape Max. Min. Max. Max. Solid/Stripe Range Piece Mounted /Green /Green M /Green * /Green M * /Green * /4 M /Green /16 M /Green / /Green /2 M /Green M / M / * / * /4 M / /16 M / / / /2 M / M /Brown M /Brown * /Brown /4 M /Brown /16 M /Brown / /Brown /2 M /Brown *vailable in small packaging quantities. Note: C dimension applies from edge of metal wire barrel to center of stud hole. 17

18 PIDG (Pre-Insulated Diamond Grip) (Continued) Ring Tongue 90 Bend Vinyl, UL 94V-0 Body and Metallic Sleeve Copper per STM B-152 pplication Tooling pg. 72 Tongue Dimensions Wire Part Number Stud Cicular Mils Thickness Size W D Diameter Loose Max. Min. Color Max. Piece Vinyl , [ ] Nylon 12-5,180-13, [ ] Rectangular Tongue s 90 Bend ( Restricting) Nylon Body Copper per STM B-152 Plating Tin per MIL-T-727 Metallic Sleeve Copper per STM B-152 Plating Nickel per QQ-N-290 or Tin per MIL-T-727 pplication Tooling pg. 72 Tongue Dimensions Wire Part Numbers Stud Thickness Size W C L D X Color Diameter Loose Max. Max. Solid /Stripe Range Piece 18 1, /White [0.96] , / [3.37] Note: C dimension applies from edge of metal wire barrel to underside of bent tongue. 18

19 Rectangular Tongue s PIDG (Pre-Insulated Diamond Grip) (Continued) Nylon except where noted. Body and Metallic Sleeve Copper per STM B-152 except where noted. pplication Tooling pg [ ] ,260 [ ] Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L X Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted M M M M M * * M * M *vailable in small packaging quantities. 1 Vinyl 2 Body Brass per MIL-C-50. Note: C dimension applies from edge of metal wire barrel to center of stud hole. 19

20 Rectangular Tongue s (Continued) PIDG (Pre-Insulated Diamond Grip) (Continued) Nylon except where noted. Body and Metallic Sleeve Copper per STM B-152 pplication Tooling pg ,180-13,0 [ ] Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L X Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted M * * M M M M *vailable in small packaging quantities. Note: C dimension applies from edge of metal wire barrel to center of stud hole. 20

21 Rectangular Tongue s ( Restricting) PIDG (Pre-Insulated Diamond Grip) (Continued) Nylon, UL 94V-2 Body Copper per STM B-152 Metallic Sleeve Copper per STM B-152 Plating Nickel per QQ-N-290 pplication Tooling pg. 72 Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L X Color Diameter Loose Max. Min. Max. Max. Solid/Stripe Range Piece / [0.24] 0.51 M /Brown M ,066 [6.11] /Brown M Note: C dimension applies from edge of metal wire barrel to center of stud hole. Spade Tongue s Nylon, UL 94V-2 Body and Metallic Sleeve Copper per STM B-152 pplication Tooling pg. 72 Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L X Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted [ ] 0.74 M [ ] * M * * * * * M ,260 [ ] * M * * * *vailable in small packaging quantities. Note: C dimension applies from edge of metal wire barrel to center of stud hole. 21

22 Spade Tongue s (Continued) PIDG (Pre-Insulated Diamond Grip) (Continued) Nylon, UL 94V-2 Body and Metallic Sleeve Copper per STM B-152 pplication Tooling pg ,180-13,0 [ ] Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L X Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted * M * * * M * * * * M * M * * * *vailable in small packaging quantities. Note: C dimension applies from edge of metal wire barrel to center of stud hole. 22

23 Flanged Spade Tongue s PIDG (Pre-Insulated Diamond Grip) (Continued) Nylon, UL 94V-2 Body and Metallic Sleeve Copper per STM B-152 pplication Tooling pg. 72 Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L X H Diameter Loose Tape Max. Min. Max. Max. Min. Color Max. Piece Mounted 2 M * * [ ] M * M * * M * , * [ ] M * M * * * M * * M * ,180-13,0 [ ] M * * *vailable in small packaging quantities. Note: C dimension applies from edge of metal wire barrel to center of stud hole. 23

24 Short Spring Spade Tongue s PIDG (Pre-Insulated Diamond Grip) (Continued) Nylon, UL 94V-2 Body Phosphor Bronze per STM B-139 Metallic Sleeve Copper per STM B-152 pplication Tooling pg [ ] ,260 [ ] 12-5,180-13,0 [ ] Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L X Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted 2 M * * M M * M * M * * M M * * /4 M * 5 M * * M * * M * * /4 M M * M * M * * /4 M * *vailable in small packaging quantities. Note: C dimension applies from edge of metal wire barrel to center of stud hole. 24

25 Long Spring Spade Tongue s PIDG (Pre-Insulated Diamond Grip) (Continued) Nylon, UL 94V-2 Body Phosphor Bronze per STM B-139 Metallic Sleeve Copper per STM B-152 pplication Tooling pg. 72 Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L X Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted [ ] 0.51 M * M , [ ] 8 M * * * M * * M * * /4 M M M ,180-13,0 [ ] /4 M *vailable in small packaging quantities. Note: C dimension applies from edge of metal wire barrel to center of stud hole. 25

26 Slotted Ring Tongue s PIDG (Pre-Insulated Diamond Grip) (Continued) Nylon except where noted. Body and Metallic Sleeve Copper per STM B-152 pplication Tooling pg. 72 Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted [ ] 0.51 M M * * M ,260 [ ] / M M M HD / /Black / M ,180-13,0 [ ].040 3/ *vailable in small packaging quantities. 1 Vinyl. Note: C dimension applies from edge of metal wire barrel to center of stud hole. Hook Tongue s Nylon except where noted. Body and Metallic Sleeve Copper per STM B-152 pplication Tooling pg ,260 [ ] Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted M * M M M * *vailable in small packaging quantities. 1 Vinyl. Note: C dimension applies from edge of metal wire barrel to center of stud hole. 26

27 Multiple Stud s PIDG (Pre-Insulated Diamond Grip) (Continued) Nylon, UL 94V-2 Body Copper per STM B-152 Metallic Sleeve Copper per STM B-152 Plating Nickel per QQ-N-290 pplication Tooling pg. 72 Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted , [ ] * ,180-13, [ ] * *vailable in small packaging quantities. Note: C dimension applies from edge of metal wire barrel to center of stud hole. Offset Ring Tongue s Nylon, UL 94V-2 Body and Metallic Sleeve Copper per STM B-152 pplication Tooling pg. 72 Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L Diameter Loose Max. Min. Max. Max. Color Max. Piece ,260 [ ] 0.84 M M Note: C dimension applies from edge of metal wire barrel to center of stud hole. 27

28 PIDG (Pre-Insulated Diamond Grip) (Continued) Offset Ring Tongue s ( Restricting) Nylon, UL 94V-2 Body and Metallic Sleeve Copper per STM B-152 pplication Tooling pg. 72 Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L Color Diameter Loose Max. Min. Max. Max. Solid/Stripe Range Piece /Green [0.38] 0.84 M / M ,186 [0.60] / , / [1.42] 0.84 M , /Green [2.15] Note: C dimension applies from edge of metal wire barrel to center of stud hole. 28

29 PIDG (Pre-Insulated Diamond Grip) (Continued) Shur-Plug Nylon, UL 94V-2 Body and Metallic Sleeve Copper per STM B-152 pplication Tooling pg. 72 Dimension Wire Part Numbers L Diameter Loose Tape Max. Color Max. Piece Mounted * Receptacle *vailable in small packaging quantities. 3-Way Connector Nylon, UL 94V-2 Body and Metallic Sleeve Copper per STM B-152 Rivet Brass per QQ-B-626 pplication Tooling pg. 72 Tongue Dimensions Wire Part Number W L Diameter Loose Thickness Max. Max. Max. Color Max. Piece * *vailable in small packaging quantities. 29

30 Tabs PIDG (Pre-Insulated Diamond Grip) (Continued) Nylon, UL 94V-2 Body and Metallic Sleeve Copper per STM B-152 pplication Tooling pg. 72 Tongue Dimensions Wire Part Numbers Style Thickness W C L D Diameter Loose Max. Min. Max. Color Max. Piece , [ ] *.033 B ,180-13,0.042 C [ ] * *vailable in small packaging quantities. Note: C dimension applies from edge of metal wire barrel to end of tab. 30

31 Butt Splices PIDG (Pre-Insulated Diamond Grip) (Continued) Sleeve Standard, Step Down ssembly and Special Nylon Radiation Resistant Polyvinylidene Fluoride (PVF 2 ) Splice Bodyand Support S l e e ve Copper per STM B-152 pplication Tooling pg. 72 Dimension Splice Wire Part Numbers 2 Style L Diameter Loose Tape Max. Color Max. Piece Mounted [ ] [ ] * , Natural.0 [ ] Standard , [ ] * * ,180-13, [ ] * to 509-1,900 [ ] / / Step Down 5,180-13,0 to 509-1,900 ssembly [ ] [ ] / 5.59/ ,180-13,0 to [ ] / 5.59/ Radiation.890 Natural w/.082 [ ] Resistant Stripes Radiation.890 Natural w/.082 [ ] Resistant Stripes , Natural w/.0 [ ] White Stripes 2.54 Radiation Resistant 509-3, Natural w/ [ ] Stripes * Natural w/ Stripes * ,180-13, Natural w/.220 [ ] Stripes * 12-5,180-13,0 Special [ ] *vailable in small packaging quantities. 1 Includes adapter insert. 2 When using two or more wires in either end of a butt splice, the combined cross sectional area must be within the (CM) circular mil area range listed range in accordance with MIL-T splices are range in accordance with MIL-T butt splice, threaded 8-32 one end. Tapetronic only. 31

32 Butt Splice Step Down dapter Inserts 1 PIDG (Pre-Insulated Diamond Grip) (Continued) dapter Body Copper per STM B-152 Plating Zinc Plate / DyeChromate pplication Tooling pg. 72 Butt Splice dapter Insert Part No. Dimension L Color Code Part Numbers ,900 [ ] * , * 12- [ ] ,180-13, [ ] * ] *vailable in small packaging quantities. 1 dapter inserts can be ordered separately for use in specific Standard PIDG Butt Splices. Knife Disconnect Splices Nylon, UL 94V-2 Splice Body and Metallic Sleeve Copper per STM B-152 pplication Tooling pg. 72 Dimensions Splice Wire W L Thickness Max. Color Diameter Max ,260 [ ] ,180-13,0 [ ] *vailable in small packaging quantities. Part Numbers Loose Piece Tape Mounted * 32446* * 32448* * 35762* 32

33 PIDG FSTON Product Facts Pre-insulated terminal designed for uniformed reliability in most difficult circuit environment Consists of an unplated or tin-plated brass body or a tin-plated phosphor bronze body with a specially designed copper sleeve and insulation sleeve fitted over the terminal barrel Design of the tool dies and construction of the terminal permits uniform insulation thickness under crimping pressure, transmitting this pressure evenly to the center of the crimp area The MP Mated Tool/ Concept MP compression crimping produces crimps for a given size wire and terminal that are alike in appearance and p e r f o r m a n c e and the crimping tool are designed as uniform matched devices Dies are precisionengineered from the finest hard-metal alloys Crimping pressure is controlled by a ratchet device on the hand tool or a corresponding pre-calibration in the crimping jaws of MP automated crimping machines The Crimp When done properly, crimping pressure can neither overstress nor understress the terminal barrel machined dies fully bottom to the precise crimp height Resulting termination is free of contamination Resistant to shock and critical environments Tensile strength approaches that of the wire itself Color Coding. insulation is color-coded by wire range to prevent errors during installation. Copper Sleeve. The specially designed copper sleeve, fitted over the terminal barrel, provides circumferential insulation support to the wire and allows the wire to be bent in any direction, without fraying the wire s insulation or breaking the conductor. Funnel Ramp Entry. Prevents a turned back strand and rapid wire insertion during high speed production. Temperature Rating: 5 C Max. MP PIDG FSTON s (Use Type TETR-CRIMP*Tooling) MP Component Wire Recognized Range File E Stranded Table of Contents LR 7189 Certified Stranded 300 V Max., 5 C. Max Stranded 1 UL& CS Nylon except where noted Nylon. Nylon sleeve has high dielectric strength. Serrations. Serrations inside barrel provide maximum contact and tensile strength after crimping. Basic. The basic terminal is constructed of fine grade high conductivity brass per STM B-36 or phosphor bronze per STM B-139. The brass terminal is either unplated or tin-plated per STM B-545. The phosphor bronze terminal is tin-plated per STM B-545. MP s special plating process creates durable corrosion resistance to salt spray and most chemical fumes. MP PIDG FSTON Line Splice Connectors 250 Series Component 5 C LR C Recognized Max. Certified Max. File E (Vinyl) (Vinyl) MPPart No. 600 V MPPart No V Max Max V V Max Max. s Receptacles Receptacles ( Restricting) Splices Line Splice Connector for 250 Series and 187 Series

34 PIDG FSTON (Continued) Receptacles Receptacle Style: No dimple with wire stop B Dimple with wire stop C No dimple, no wire stop Nylon, UL 94V-2 Receptacle Body Brass per STM B-36 or Phosphor Bronze per STM B-139 except where noted. Metallic Sleeve Copper per STM B-152 pplication Tooling pg Dimensions Wire Fits Part Numbers Series Style W L Recept. Stock Tab Loose Tape Strip Nom. Max. Color Diameter Matl. Thk. Max. Thk. Piece Mounted Form Brass * ,900 B [ ] Brass B Brass * Green Brass * ,831-6,470 1 B [ ] Green Phos. Brz * Brass * ,180-13,0 B [ ] Phos. Brz , Brass [ ] Low Insertion Brass Brass Brass * ,900 B [ ].800 /Black Brass Brass * Brass * B.800 Brass * B Brass * [ ] Brass * ,900 B [ ].800 Brass Not ULor CSapproved or listed. *vailable in small packaging quantities. 1 Wire range is limited as noted. 2 Unplated receptacle body.

35 PIDG FSTON (Continued) Receptacles (Continued) Series Dimensions Wire Fits Part Numbers Style W L Recept. Stock Tab Loose Tape Strip Nom. Max. Color Diameter Matl. Thk. Max. Thk. Piece Mounted Form Brass * B.900 Brass , Brass [ ] Low Insertion Brass Natural Brass * Natural.1 Brass * Standard 509-1,900 B Natural.1 Brass * Black Brass Brass [ ] Standard Brass Brass Low ,900 [ ] Brass * Low Brass Insertion * Brass * Brass * B Brass C Brass Not UL or CSapproved or listed. *vailable in small packaging quantities. Receptacles ( Restricting) Nylon, UL 94V-2 Receptacle Body Brass per STM B-36 Receptacle Style B Dimple with wire stop Metallic Sleeve Copper per STM B-152 or Nickel per QQ-N-290 pplication Tooling pg. 73 Dimensions Wire Fits Part Numbers Series Recept. Stock Style W L Tab Loose Tape Strip Color Diameter Matl. Thk. Nom. Max. Solid / Stripe Range Thk. Piece Mounted Form B / Brass Standard [0.38] Green

36 PIDG FSTON (Continued) Line Splice Connector for 250 Series s Vinyl, UL 94V-0 Color Natural Splice Body Brass per STM B-36 except where noted. Dimensions Part Numbers Plating W L Max. E Min. Loose Piece Unplated * Tin Unplated Tin Unplated *vailable in small packaging quantities. 1 Oval expansion at end opposite w. (.380 x.320 inside diameter.) 2 E min. on expansion end only. Line Splice Connector for 187 Series s Housing Nylon, UL 94V-2 Splice Body Brass per STM B-36 Type Single Dual Dual ULFile E V Max Housing Dimensions Temperature Part Numbers Color W L Rating Loose Piece Natural Natural Black C C Receptacle (Low Insertion Force) Dimensions Wire Fits Part Numbers Series W L Recept. Stock Tab Loose Tape Strip Nom. Max. Color Diameter Matl. Thk. Max. Thk. Piece Mounted Form Low , Brass Insertion [ ] Low Brass Insertion Low , Brass Insertion [ ] Low Brass Insertion

37 PLSTI-GRIP Product Facts Pre-insulated PLSTI-GRIP solderless terminals and splices Designed specifically to answer the need for inexpensive, insulated electrical terminations Can be used in almost every type of commercial application ccommodate wire sizes from 22 WG through 2/0 WG The Crimp Carefully engineered application tooling has been developed to ensure uniformly high quality terminations Tool and terminal have been designed as a team to promote ease and speed of application and at the same time to provide precise crimping pressure for every wire size The wire and the terminal barrel form a homogeneous mass of metal, providing a connection of maximum conductivity, tensile strength, and high resistance to corrosion The quality performance, the facility of installation and the inherent simplicity make them ideal for many industrial applications Color Coding. insulation is color-coded by wire size range to eliminate errors during installation. Funnel Entry. ssures rapid wire insertion during high speed production. (Except 8 to 2/0 range.) Temperature Rating: 90 C Max. Basic. The basic terminal is constructed of fine grade high conductivity copper per STM B-152 and tin-plated per STM B-545. Basic material for Spring Spade Tongue s is phosphor bronze per STM B-139 or brass per STM B-36 and tin-plated per STM B-545. MP s special plating process creates durable corrosion resistance to salt spray and most chemical fumes. Serrations. Serrations inside barrel provide maximum contact and tensile strength after crimping. Dimples on 8 to 2/0 range.. Vinyl insulation sleeve provides good dielectric strength and supports the wire insulation so that no bare wire is exposed. MP PLSTI-GRIP s and Splices (Use PLSTI-GRIP or PIDG Tooling) MP Wire Range Listed Except as noted with individual part number listing. LR thru 4/0 Certified 600V s, Butt & Parallel Splices Solid or Stranded V Max. Recognized under s, Butt & Parallel Splices (00 V Fixture the component program Solid or Stranded 1 or Sign) of Underwriters s, Butt & Parallel Splices 90 C Max. Laboratories Incorporated File No. E Solid or Stranded 1 Note: terminals and splices are stamped in accordance with MIL-T Stranded wire only using TETR-CRIMPtooling. Table of Contents s Ring Tongue Ring Tongue 90 Bend and Rectangular Tongue Spade Tongue Flanged Spade Tongue Short Spring Spade Tongue and Long Spring Spade Tongue , 47 Slotted Ring Tongue and Hook Tongue Flag Tongue and Multiple Stud Splices Butt Parallel and Shur-Plug (.093,.156 and.180 Series) Way Connector and Tube Cap ssembly

38 PLSTI-GRIP (Continued) Ring Tongue s Vinyl, UL 94V-0 Body Copper per STM B-152 pplication Tooling pg ,260 [ ] Tongue Dimensions Wire Part Numbers Stud Style Thickness Size W C E L Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted 2 M * * * * * * * M Black * * * M * * * * Black * * * / M * Black *vailable in small packaging quantities. Note: C dimension applies from edge of metal wire barrel to center of stud hole. (Styles & E). 38

39 PLSTI-GRIP (Continued) Ring Tongue s (Continued) Tongue Dimensions Wire Part Numbers Stud Style Thickness Size W C E L Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted * / M Black , [ ] * / Black * * * M * * * * M * * * Black * /4 M * Black /16 M * / * Black /Blk..200 M HD /Blk M /Blk * /Blk Not ULor CSpproved or Listed. *vailable in small packaging quantities. 1 Heavy Duty for extra mechanical strength. Note: C dimension applies from edge of metal wire barrel to center of stud hole. (Styles & E). 39

40 PLSTI-GRIP (Continued) Ring Tongue s (Continued) C Vinyl, UL 94V-0 Body Copper per STM B-152 pplication Tooling pgs. 72 & 73 E 40 Tongue Dimensions Wire Part Numbers Stud Style Thickness Size W C E L Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted /Blk / M /Blk HD / /Blk M / /Blk /2 M /Blk * M * M * * Black ,180-13, [ ] * * E Black.300 1/ M * * * /16 M Black * / * /2 M * *vailable in small packaging quantities. 1 Heavy Duty for extra mechanical strength. Note: C dimension applies from edge of metal wire barrel to center of stud hole. (Styles & E).

41 PLSTI-GRIP (Continued) Ring Tongue s (Continued) 8 13,0-20,800 [ ] 6 20,800-33,0 [ ] B C D F Tongue Dimensions Wire Part Numbers Stud Style Thickness Size W C E L Diameter Loose Tape Max. Max. Max. Color Max. Piece Mounted 8 M4 C D B /4 M6 C * /16 M8 C * /8 C * /2 M M4 C * B * C * F / M C * /16 M8 B * /8 B * /2 M12 C *1 *vailable in small packaging quantities. Note: C dimension applies from edge of metal wire barrel to center of stud hole. (Styles & E). 41

42 PLSTI-GRIP (Continued) Ring Tongue s (Continued) Vinyl, UL 94V-0 Body Copper per STM B-152 pplication Tooling pg. 73 B Tongue Dimensions Wire Part Numbers Stud Style Thickness Size W C E L Diameter Loose Tape Max. Max. Max. Color Max. Piece Mounted B * /4 M6 B * ,0-52, [ ] / M8 B * 3/8 B * /4 M6 B * ,600-83, / B [ ] 1.52 M /8 B /16 M8 B / , , /8 B [ ] /2 M12 B /0 119, , /16 B [ ] 2.11 M *vailable in small packaging quantities. 42

43 PLSTI-GRIP (Continued) Ring Tongue 90 Bend s Vinyl, UL 94V-0 Body Copper per STM B-152 pplication Tooling pg ,0-20,800 [ ] 6 20,800-33,0 [ ] Tongue Dimensions Wire Stud Thickness Size W D Diameter Max. Min. Color Max / M / M Part Numbers Loose Piece Rectangular Tongue s Vinyl, UL 94V-0 Body Copper per STM B-152 pplication Tooling pg. 72 Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L X Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted M Note: C dimension applies from edge of metal wire barrel to center of stud hole. 43

44 PLSTI-GRIP (Continued) Spade Tongue s Vinyl, UL 94V-0 Body Copper per STM B-152 pplication Tooling pg. 72 Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L X Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted * M * * , [ ] M * * * * M * M * * ,180-13, [ ] * *vailable in small packaging quantities. Gold Note: C dimension applies from edge of metal wire barrel to center of stud hole. 44

45 PLSTI-GRIP (Continued) Flanged Spade Tongue s Vinyl, UL 94V-0 Body Copper per STM B-152 pplication Tooling pg ,260 [ ] 12-5,180-13,0 [ ] Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L X H Diameter Loose Tape Max. Min. Max. Max. Min. Color Max. Piece Mounted * M M * * * M M M * M * *vailable in small packaging quantities. Note: C dimension applies from edge of metal wire barrel to center of stud hole. 45

46 PLSTI-GRIP (Continued) Short Spring Spade Tongue s Vinyl, UL 94V-0 Body Phosphor Bronze per STM B-139 for wire sizes 24 to 14 Brass per STM B-36 for wire sizes 12 to except where noted pplication Tooling pg. 72 Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L X Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted , White [ ] * M * * M * * * , [ ] M * * * * * * M * * M * * * * * *vailable in small packaging quantities. 1 body plating Gold per MIL-G over Nickel per QQ-N-290. Note: C dimension applies from edge of metal wire barrel to center of stud hole. 46

47 PLSTI-GRIP (Continued) Short Spring Spade Tongue s (Continued) 12-5,180-13,0 [ ] Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L X Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted * M * * M * * * * * * *vailable in small packaging quantities. 1 body plating Gold per MIL-G over Nickel per QQ-N-290. Note: C dimension applies from edge of metal wire barrel to center of stud hole. Long Spring Spade Tongue s Vinyl, UL 94V-0 Body Phosphor Bronze per STM B-139 for wire sizes 22 to 14 Brass per STM B-36 for wire sizes 12 to pplication Tooling pg ,260 [ ] 12-5,180-13,0 [ ] Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L X Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted 6 M * M * * M * M B l u e 52464* * M * * *vailable in small packaging quantities. Note: C dimension applies from edge of metal wire barrel to center of stud hole. 47

48 PLSTI-GRIP (Continued) Slotted Ring Tongue s Vinyl, UL 94V-0 Body Copper per STM B-152 pplication Tooling pg. 72 Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted M , [ ] M Note: C dimension applies from edge of metal wire barrel to center of stud hole. Hook Tongue s Vinyl, UL 94V-0 Body Copper per STM B-152 pplication Tooling pg. 72 Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted M Note: C dimension applies from edge of metal wire barrel to center of stud hole. 48

49 PLSTI-GRIP (Continued) Flag Tongue s Vinyl, UL 94V-0 Color Natural Body Copper per STM B-152 pplication Tooling pg. 72 B Tongue Dimensions Wire Part Numbers Style Stud Thickness Size W C L D Stripe Diameter Loose Piece Max. Min. Max. Max. Color Max HD 1 8-3, Green [ ] B HD Black Black ,180-13, [ ] Heavy Duty for extra mechanical strength. Multiple Stud s Vinyl, UL 94V-0 Body Copper per STM B-152 pplication Tooling pg. 72 Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L Diameter Loose Tape Max. Min. Max. Max. Color Max. Piece Mounted , [ ] Note: C dimension applies from edge of metal wire barrel to center of stud hole. 49

50 PLSTI-GRIP (Continued) Butt Splices Vinyl, UL 94V-0 Splice Body Copper per STM B-152 pplication Tooling pg. 72 Dimension Splice Wire Part Numbers 1 L Diameter Loose Tape Max. Color Max. Piece Mounted [ ] * / / Stripe * * Natural w/ Letters * 509-3,260 [ ] * Natural w/ Stripes * x x * * Natural w/ Letters * * Natural w/ Stripes * * x x * * Natural w/ Stripes * * 5,180-13,0 [ ] x x x 3.51 x * Not UL or CSpproved or Listed. *vailable in small packaging quantities. 1 When using two or more wires in either end of a butt splice, the combined cross sectional area must be within the (CM) circular mil range listed. (Not ULor CSapproved with use of multiple wires.) splices are range in accordance with MIL-T Oval expansion. 4 Funnel entry 5 Oval expansion at one end; circular expansion at other end. 50

51 PLSTI-GRIP (Continued) Parallel Splices Vinyl, UL 94V-0 Splice Body Copper per STM B-152 pplication Tooling pg. 72 Dimension Splice Wire 1 L Max. Color Diameter Max ,260 [ ] x x ,180-13,0 [ ] *vailable in small packaging quantities. 1 When using two or more wires in a parallel splice, the combined cross sectional area must be within the (CM) circular mil area listed. 2 Oval expansion. Part Numbers Loose Piece 34131* 34132* 34133* 34134* * * Shur-Plug (.093,.156 and.180 Series).093 Series (.093 Series) Vinyl, UL 94V-0 Body Brass per STM B-36 pplication Tooling pg. 72 (.156 &.180 Series).156 Series Vinyl, UL 94V-0 Body Copper per STM B Series Tongue Dimension Wire Part Numbers Series L Diameter Loose Tape Thickness Max. Max. Color Max. Piece Mounted , [ ] * * Not UL or CSpproved or Listed. *vailable in small packaging quantities. 51

52 PLSTI-GRIP (Continued) 3-Way Connector Vinyl, UL 94V-0 Body Copper per STM B-152 Rivet Brass per QQ-B-626 pplication Tooling pg. 72 Tongue Dimensions Wire Part Number Thickness W L Diameter Max. Max. Max. Color Max. Loose Piece * *vailable in small packaging quantities. Tube Cap ssembly Vinyl, UL 94V-0 Body Copper per STM B-152 Tube Cap Copper/Zinc alloy per MIL-C-50 Rivet Brass over Copper pplication Tooling pg. 72 Tongue Dimensions Wire Part Number Thickness E L Diameter Max. Max. Max. Color Max. Loose Piece , Black [ ] Not UL or CSpproved or Listed. Wire Pins Body Sleeve L Dimensions Wire Tab Ins. L Diameter Max. Color Max. Part Number (Tape) (Loose Piece) 52

53 MPLI-BOND Product Facts Designed to accommodate wire gauges 8 WG through 4/0 WG The first large wire terminal to feature vinyl insulation bonded to the terminal sleeve s for wire sizes 8 WG through 4/0 WG meet the requirements of MIL-T-7928, Type II, Class 2 Precision-engineered terminal offering the heavyduty wire user uniformly high quality connections with permanent insulation support and protection against flash over pplied in a single effortless operation with the MP DYN-CRIMP tool Why Bonding? insulators need to withstand intense crimping pressures necessary for t o d a y s high wire-to-terminal contact requirements Bonded insulation transmits this pressure evenly to the center of the crimp area positive bond allows for uniform insulation thickness, maintains proper dielectric and tensile values and controls the extrusion of plastic under the crimping dies in the finished connection The Crimp Because both wire and terminal are confined over a greater area during the crimp, a homogeneous mass is achieved Crimp is applied gradually to encourage full movement of the wire with minimum extrusion Compare this MP method of applying pre-insulated solderless terminals to large gauge wires with the cumbersome mechanical fitting, brazing and manual insulating techniques still used in many plants Inner Bonding Sleeve. is bonded to this (STM B-152) copper sleeve the primary property of superior MPLI-BOND terminal construction. Fully Protected Rear Support Ring. Separate metal ring provides insulation support to dampen vibration and prevent sharp bends on conductor. Steel (STM -9, Tin plated per STM B-545). Temperature Rating: 5 C Max. Table of Contents Barrel with Brazed Seam, Dimpled Inner Surface. Each MPLI-BOND terminal body is individually brazed for ruggedness and deformation control during the crimping operation. Dimpling on inner barrel surface provides more contact area of wire to terminal and additional tensile strength. Basic. The basic terminal is constructed of fine grade high conductivity copper per STM B-152 and tin-plated per STM B-545. MP s special plating process creates durable corrosion resistance to salt spray and most chemical fumes. Proofmarked and Color Coded. Color coding of terminals provides rapid indentification, for selection of proper terminal. For additional quality control, crimping die embosses wire size number on insulation. Vinyl insulation extends minimum distance beyond terminal barrel to prevent exposure of conductor during stress and vibration. s Ring Tongue MPLI-BOND s meet or exceed the requirements of MIL-T-7928, Type II,Class 2. Refer to MP Qualified Products for Military pplication, Catalog for Military Specification Number to MP Part Number cross reference. 53

54 MPLI-BOND (Continued) Ring Tongue s Vinyl Body Copper per STM B-152 Support Ring Steel per STM -9 except where noted. pplication Tooling pg. 73 Tongue Dimensions Wire Part Numbers Stud Thickness Size Style W C E L D Diameter Loose Tape Max. Max. Max. Min. Color Max. Piece Mounted M B ,0-20, [ ] B / M B /16 M / /2 M body plating Gold per MIL-G over Nickel per QQ-N

55 MPLI-BOND (Continued) Ring Tongue s (Continued) Tongue Dimensions Wire Part Numbers Stud Thickness Size Style W C E L D Diameter Loose Tape Max. Max. Max. Min. Color Max. Piece Mounted B ,800-33, [ ] 1/ M B / M * / / M ,0-52, B [ ] / M8 B / B /2 M / M ,600-83,700 [ ] B / M B *vailable in small packaging quantities. 55

56 MPLI-BOND (Continued) Ring Tongue s (Continued) Vinyl Body Copper per STM B-152 Support Ring Steel per STM -9 pplication Tooling pg ,600-83,700 [ ] 1/0 83, ,500 [ ] 2/0 119, ,500 [ ] 3/0 150, ,000 [ ] 4/0 190, ,000 [ ] Tongue Dimensions Wire Part Numbers Stud Thickness Size Style W C E L D Diameter Loose Tape Max. Max. Max. Min. Color Max. Piece Mounted / B /2 M / M6 B /16 M / B /2 M /16 M / B /2 M /16 M / B / M / / M

57 Product Facts Bonded insulation bbreviated copper support sleeve (does not extend beyond end of wire barrel) Special insulation colors Designed with signal in mind Designed not to slip or fall off due to heat cycling or vibration Fast accurate product and wire identification Low profile Meets the requirements of R (ssociation of merican Railroads signal manual) ccommodates wire gauges 20 WG through WG PLSTI-BOND. Vinyl insulation extends beyond terminal barrel to prevent exposure of conductor during stress and vibration. Insulated sleeve provides circumferential support to the wire and allows the wire to be bent in any direction, without fraying the wire s insulation or breaking the conductor. Inner Bonding Sleeve. is bonded to an STM B-152 copper sleeve. Temperature Rating: 85 C Max. Serrations. Serrations inside barrel provide maximum contact and tensile strength after crimping. Basic. The basic terminal is constructed of fine grade high conductivity copper per STM B-152 and tin-plated per STM B-545. MP s special plating process creates durable corrosion resistance to salt spray and most chemical fumes. Table of Contents s Ring Tongue and Tooling

58 PLSTI-BOND (Continued) Ring Tongue s Vinyl Body and Metallic Sleeve Copper per STM B-152 pplication Tooling shown below Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L Diameter Loose Max. Min. Max. Max. Color Max. Piece Green 20-16HD , [ ] Green HD / M Black / ,180-13,0 [ ] 1.07 M Black Heavy duty for extra mechanical strength. Note: C dimension applies from edge of metal wire barrel to center of stud hole. Tooling Tool Part No (20-16 HD, ) Tool Part No (12- EXP.) 58

59 TERMINYL Product Facts Designed to provide insulated terminals and splices for large wire sizes, many of which are used in airborne and ground support applications Tested under the procedures stipulated by MIL Spec. MIL-T-7928, they meet and exceed requirements Designed and engineered to withstand extreme vibration, shock and structural stresses, elevated temperatures and other conditions which could adversely affect the circuit requirements in complex air and space flight equipment The use of matching MP tooling provides for precision crimping which makes all terminations identical This uniformity promotes maximum reliability and, coupled with tool die marks on the barrel indicating the wire size and color coding of the insulation sleeve, also serves as a built-in quality control factor Pre-insulated with color coded nylon which also acts as insulation support Wire size range of terminals is 8 WG through 4/0 WG Funnel Entry. Molded insulation for ease of wire insertion and snug fit over MIL-standard wire diameters. Dimples. Dimples afford maximum contact of barrel and wire and maximum tensile strength. Temperature Rating: 5 C Max. Table of Contents Basic. The basic terminal is constructed of fine grade high conductivity copper per STM B-152 and tin-plated per STM B-545. MP s special plating process creates durable corrosion resistance to salt spray and most chemical fumes.. Nylon insulation for dielectric strength, color coded to wire size. s Ring Tongue , 61 Splices Butt TERMINYL s meet or exceed the requirements of MIL-T-7928, Type II,Class 2. Refer to MP Qualified Products for Military pplication, Catalog for Military Specification Number to MP Part Number cross reference. 59

60 TERMINYL (Continued) Ring Tongue s Nylon, UL 94V-2 Body Copper per STM B-152 pplication Tooling pg. 73 Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L Diameter Loose Max. Max. Max. Color Max. Piece 8 M / ,0-20, M [ ] 5/ M / / ,800-33, M [ ] 5/ M / M / ,0-52, M [ ] 5/ M / * 1/2 M /4 M HD / ,0-52, M [ ] 3/ /4 M / ,600-83, M [ ] 3/ /2 M *vailable in small packaging quantities. 1 Rectangular tongue terminal bend ring tongue terminal. 3 Heavy duty for extra mechanical strength. 60

61 TERMINYL (Continued) Ring Tongue s (Continued) Tongue Dimensions Wire Part Numbers Stud Thickness Size W C E L Diameter Loose Max. Max. Max. Color Max. Piece / M /0 83, , / M [ ] 3/ /2 M / M /0 119, , / [ ] 1/2 M /0 150, , / [ ] /0 3/8 190, , [ ] 1/2 M

62 TERMINYL (Continued) Butt Splices Sleeve Nylon, UL 94V- 2 Splice Body Copper per STM B-152 pplication Tooling pg. 73 Dimension Splice Wire Diameter Max. Style L Max. Color Single End Multiple End Part Numbers 8 to 12-13,0-20,800 [ ] Single to Single w/ Step-Down at.255 to ssembly adapter end ,180-13, [ ] 6 to 8 20,800-33,0 [ ] Single to Single w/ Step-Down at.3 to ssembly adapter end ,0-20, [ ] 8 13,0-20, [ ] ,800-33, [ ] Single to Single Standard Splice 33,0-52, [ ] ,600-83, [ ] ,0-20, [ ] Single to Multiple 20,800-33, Standard Splice [ ] ,0-52, [ ] ,0-20, [ ] Multiple to Multiple 20,800-33, Standard Splice [ ] ,600-83, [ ] Step-Down ssembly includes adapter which is visible through insulation sleeve window. 62

63 CERTI-SEL Product Facts Nylon window splice for military, commercial, aircraft, and missile applications that seals out vapors and fluids and imparts exceptional wire insulation support Metal rings at both ends of splice and permanently crimped to wire insulation for a moisture tight seal, even at altitude Designed to fit more than 0 insulation diameters in MIL-Spec wires from #24 to # WG, and is available in three types First type is made with a nylon ring adapter within the wire entrance Second type, without nylon ring adapters Third type with a nylon ring adapter in one end only Special notch feature on the outside of the splice allows locator in the crimping tool to precisely position splice before crimping and to prevent twisting or horizontal movement during crimping Window area of each splice permits visual inspection of the linear plane of the crimp in relation to the inner metal sleeve Wire-stops in splice barrel indicate exact insertion depth of stripped wire-ends Color Coding. The splice body is color coded by wire size: Tin plated for 24-20, for 22-18, for, for 12-. The metal rings are color coded green or orange to identify the presence of adapters. Rings. Metal rings at both ends permanently seal the splice to the wire insulation for a moisture tight seal. dapters. Nylon ring adapter allows for smaller wire insulation diameters. Table of Contents Basic Splice. The basic splice body is constructed of fine grade high conductivity copper per STM B-152 and is either color coded or tin-plated per STM B-545. MP s special plating process creates durable corrosion resistance to salt spray and most chemical fumes.. Nylon insulation assures high dielectric strength. Special notch feature allows crimping tool locator to position the splice to prevent twisting during crimping. Splices and Tooling

64 CERTI-SEL (Continued) Splice Nylon, UL 94V-2 Splice Body Copper per STM B-152 or Zinc Plate/Dye Chromate pplication Tooling shown below Splices with nylon wire insulation diameter adapters L Body Ring Wire Max. Color Color Dia.Max. Part Numbers Hand Tool Part No , Tin Plated Green.065 [ ] , Tin Plated Orange.073 [ ] , Green.1 [ ] Green ,180-13, Green.150 [ ] Splices without nylon wire insulation diameter adapters L Body Ring Wire Max. Color Color Dia.Max. Part Numbers Hand Tool Part No , Tin Plated Tin Plated.0 [ ] Tin Plated.133 [ ] Tin Plated ,180-13, Tin Plated.218 [ ] HD Tin Plated Tin Plated Splices with nylon wire insulation diameter adapter in one end L Body Ring Wire Dia.Max. Part Hand Tool [mm Max. Color Color dapter End Other End Number Part No. 2 ] , Tin Plated Orange & Tin Plated [ ] Tooling Tool Part No or Tool Part No or Hand tooling features the MP CERTI-CRIMPratchet so that the operator fully closes tool so that crimping dies in tool head fully bottom. Locator feature in head assures that splice is properly oriented in tool. CERTI-SEL Tools do not require wire insulation adjustment prior to crimping. 64

65 Class 1 and Class 2 Military pprovals pproval Dimensional Requirement pplication Tooling Use Performance Requirement s must comply Hand application tool For procurement with the dimensional which must conform to by government Class 1 requirements specified the military s dimensional agencies for by the military. and performance maintenance and specification. repair. s must comply The terminal For procurement Per Military with the dimensional manufacturers by contractors Specification requirements specified recommended and Mil-T-7928G by the manufacturer s application tooling. manufacturers Class 2 customer drawing. For field repair purposes Note: Several tape mounted part numbers for high volume production, Class 2 terminals must are currently Class 2 modification, be capable of being approved. and repair. replaced by Class 1 s. Military Specifications MS WG MS25036 PIDG Part Numbers Dash Numbers Loose Piece Tape Mounted Class Stud Size & & & & & & 2 5/ / & 2 5/ / & 2 3/ / & 2 3/ / & & & & 2 5/ / & 2 3/ / & & & & & 2 5/ / & 2 5/ / & 2 3/ & 2 3/ /8 65

66 Class 1 and Class 2 Military pprovals (Continued) Military Specifications MS (Continued) WG MS25036 Dash Numbers MPLI-BOND and TERMINYL Part Numbers Loose Piece Tape Mounted Class Stud Size / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / /4 1/ / / / / / /16 2/ / / / / / / / /2 4/ / / / /2 1 MP Incorporated recommends #1/0 WG terminals for #1 WG application. 66

67 Class 1 and Class 2 Military pprovals (Continued) Military Specifications MS (Continued) WG MS25036 Dash Numbers PIDG Part Numbers Loose Piece Tape Mounted Class Stud Size & & & & & & & & & & 2 1/ / & 2 1/ / & 2 1/ & & & 2 1/ / & 2 1/ & & & 2 1/ / & 2 1/ / /2 67

68 Class 1 and Class 2 Military pprovals (Continued) Military Specifications M7928/1 M7928/1 PIDG- Restricting WG Dash Part Numbers Class Stud Size Numbers Loose Piece Tape Mounted & & & & & & & & & & & & & & & & 2 1/ & 2 5/ & 2 3/ & 2 1/ & & & & & & 2 1/ & 2 5/ & 2 3/ & 2 1/ & & & & & & 2 1/ & 2 5/ & 2 3/ & 2 1/ & & & & & & 2 1/ & 2 5/ & 2 3/ & 2 1/2 68

69 Class 1 and Class 2 Military pprovals (Continued) Military Specifications M7928/1 (Continued) M7928/1 PIDG- Restricting WG Dash Part Numbers Class Stud Size Numbers Loose Piece Tape Mounted & & & & & & 2 1/ & 2 5/ & 2 3/ & 2 1/ & & & & 2 1/ & 2 5/ & 2 3/ / & & & & 2 1/ / & 2 5/ & 2 3/ /2 Military Specifications M7928/4 M7928/4 PIDG PVF 2 WG Dash Part Numbers Class Stud Size Numbers Loose Piece Tape Mounted & & & & 2 5/ & 2 3/ & & & & 2 5/ & 2 3/ & & & 2 5/ & 2 3/ & & & & & 2 69

70 Class 1 and Class 2 Military pprovals (Continued) Military Specifications M7928/4 (Continued) M7928/4 PIDG PVF 2 WG Dash Part Numbers Class Stud Size Numbers Loose Piece Tape Mounted & & & 2 1/ / & 2 1/ & & & 2 1/ & 2 1/ & & 2 1/ /2 Military Specifications M7928/5 M7928/5 PIDG Window Splice WG Dash Part Numbers Class Numbers Loose Piece Tape Mounted & & & & & 2 Military Specifications M7928/6 M7928/6 PIDG Window Splice PVF 2 WG Dash Part Numbers Class Numbers Loose Piece Tape Mounted & & & & 2 70

71 .Class 1 and Class 2 Military pprovals (Continued) Military Specifications MS MS17143 PIDG WG Dash Part Numbers Class Stud Size Numbers Loose Piece Tape Mounted & & & & & & & & & & & & & & & & & & & & &

72 Tooling Insulated s and Splices 30 to WG Wire Range Description Tools for Loose Piece Termination Tools for Tape Mounted Terminations Hand Tools Pneumatic Tools Tape Dies for Tape Dies for Tape Dies for Tape Dies for Tape Dies for MP Single Multi- Heads for Heads for Dies for MPOMTOR Wire Wire Wire , TPETRONIC MP-O-LECTRIC UTO-PRO CLS III G, CLS IV MP-O-LECTRIC Range Range Range Single Wire Multi-Wire , No pplicator Model G pplicator pplicator Model K Range Range , Required pplicator pplicator u s e s Terms P I D G * 69872* 69872* 69872* 69872* s & S p l i c e s a n d P L S T I - G R I P ( exp.) * 69873* 69873* 69873* 69873* T e r m i n a l s Std * 69874* 69874* 69874* 69874* HD (.300 exp.) (.300 exp.) (.300 exp.) (.300 exp.) (.300 exp.) (.300 exp.) (.300 exp.) (butt spl. only) (butt spl. only) (butt spl. (butt spl o n l y ) o n l y ) (butt spl. only) (butt spl. only) (butt spl. only) (butt spl. only) (butt spl. only) (parallel spl. only) P L S T I - G R I P (butt spl. only) (butt spl. (butt spl S p l i c e s o n l y ) o n l y ) (butt spl. only) (butt spl. only) (butt spl. only) (butt spl. only) (butt spl. only (parallel spl. only) (butt spl. only) HD (.300 exp. (butt spl. butt spl. only) o n l y ) (butt spl. only) (butt spl. only) (butt spl. only) (butt spl. only) (butt spl. only) (parallel spl. only) Tooling with adjustable insulation crimp. *Same die set/configuration as in hand tools. 1 TETR-CRIMP die configuration. 2 PRO-CRIMPER II commercial tool not approved for UL applications hand tool Pneumatic Tool dapter 72 For additional information call the Tooling ssistance Center

73 Tooling (Continued) Insulated s and Splices 8 to 4/0 WG Wire Range Tools for Loose Piece Terminations Tools for Tape Mounted Terminations Description Wire Hand Tools Dies for Crimp Head Dies for Head for Dies for Dies for MP Size Crimp Head Penumatic MP Tapetronic Tapetronic Machine & Hydraulic Hand Tool Hand Tool Machine with & djustment PLSTI-GRIP s and Splices / / MPLI-BOND s 1/ / / / TERMINYL s 1/ and Splices 2/ / / HD Heads for Power Units , , or No insulation crimp. 3 Large expansion dies. 4 Without insulation crimp. 5 With insulation crimp. Insulated FSTON 26 to WG Wire Range Tools for Tape Mounted Terminations Tools for Strip Form Terminations Hand Tool Tape Dies for TPETRONIC Tape Dies for MP-O-LECTRIC 1 Tape Dies for MPOMTOR MPOMTOR CLS III G, CLS IV No pplicator Required Model G CLS III G, CLS IV pplicators pplicator pplicator * (Natural) * * *Only UL and CS approved. 1 MP-O-LECTRIC Model K uses applicator Die included with applicator. For additional information call the Tooling ssistance Center

74 Tooling (Continued) Loose Form and Splice Tooling CERTI-CRIMP Hand Tools Double ction Hand Tool Heavy Head Hand Tool C Head Straight ction Hand Tool Part No PRO-CRIMPER II Hand Tool Part No T-HED Tool Part No , TETR-CRIMP Hand Tool Part No Hydraulic Hand Tools Part No (Dies Required) 74

75 Tooling (Continued) Pneumatic Tools Part No (Hand ctuation) Part No (Foot ctuation) Part No Crimping Heads Part No ( ) Part No ( ) Latch Heads and Dies Part No Tool 75

76 Tooling (Continued) Tape Mounted MP-TPETRONIC Machine 69875, (Requires Dies) MP-O-LECTRIC, Model G Machine (Requires pplicator and Dies) UTO-PRO Machine (Requires pplicator and Dies) MPOMTOR CLS IV Machine (Requires pplicator and Dies) 76