Ultra- Fast Seres 0, 25, Applcaton Specfcaton 87, 205, and 250 Fully- Insulated 4-223 FASTON* Termnals 22 FEB 3 Rev H All numercal values are n metrc unts [wth U.S. customary unts n brackets]. Dmensons are n mllmeters [and nches]. Unless otherwse specfed, dmensons have a tolerance of +0.3 [+.005] and angles have a tolerance of +2. Fgures and llustratons are fordentfcaton only and are not drawn to scale.. INTRODUCTION Ths specfcaton covers the requrements for applcaton of Ultra--Fast, Ultra--Fast Flag, Ultra--Fast Tab, Ultra--Fast Plus, and Ultra--Fast Plus Tab Seres 0/25, 87, 205, and 250 Fully--Insulated FASTON Termnals. These termnals are desgned for use n 600--V applcatons. The translucent nylon 6/6 nsulated housng on the termnals provdes protecton from short crcuts and shock hazard. Ultra--Fast Termnal famly products are color coded by wre sze. Many of these products are avalable wth ether a standard or large nsulaton dameter (LID) barrel. Each termnal has the seres number and wre sze molded nto the nsulaton. Internal serratons n the wre barrel permt F crmp relablty. Ultra--Fast Plus Termnals feature a co--molded housng produced from two dfferent nylon materals. Ths nsulaton barrel s crmpable and provdes wre stran relef n extreme wre dress stuatons or where vbraton s present. The termnals are avalable n strp form for termnatng wth sem--automatc or fully--automatc powered machnes, and n loose--pece for termnatng wth manual hand--held tools. When correspondng wth TE Connectvty Personnel, use the termnology provded n ths specfcaton to facltate your nqures for nformaton. Basc terms and features of ths product are provded n Fgure. Ultra- Fast FASTON Flag Termnal (Receptacle Shown) Corrugatons Low Inserton Force (LIF) Splt Roll Feature Metal Carrer Strp Insulaton Gude TabSlot(2Places) Ultra- Fast FASTON Straght Termnal (Tab Shown) Insulaton Gude Insulaton Barrel Wre Barrel Ultra- Fast Plus FASTON Termnal (Receptacle Shown) Wre Inspecton Wndow Wre Stop Plastc Carrer Strp Funnel Entry Wre Sze and Seres Number Markng Color -Coded Insulated Housng Cutoff Tab Plastc Carrer Strp Fgure 203 Tyco Electroncs Corporaton, a TE Connectvty Ltd. Company TOOLING ASSISTANCE CENTER -800-722 - All Rghts Reserved PRODUCT INFORMATION -800-522 -6752 TE logo s a trademark. *Trademark. Other product names, logos, or company names mght be trademarks of ther respectve owners. Ths controlled document s subject to change. For latest revson and Regonal Customer Servce, vst our webste at www.te.com of 5 LOC B
2. REFERENCE MATERIAL 2.. Revson Summary Added new text to Paragraph 3.5.B 2.2. Customer Assstance Product Part Number 52026 and Product Code 7 are representatve of Ultra--Fast Fully--Insulated FASTON Termnals. Use of these numbers wll dentfy the product lne and expedte your nqures through a servce network establshed to help you obtan product and toolng nformaton. Such nformaton can be obtaned through a local TE Representatve or, after purchase, by callng the Product Informaton Center at the number at the bottom of page. 2.3. Drawngs Customer drawngs for product part numbers are avalable from the servce network. If there s a conflct between the nformaton contaned n the Customer Drawngs and ths specfcaton or wth any other techncal documentaton suppled by TE, call the Product Informaton Center at the number at the bottom of page. 2.4. Specfcatons The followng Product Specfcatons cover test and performance requrements: 08--207 Ultra--Fast Tabs 08--2043 Ultra--Fast Receptacles and Ultra--Fast Flag Receptacles 08--2044 Ultra--Fast Plus Receptacles 2.5. Instructonal Materal The followng lst ncludes avalable nstructon sheets (408--seres) that provde assembly procedures for product, operaton, mantenance and repar of toolng; and customer manuals (409--seres) that provde setup, operaton, and mantenance of machnes. 408--2095 Hand Crmpng Tools 6970-- 408--3295 Preparng Reel of Contacts for Applcator Toolng 408--405 Straght Acton Crmper 27200-- 408--453 Crmpng De Assembles 224027-- and --2 408--6976 Hand Crmpng Tool Frame 58078--3 408--805 Mnature Quck--Change Applcators (Sde--Feed Type) 408--8053 Converson Gude for Mnature Quck--Change Applcators 408--8058 Mnature Quck--Change Applcators (End--Feed Type) 408--8079 Mnature Quck--Change Applcators (Sde--Feed Type wth Insulaton Crmper) 408--9225 Crmpng De Assembles 58269--2 through 58269--5 408--9227 Crmpng De Assembles 58268-- and 58268--2 408--9277 Crmpng De Assembly 58052--3 408--9278 Crmpng De Assembles 58079--3 and 58080--3 408--9279 Crmpng De Assembles 90390--3 and 9039--3 408--9296 Crmpng De Assembles 58308-- and 58308--2 408--986 Handlng of Reeled Products 408--9902 Applcator Toolng Matrx (for Applcators 466778--4, 466779--4, 56704--2, 567082--2, 5677--2, and 56742--2) 409--528 AMP--O--LECTRIC* Model K Termnatng Machne 565435--5 409--5842 AMP--O--LECTRIC Model G Termnatng Machne 354500-- 409--5862 626 Pneumatc Toolng Assembles 8972-- and 89722-- 409--5878 AMPOMATOR* CLS IV+ Lead--Makng Machne 356500--[ ] 3. REQUIREMENTS 3.. Storage A. Ultravolet Lght Prolonged exposure to ultravolet lght wll attack and break down the nylon used n the termnal nsulaton. B. Reel Storage When usng reeled termnals, store col wound reels horzontally and traverse wound reels vertcally. 2 of 5 Rev H
C. Shelf Lfe 4-223 The termnals should reman n the shppng contaners untl ready for use to prevent damage to the termnals. The termnals should be used on a frst n, frst out bass to avod storage contamnaton that could adversely affect sgnal transmssons. D. Chemcal Exposure Do not store termnals near any chemcals lsted below, as stress corroson crackng may occur. Alkales Ammona Ctrates Phosphates Ctrates Sulfur Compounds Amnes Carbonates Ntrtes Sulfur Ntrtes Tartrates CAUTION! Where the above envronmental condtons exst, phosphor -bronze termnals are recommended nstead of brass. Exposure to alcohol wll break down the nsulaton barrel of Ultra -Fast Plus termnals. 3.2. Termnal Selecton These termnals are easly matched to the correct wre sze by ther color--coded nsulated housngs. Termnal color and correspondng wre range are lsted n Fgure 2. Termnals are also desgnated by tab thckness and tab wdth (seres number). Each product groupng offers a partcular assortment of choces. Contact your local TE Representatve for current avalable choces. COLOR WIRE RANGE Volet 26-22 Red 22-8 Blue 6-4 Yellow 2-0 Fgure 2 3.3. Wre Selecton The termnals wll accept sold, fused, and stranded wre (except flag termnals whch accept stranded wre only) szes and nsulaton dameter shown n Fgure 3. TYPE WIRE SIZE RANGE (AWG) WIRE INSULATION DIAMETER Ultra -Fast 26-0 8.3 [.320] Max Ultra -Fast Flag 22-4 6.60 [.260] Max Ultra -Fast Plus 22-4.52-4.06 [.060 -.60] 3.4. Wre Preparaton Strp the wre to the dmensons gven n Fgure 4. Fgure 3 CAUTION! DO NOT nck, cut, or scrape the wre conductor durng the strppng operaton. Rev H 3 of 5
Note: Not to Scale Wre Strp Length SERIES WIRE SIZE RANGE WIRE STRIP LENGTH (+0.4 [+.06]) (AWG) ONEWIRE TWO WIRES 0/25 26-4 7.4 [.28] 7.92 [.32] 87 22-4 7.4 [.28] 7.92 [.32] 87 Flag Termnals LID (Large Insulaton Dameter Wre) 6-4 7.92 [.32] 8.5 [.335] 205 22-8 7.4 [.28] 7.92 [.32] 205 Flag Termnals 22-8 7.92 [.32] 8.5 [.335] 250 22-4 7.4 [.28] 7.92 [.32] 2-0 7.92 [.32] 9.52 [.375] 250 Flag Termnals 22-4 7.92 [.32] 8.5 [.335] Fgure 4 3.5. Crmp Requrements The termnal must be crmped n the approprate toolng accordng to the nstructons packaged wth the toolng. CAUTION Termnal nsulaton shall NOT be cut or broken durng the crmpng operaton. Reasonable care should be taken by toolng operators to provde undamaged termnatons.! A. Delectrc Wthstandng Voltage Test Durng ntal toolng setup or after any toolng change or replacement, fve sample termnals shall be tested for delectrc wthstandng voltage as follows: Prepare samples by applyng them to wre n accordance wth the crmp requrements. Seal the matng end of the termnal wth delectrc wax or other sutable materal to prevent entrance of the lead shot. Embed the samples n lead shot no. 2 (.27 [.050] n dameter). Apply a test potental of 3400 Vac to the wre at a rate of 500 V per second for one mnute, wth the lead shot actng as the other electrode. The samples shall show no electrcal breakdown or flash--over as a result of ths testng procedure. B. Crmp Heght Because these termnals are fully nsulated, crmp heght readngs cannot be measured over the nsulaton. Proper crmp heght must be measured usng a slug of sold--core solder wth a rato of 60% tn to 40% lead, 50/50 or tn Lead--Free verson solder s acceptable. Solder dameter accordng to wre sze s lsted n Fgure 5. WIRE SIZE RANGE (AWG) SOLDER DIAMETER 26-8 3.8 [.25] 22-8 (Flag Termnals) 4.75 [.87] 6-4 4.75 [.87] 2-0 6.35 [.250] Fgure 5 The heght of the crmped solder must meet the dmensons gven n Fgure 6. Solder slug crmp heghts are for applcators used n AMP -O -LECTRIC termnatng machne and AMPOMATOR lead -makng machne. Check nstructon sheets (408 -seres) for crmp heghts for de assembles used n AUTO -PRO machne and hand tools. DO NOT measure termnal wre barrel to obtan crmp heght. Follow these requrements for measurng crmp heght. Refer to Fgure 6 (solder slug crmp heght). 4 of 5 Rev H
CAUTION! Crmp heght dmensons must not be appled drectly to termnal. Ths practce wll over -crmp the termnal, crackng the wre barrel, and possbly cause damage to toolng. C. Cutoff Tab and Burr Cutoff tabs are the remanng porton of the carrer strp after the termnal s cut from the strp. The cutoff tab and burr must be vsble as shown n Fgure 6. D. Effectve Crmp Length Effectve crmp length s defned as that porton of the wre barrel, excludng bellmouths, fully formed by the crmpng tool. For optmum crmp effectveness, the crmp must be wthn the area shown and must meet the crmp requrements provded n Fgure 6. Straght Termnal (Receptacle Shown) Plus Receptacle Effectve Crmp Length (Crmp Must Be Centered +0.25 [+.00] Between Termnal Corrugatons) Wre Must Be Fully Inserted Wre Conductor Must Be Vsble Insulaton Barrel Must Be Tghtly Crmped Conductor Strands Must Be Vsble Through Inspecton Wndow Mn A Flag Receptacle 3.30-4.32 [.70 -.30] Secton A -A A Cutoff Tab Vsble Effectve Crmp Length (Crmp Must Be Centered +0.25 [+.00] Between Termnal Corrugatons) 0.38 [.05] Mn Fgure 6 (cont d) Rev H 5 of 5
SERIES 0/25 STRAIGHT RECEPTACLES INSULATION BARREL WIRE SOLDER SLUG TENSILE CRIMP HEIGHT STRENGTH WIRE RANGE TYPE DIAMETER QUANTITY SIZE (AWG) +0.05 [+.002] (Mn) N [lb] 26.52 [.060] 7.8 [4] 26-22 Standard d 2.54 [.00] Max 24.52 [.060] 26.7 [6] Standard 3.05 [.20] Max 20.65 [.065] 7.2 [6] 8.78 [.070] 89.0 [20] 22-8 20.65 [.065] 7.2 [6] Large 5.84 [.230] Max 8.78 [.070] 89.0 [20] 2 22.78 [.070] 44.5 [0] 20.78 [.070] 7.2 [6] 6.78 [.070] 33.4 [30] 6-4 Large 6.60 60 [.260] Max 4.90 [.075] 266.9 [60] 2 8.78 [.070] 89.0 [20] SERIES 87, 205, AND 250 STRAIGHT RECEPTACLES AND TABS INSULATION BARREL WIRE SOLDER SLUG TENSILE CRIMP HEIGHT STRENGTH WIRE RANGE TYPE DIAMETER QUANTITY SIZE (AWG) +0.05 [+.002] (Mn) N [lb] 20.65 [.065] 7.2 [6] Standard d 3.43 3 [.35] Max 8.78 [.070] 89.0 [20] 22.78 [.070] 44.5 [0] 2 20.78 [.070] 7.2 [6] 22-8 20.65 [.065] 7.2 [6] Large 5.84 [.230] Max 8.78 [.070] 89.0 [20] 2 22.78 [.070] 44.5 [0] 20.78 [.070] 7.2 [6] 6.78 [.070] 33.4 [30] Standard d 4.06 [.60] Max 4.90 [.075] 266.9 [60] 2 8.78 [.070] 89.0 [20] 6-4 6.78 [.070] 33.4 [30] Large 6.60 60 [.260] Max 4.90 [.075] 266.9 [60] 2 8.78 [.070] 89.0 [20] 2-0 Large 8.3 [.320] Max 2 2.4 [.095] 3.4 [70] 0 2.54 [.00] 355.9 [80] 2 6 2.4 [.095] 33.4 [30] 4 2.4 [.095] 266.9 [60] Seres 250 (2-0) termnals are avalable wth large dameter nsulaton barrel only. Fgure 6 (cont d) Refer to n Paragraph 3.5, B, Crmp Heght 6 of 5 Rev H
SERIES 87, 205, AND 250 FLAG RECEPTACLES INSULATION BARREL WIRE SOLDER SLUG CRIMP HEIGHT WIRE RANGE TYPE DIAMETER QUANTITY SIZE (AWG) +0.05 [+.002] 22-8 6-4 TENSILE STRENGTH (Mn) N [lb] 20.65 [.065] 7.2 [6] Standard 4.9 [.65] Max 8.78 [.070] 89.0 [20] 2 22.78 [.070] 44.5 [0] 20.78 [.070] 7.2 [6] 20.65 [.065] 7.2 [6] Large 5.84 [.230] Max 8.78 [.070] 89.0 [20] 2 22.78 [.070] 44.5 [0] 20.78 [.070] 7.2 [6] Standard d 4.70 [.85] Max Large 6.60 60 [.260] Max SERIES 0/25 PLUS RECEPTACLES 6.78 [.070] 33.4 [30] 4.90 [.075] 266.9 [60] 2 8.78 [.070] 89.0 [20] 6.78 [.070] 33.4 [30] 4.90 [.075] 266.9 [60] 2 8.78 [.070] 89.0 [20] INSULATION BARREL WIRE SOLDER SLUG WIRE RANGE CRIMP HEIGHT TYPE DIAMETER QUANTITY SIZE (AWG) +0.05 [+.002] 22-8 Standard.52-3.05 [.060 -.20] 0.76 -.52 [.030 -.060] TENSILE STRENGTH (Mn) N [lb] 20.65 [.065] 7.2 [6] 8.78 [.070] 89.0 [20] 2 22.78 [.070] 44.5 [0] SERIES 87 AND 250 PLUS RECEPTACLES AND SERIES 250 PLUS TABS INSULATION BARREL WIRE SOLDER SLUG WIRE RANGE CRIMP HEIGHT TYPE DIAMETER QUANTITY SIZE (AWG) +0.05 [+.002] 22-8 Standard 6-4 Standard.52-3.43 [.060 -.35] 0.76 -.70 [.030 -.067] 2.29-4.06 [.090 -.60].4-2.03 [.045 -.080] TENSILE STRENGTH (Mn) N [lb] 20.65 [.065] 7.2 [6] 8.78 [.070] 89.0 [20] 2 22.78 [.070] 44.5 [0] 6.90 [.075] 33.4 [30] 4 2.03 [.080] 266.9 [60] 2 8.90 [.075] 89.0 [20] Fgure 6 (end) Refer to n Paragraph 3.5, B, Crmp Heght Rev H 7 of 5
E. Straghtness 4-223 The force appled durng crmpng may cause some bendng between the wre barrel and the matng porton of the termnal. Such deformaton s acceptable wthn the followng lmts. The crmped porton, ncludng cutoff tab and burr, must not be bent beyond the lmts shown n Fgure 7. Straght Termnals and Plus Termnals Datum Lne.02 [.040] Max Bend Datum Lne Flag Termnals 90 Max 85 Mn F. Twst and Roll Fgure 7 There should be no twst or roll of the wre barrel or matng porton of the crmped termnal that would cause overstress or mpar usage. 3.6. Matng Overcycle The rolled shape of the receptacles determnes the contact matng force. Ths desgn s NOT ntended for a hgh number of matng cycles over the lfe of the product. Therefore, the maxmum number of matng cycles (matngs/un--matngs) recommended s 0. The forces requred to mate and unmate a test matng tab and receptacle are specfed n the Product Specfcatons (08--seres) lsted n Paragraph 2.4. The force must be measured usng a testng devce capable of holdng the readng. It must also provde accurate algnment wth slow and steady matng and unmatng of the test tab and receptacle. 3.7. Matng Tab Dmensons Features and dmensonal requrements for tab termnals ntended for matng wth these receptacles s lsted n Fgure 8. Test tabs shall have dmensons as shown n Fgure 8, except Dmenson C shall have a tolerance of +0.008 [+.0003] for brass tabs and +0.03 [+.0005] for steel, and rased plateaus around the detents shall be lmted to a total of 0.03 [.00] for both sdes. 8 of 5 Rev H
Tab Wthout Shoulders H B 0.76 [.030] Max (Sde Surface Bevel to Top Surface Bevel) C 45 Approx (2 Places) Center of Detent G Radus 0.25 [.00] Max Cutoff Flash No Wder or Thcker than Lead Edge D Overall Wdth of Shoulders Not Desgnated.4 [.045] Mn A (Front to Top Surface Bevel Use If Shoulder Exsts F E Use If No Shoulder Exsts Shoulders Optonal 0 +2 (Typ) Bevel need not be straght lne f wthn confnes as shown or Dmenson G+ [+.020] may be substtuted. TAB SIZE (Nomnal) 6.35 0.8 [.250.032] Wth Dmple 6.35 0.8 [.250.032] Wth Hole 5.2 0.8 [.205.032] Wth Dmple 5.2 0.8 [.205.032] Wth Hole 4.75 0.8 [.87.032] Wth Dmple 4.75 0.8 [.87.032] Wth Hole 4.75 [.87.020] Wth Dmple 4.75 [.87.020] Wth Hole 3.8 0.8 [.25.032] Wth Dmple or Hole 3.8 [.25.020] Wth Dmple or Hole 2.79 0.8 [.0.032] Wth Dmple or Hole 2.79 [.0.020] Wth Dmple or Hole A +0.3 [+.005] 0.76 [.030] 0.76 [.030] B (Mn) 7.80 [.307] 7.80 [.307] 6.20 [.244] 6.20 [.244] 6.22 [.245] 6.22 [.245] 6.22 [.245] 6.22 [.245] 6.98 [.275] 6.98 [.275] 6.98 [.275] 6.98 [.275] C +0.03 [+.00] 0.8 [.032] 0.8 [.032] 0.8 [.032] 0.8 [.032] 0.8 [.032] 0.8 [.032] 0.8 [.032] D +0.08 [+.003] 6.35 [.250] 6.35 [.250] 5.20 [.205] 5.20 [.205] 4.75 [.87] 4.75 [.87] 4.75 [.87] 4.75 [.87] 3.8 [.25] 3.8 [.25] 2.79 [.0] 2.79 [.0] DIMENSION E +0.20 [+.008] 3.86 [.52] 4.52 [.78] 2.54 [.00] 3.8 [.25] 2.54 [.00] 3.8 [.25] 2.54 [.00] 3.8 [.25].57 [.062].57 [.062].57 [.062].57 [.062] F +0.08 [+.003] 4.06 [.60] 3.40 [.34] 3.8 [.50] 3.8 [.25] 3.8 [.50] 3.8 [.25] 3.8 [.50] 3.8 [.25] 5.54 [.28] 5.54 [.28] 5.54 [.28] 5.54 [.28] G + [+.020].27 [.050].27 [.050].27 [.050].27 [.050].27 [.050].27 [.050].4 [.045].4 [.045] Notes:. For tab detent dmensons, see Paragraph 3.8. 2. Top and bottom tab surfaces shall be wthn.% and free from burrs greater than 0% of tab thckness or rased plateaus, except as noted n Paragraph 3.7. 3. Dmensonal measurements shall not nclude platng, burrs, or flatness tolerance. Fgure 8 H (Mn) 8.94 [.352] 8.94 [.352] 7.29 [.287] 7.29 [.287] 7.37 [.290] 7.37 [.290] 7.37 [.290] 7.37 [.290] 8.3 [.320] 8.3 [.320] 8.3 [.320] 8.3 [.320] Rev H 9 of 5
3.8. Tab Detent Confguratons A tab havng no lockng feature may be used for applcatons where low matng retenton forces are desrable. Where hgher forces are sought, a tab wth a detent meetng the requrements shown should be used. Hole detents provde the greatest retenton forces, whle dmples provde acceptable medum--range forces. Refer to Fgure 9. L (Dmple) K +0.3 [+.005] 0.08 [.003] Mn Depth (2 Places) Sphercal Radus J +0.3 [+.005] 0.08 [.003] Mn Depth (2 Places) Radus L (Through Hole) Note: Hole or dmple detents may be at the same locaton on the longtudnal centerlne f no shoulder or obstructon s present at the base of the tab. TAB WIDTH (Nomnal) DIMPLE DETENT DIMENSION +0.3 [.005] DIMPLE OR THROUGH HOLE DETENT DIAMETER J K L 6.35 [.250] 2.36 [.093].90 [.075].78 +0.25/ -0.3 [.070 +.00/ -.005] 5.20 [.205] 2.36 [.093].90 [.075].75+0.5 [.069+.006] 4.75 [.87].57 [.062].37 [.054].40+0.3 [.055+.005] 2.79 [.0].57 [.062].22 [.048].22+0.08 [.048+.003] Fgure 9 4. QUALIFICATION Because of the many varatons of qualfcatons and performance capabltes wthn ths product lne, contact the Product Informaton Center at the number lsted at the bottom of page for specfc requrements. Ultra--Fast Fully--Insulated FASTON Termnals are supported by the followng commercal, mltary, and government qualfcaton and specfcaton organzatons. 4.. Underwrters Laboratores Inc. (UL) and CSA Internatonal These termnals meet Specfcaton UL--30 for quck--connect termnals and are Lsted by UL n Fle E6677. These termnals meet CSA C22.2 Specfcaton 53 for quck--connect termnals and are Certfed to CSA Internatonal n Fle LR 789. UL does not qualfy ths type of termnal when desgned for applcaton to wre sze 24 AWG or smaller, 0.4 [.06] -thck tabs, or wre sze 4 AWG appled to Seres 0/25 termnals. 0 of 5 Rev H
4.2. Verband Deutscher Electrotechnker (VDE) These termnals are VDE tested accordng to DIN VDE 0627/9.9, VDE--Reg. 593. 4.3. TUV Rhenland Ultra--Fast Plus Termnals have been tested by TUV Rhenland of North Amerca, Inc., TUV Fle E907003 and has been found sutable for end product certfcaton to: EN 60 950/09.87 DIN IEC 60-- Part /VDE 0750 T/05.82 DIN IEC 380/VDE 0806/08.8 DIN VDE 0700 t/02.8 5. TOOLING Toolng that accommodates the full wre sze range are desgned for termnatng these termnals. Toolng part numbers and nstructonal materal packaged wth the toolng are shown n Fgure 0. TE has desgned machnes for a varety of applcaton requrements. For assstance n settng up prototype and producton lne equpment, contact Tool Engneerng through your local TE Representatve or call the Toolng Assstance Center at the number at the bottom of page. 5.. Hand Crmpng Tools Hand crmpng tools are desgned for prototype and low--volume applcatons such as repar of damaged termnals. 5.2. Applcators Applcators are desgned for the full wre sze range of strp--fed, precson formed termnals, and provde for hgh volume, heavy duty producton requrements. The applcators must be used n bench or floor model power unts. Each applcator s shpped wth a metal dentfcaton tag attached. Also, a packet of assocated paperwork s ncluded n each applcator shpment. Some changes may have to be made to the applcators to run n all related power unts. 5.3. De Assembles Des assembles are desgned for easy nstallaton and removal n hand tool frame assembles or applcators. 5.4. Power Unts Power unts are fully--automatc or sem--automatc machnes used to assst n the applcaton of a product. Power unts nclude the power source used to supply the force to an applcator. AMP -O -LECTRIC Model K Termnatng Machne 565435-5 has been superseded by Model G Termnatng Machne 354500 - for new applcatons. For exstng applcatons, the Model K can stll be used because of the large number of nstalled machnes. Rev H of 5
Typcal De Assembly (Refer to Table) DIE ASSEMBLY (For Applcators) (DOCUMENT) 58268 -, 58268-2 408-9227 58269-2, 58269-3, 58269-4, 58269-5 408-9225 58308 -, 58308-2 408-9296 AMP -O -LECTRIC Model G Termnatng Machne 354500 - (409-5842) AMPOMATOR CLS IV+ Lead -Makng Machne 356500 -[ ] (409-5878) Typcal Applcator (Refer to Table) AMP -O -LECTRIC Model K Termnatng Machne 565435-5 (409-528) APPLICATOR (DOCUMENT) 466778-3 408-805 466778-4 408-805, 408-9902 466778-6 408-805 466779-3 408-805 466779-4 408-805, 408-9902 466779-6 408-805 466784-408 -8058 466784-2 408-8058 466785-408 -8058 466785-2 408-8058 56704-408 -805 56704-2 408-805, 408-9902 56704-4 408-805 567082-408 -805 567082-2 408-805, 408-9902 567083-408 -8058 567083-2 408-8058 567085-408 -8058 567085-2 408-8058 567-408 -8079 567-2 408-8079 567-3 408-805 5672-408 -8079 5672-2 408-8079 5672-3 408-805 5677-408 -805 5677-2 408-805, 408-9902 56742-56742 -2 408-805, 408-9902 56742-4 408-805 567228-408 -8058 567228-2 408-8058 567276-567276 -2 408-8079 567276-4 408-805 567460-408 -8058 567494-567494 -2 408-8058 Fgure 0 (cont d) 2 of 5 Rev H
SERIES 0/25 87 205 TYPE WIRE RANGE AMP-O -LECTRIC Model K Machne 565435-5 APPLICATOR FOR POWER UNIT AMP-O -LECTRIC Model G Machne 354500- AMPOMATOR CLS IV+ Machne 356500-[ ] DIE ASSEMBLIES FOR APPLICATOR 88058-2 88058-3 26-22 567082-2 567082 - Receptacle 22-8 56704-2 56704-4 56704-58269 -2 6-4 5677-2 5677-58269 -3 Plus Receptacle 22-8 567276-2 567276-4 567276-58268 - Receptacle Plus Receptacle 22-8 466779-4 466779-6 466779-3 58269-2 6-4 466778-4 466778-6 466778-3 58269-3 22-8 567-2 567-3 567-58268 - 6-4 5672-2 5672-3 5672-58268 -2 Tab 22-8 466779-4 466779-6 466779-3 58269-2 Flag 22-8 567083-2 567083-58308 - 6-4 567085-2 567085-58308 -2 Flag LID 6-4 567460-58308 -2 Receptacle 22-8 466779-4 466779-6 466779-3 58269-2 Flag 22-8 466784-2 466784-58308 - Receptacle Plus Receptacle 250 Tab Plus Tab Flag Flag LID 22-8 466779-4 466779-6 466779-3 58269-2 6-4 466778-4 466778-6 466778-3 58269-3 2-0 56742-2 56742-4 56742-58269 -4 58269-5 22-8 567-2 567-3 567-58268 - 6-4 5672-2 5672-3 5672-58268 -2 22-8 466779-4 466779-6 466779-3 58269-2 6-4 466778-4 466778-6 466778-3 58269-3 2-0 56742-2 56742-4 56742-58269 -4 58269-5 22-8 567-2 567-3 567-58268 - 6-4 5672-2 5672-3 5672-58268 -2 22-8 466784-2 466784-58308 - 6-4 466785-2 466785-58308 -2 22-8 567228-2 567228-58308 - 6-4 567494-2 567494-58308 -2 Applcators may be convertble from one machne to another. Contact Toolng Assstance Center at the number at the bottom of page for more nformaton. Fgure0(cont d) Termnates wre sze 22 AWG only. Termnates wre sze 2 AWG only. Termnates wre sze 0 AWG only. Rev H 3 of 5
DIE ASSEMBLY (For Hand Tool Frames) (DOCUMENT) 58052-3 408-9277 58079-3 408-9278 58080-3 408-9278 90390-3 408-9279 9039-3 408-9279 224027-408 -453 Hand Tool Frame 58078-3 (408-6976) wth Typcal De Assembly Hand Tool Frame 6970 - (408-2095) Typcal De Assembly (Refer to Table) 224027-2 408-453 SERIES 0/25 87 250 TYPE WIRE RANGE DIE ASSEMBLY FOR HAND TOOL FRAME 58078-3 6970-26 -22 58052-3 Receptacle 22-8 90390-3 6-4 9039-3 Plus Receptacle 22-8 58079-3 Receptacle Plus Receptacle Flag Termnal 22-8 90390-3 6-4 9039-3 22-8 58079-3 6-4 58080-3 22-8 90390-3 6-4 9039-3 Tab Termnal 22-8 90390-3 Receptacle 22-8 90390-3 or 58079-3 6-4 9039-3 2-0 224027-224027 -2 Plus Receptacle 6-4 58080-3 Flag Termnal Tab Termnal 22-8 90390-3 6-4 9039-3 22-8 90390-3 6-4 9039-3 2-0 224027-2 224027 - Ths de assembly can also be used n 626 Pneumatc Toolng Assembly 8972 - or 89722 - (409-5862) when nstalled onto Straght Acton Crmper 27200 - (408-405). Termnates wre sze 2 AWG only. Termnates wre sze 0 AWG only. Fgure 0 (end) 4 of 5 Rev H
6. VISUAL AID Fgure shows a typcal applcaton of Ultra--Fast Fully--Insulated FASTON Termnals. Ths llustraton should be used by producton personnel to ensure a correctly appled product. Applcatons whch DO NOT appear correct should be nspected usng the nformaton n the precedng pages of ths specfcaton and n the nstructonal materal shpped wth the product or toolng. ULTRA- FAST FASTON FLAG RECEPTACLE CRIMP MUST BE CENTERED BETWEEN CORRUGATIONS WIRE CONDUCTOR MUST BE VISIBLE INSULATION GUIDE SHALL NOTBEBENTAWAYFROM BODY ULTRA-FAST FASTON STRAIGHT RECEPTACLE WIRE MUST BE FULLY INSERTED INTO INSULATION GUIDE AREA SLIGHT BOWING PERMISSIBLE (NO EXCESSIVE TWIST OR ROLL ALLOWED) ULTRA-FAST PLUS FASTON RECEPTACLE INSULATION BARREL MUST BE CRIMPED TIGHTLY ON WIRE INSULATION Bottom Vew SLIGHT BOWING PERMISSIBLE (NO EXCESSIVE TWIST OR ROLL ALLOWED) WIRE CONDUCTOR STRANDS MUST BE VISIBLE THROUGH INSPECTION WINDOW WIRE BARREL CRIMP MUST BE CENTERED BETWEEN CORRUGATIONS Bottom Vew WIRE CONDUCTOR STRANDS MUST BE VISIBLE THROUGH INSPECTION WINDOW FIGURE. VISUAL AID Rev H 5 of 5