Catalog 82042 Standard Terminals and Splices Revised 8-00 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 AMP 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 AWG through 4/0 AWG Basic Terminal Material. The basic terminal is constructed of fine grade high conductivity copper per ASTM B-152 and tin-plated per ASTM B-545. AMP’s special plating process creates durable corrosion resistance to salt spray and most chemical fumes. Funnel Entry. Molded insulation for ease of wire insertion and snug fit over MIL-standard wire diameters. Insulation. Nylon insulation for dielectric strength, color coded to wire size. Dimples. Dimples afford maximum contact of barrel and wire and maximum tensile strength. Temperature Rating: 105°C Max. Table of Contents Terminals Ring Tongue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60, 61 Splices Butt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 TERMINYL Terminals meet or exceed the requirements of MIL-T-7928, Type II,Class 2. Refer to AMP Qualified Products for Military Application, Catalog 73-159 for Military Specification Number to AMP Part Number cross reference. 59 Dimensions are shown for reference purposes only. Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Specifications subject to change. Technical Support Center 1-800-522-6752 www.amp.com Catalog 82042 Standard Terminals and Splices Revised 8-00 TERMINYL (Continued) Ring Tongue Terminals Wire Size Circular Mils [mm2] Tongue Material Thickness Max. Stud Size 8 M4 10 8 13,100-20,800 [6.64-10.5] .043 1.09 1/4 M6 5/16 M8 3/8 10 6 20,800-33,100 [10.5-16.8] .048 1.22 1/4 M6 5/16 M8 3/8 8 M4 10 4 33,100-52,600 [16.8-26.7] .051 1.30 1/4 M6 5/16 M8 3/8 4HD3 33,100-52,600 [16.8-26.7] 1/2 M12 1/4 M6 5/16 M8 .094 2.39 3/8 10 2 52,600-83,700 [26.7-42.4] 1/4 M6 5/16 M8 .060 1.52 3/8 1/2 M12 W .478 12.14 .431 10.95 .478 12.14 .587 14.91 .587 14.91 .398 10.11 .468 11.89 .500 12.70 .625 15.88 .625 15.88 .437 11.10 .437 11.10 .546 13.87 .546 13.87 .679 17.25 .679 17.25 .679 17.25 .500 12.70 .679 17.25 .679 17.25 .711 18.06 .679 17.25 .711 18.06 .711 18.06 .855 21.72 Material Related Product Data Insulation — Nylon, UL 94V-2 Terminal Body — Copper per ASTM B-152 Plating — Tin per ASTM B-545 Insulation Color Code — pg. 4 Packaging Quantities — pg. 4 Performance Specifications — pgs. 4 & 5 Application Tooling — pg. 73 Dimensions C E Max. .437 11.10 .437 11.10 .437 11.10 .500 12.70 .500 12.70 .515 13.08 .421 10.69 .515 13.08 .515 13.08 .515 13.08 .265 6.73 .265 6.73 .531 13.49 .531 13.49 .531 13.49 .531 13.49 .531 13.49 .390 9.91 .456 11.58 .456 11.58 .578 14.68 .578 14.68 .578 14.68 .578 14.68 .578 14.68 1.183 30.05 1.183 30.05 1.183 30.05 1.246 31.65 1.246 31.65 1.447 36.75 1.338 33.99 1.447 36.75 1.447 36.75 1.447 36.75 1.155 29.34 1.155 29.34 1.536 39.01 1.536 39.01 1.536 39.01 1.536 39.01 1.536 39.01 1.349 34.26 1.565 39.75 1.565 39.75 1.705 43.31 1.705 43.31 1.705 43.31 1.705 43.31 1.705 43.31 L Max. 1.425 36.20 1.402 35.61 1.425 36.20 1.542 39.17 1.542 39.17 1.700 43.18 1.575 40.01 1.700 43.18 1.762 44.75 1.762 44.75 1.376 34.95 1.376 34.95 1.812 46.02 1.812 46.02 1.878 47.70 1.878 47.70 1.878 47.70 1.602 40.69 1.907 48.44 1.907 48.44 2.063 52.40 2.045 51.94 2.063 52.40 2.063 52.40 2.135 54.23 Terminal Insulation Color Red Red Red Red Red Blue Blue Blue Blue Blue Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Red Red Red Red Red Wire Insulation Diameter Max. .256 6.50 .256 6.50 .256 6.50 .256 6.50 .256 6.50 .314 7.98 .314 7.98 .314 7.98 .314 7.98 .314 7.98 .382 9.70 .382 9.70 .382 9.70 .382 9.70 .382 9.70 .382 9.70 .382 9.70 .443 11.25 .443 11.25 .443 11.25 .468 11.89 .468 11.89 .468 11.89 .468 11.89 .468 11.89 Part Numbers Loose Piece 53041 324043 324082 324044 324045 53119-11 324046 324047 324048 324049 331456 1-331456-0 324111 324050 324051 324052* 324114 330966 1-331421-0 1-331421-1 *Available in small packaging quantities. 1 Rectangular tongue terminal. 2 90° bend ring tongue terminal. 3 Heavy duty for extra mechanical strength. 60 Dimensions are shown for reference purposes only. Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Specifications subject to change. Technical Support Center 1-800-522-6752 www.amp.com 328655 324053 324112 324054 324055 Catalog 82042 Standard Terminals and Splices Revised 8-00 TERMINYL (Continued) Ring Tongue Terminals (Continued) Wire Size Circular Mils [mm2] Tongue Material Thickness Max. Stud Size .073 1.85 3/0 150,500-190,000 [76.3-96.3] 4/0 190,000-231,100 [96.3-117] .094 2.39 .105 2.67 Part Numbers Loose Piece Yellow Wire Insulation Diameter Max. .580 14.73 .580 14.73 .580 14.73 .580 14.73 .580 14.73 .610 15.49 .610 15.49 .610 15.49 Terminal Insulation Color 1/2 M12 2.033 51.64 2.033 51.64 2.033 51.64 2.033 51.64 2.017 51.23 2.026 51.46 2.026 51.46 2.026 51.46 2.360 59.94 2.426 61.62 2.426 61.62 2.426 61.62 2.454 62.33 2.416 61.37 2.416 61.37 2.416 61.37 3/8 1.082 27.48 .625 15.88 2.294 58.27 2.794 70.97 Red .680 17.27 324185 .835 21.21 1.150 29.21 1.150 29.21 .625 15.88 .625 15.88 .625 15.88 2.295 58.29 2.295 58.29 2.295 58.29 2.700 68.58 2.858 72.59 2.858 72.59 Blue .765 19.43 .765 19.43 .765 19.43 329150 5/16 M8 1/2 M12 5/16 M8 .083 2.11 L Max. .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 3/8 2/0 119,500-150,500 [60.6-76.3] Dimensions C E Max. .675 17.15 .807 20.50 .807 20.50 .807 20.50 .875 22.23 .926 23.52 .926 23.52 .926 23.52 1/4 M6 1/0 83,700-119,500 [42.4-60.6] W 3/8 3/8 1/2 M12 Blue Blue Blue Blue Blue Yellow Yellow Blue Blue 55822-1 324056 324113 324057 324058 324083 324084 324085 324187 324188 61 Dimensions are shown for reference purposes only. Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Specifications subject to change. Technical Support Center 1-800-522-6752 www.amp.com Catalog 82042 Standard Terminals and Splices Revised 8-00 TERMINYL (Continued) Butt Splices Wire Size Circular Mils [mm2] 8 to 12-10 13,100-20,800 [6.64-10.5] to 5,180-13,100 [2.62-6.64] 6 to 8 20,800-33,100 [10.5-16.8] to 13,100-20,800 [6.64-10.5] 8 13,100-20,800 [6.64-10.5] 6 20,800-33,100 [10.5-16.8] 4 33,100-52,600 [16.8-26.7] 2 52,600-83,700 [26.7-42.4] 8 13,100-20,800 [6.64-10.5] 6 20,800-33,100 [10.5-16.8] 4 33,100-52,600 [16.8-26.7] 8 13,100-20,800 [6.64-10.5] 6 20,800-33,100 [10.5-16.8] 2 52,600-83,700 [26.7-42.4] 1 Material Related Product Data Insulation Sleeve — Nylon, UL 94V-2 Splice Body — Copper per ASTM B-152 Plating — Tin per ASTM B-545 Insulation Color Code — pg. 4 Packaging Quantities — pg. 4 Performance Specifications — pgs. 4 & 5 Application Tooling — pg. 73 Style Dimension L Max. Splice Insulation Color Single to Single Step-Down Assembly 2.066 52.48 Red w/ Yellow at adapter end .255 6.48 — 328569 Single to Single Step-Down Assembly 2.265 57.53 Blue w/ Red at adapter end .310 7.87 — 328571 2.066 52.48 Red .255 6.48 — 324625 2.265 57.53 Blue .310 7.87 — 324660 2.804 71.22 Yellow .370 9.40 — 324622 3.094 78.59 Red .445 11.30 — 324623 2.171 55.14 Red .255 6.48 .335 8.51 324658 2.359 59.92 Blue .310 7.87 .415 10.54 324621 2.804 71.22 Yellow .370 9.40 .495 12.57 324662 2.276 57.81 Red — .335 8.51 324657 2.484 63.09 Blue — .415 10.54 324659 3.094 78.59 Red — .595 15.11 324663 Single to Single Standard Splice Single to Multiple Standard Splice Multiple to Multiple Standard Splice Wire Insulation Diameter Max. Single End Multiple End Part Numbers Step-Down Assembly includes adapter which is visible through insulation sleeve window. 62 Dimensions are shown for reference purposes only. Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Specifications subject to change. Technical Support Center 1-800-522-6752 www.amp.com Catalog 82042 Standard Terminals and Splices Revised 8-00 CERTI-SEAL 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 100 insulation diameters in MIL-Spec wires from #24 to #10 AWG, 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 crimp ing tool to precisely posi tion 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, Red for 22-18, Blue for 16-14, Yellow for 12-10. The metal rings are color coded green or orange to identify the presence of adapters. Basic Splice Material. The basic splice body is constructed of fine grade high conductivity copper per ASTM B-152 and is either color coded or tin-plated per ASTM B-545. AMP’s special plating process creates durable cor rosion resistance to salt spray and most chemical fumes. Rings. Metal rings at both ends permanently seal the splice to the wire insulation for a moisture tight seal. Insulation. Nylon insulation assures high dielectric strength. Special notch feature allows crimping tool locator to position the splice to prevent twisting during crimping. Adapters. Nylon ring adapter allows for smaller wire insulation diameters. Table of Contents Splices and Tooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 63 Dimensions are shown for reference purposes only. Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Specifications subject to change. Technical Support Center 1-800-522-6752 www.amp.com Catalog 82042 Standard Terminals and Splices Revised 8-00 CERTI-SEAL (Continued) Splice Material Related Product Data Insulation — Nylon, UL 94V-2 Splice Body — Copper per ASTM B-152 Plating — Tin per ASTM B-545 or Zinc Plate/Dye Chromate Insulation Color Code — pg. 4 Packaging Quantities — pg. 4 Performance Specifications — pgs. 4 & 5 Application Tooling — shown below Splices with nylon wire insulation diameter adapters Wire Size Circular Mils [mm2] 24-20 320-1,290 [0.16-0.65] 24-20 320-1,290 [0.16-0.65] 22-18 509-1,900 [0.26-0.96] 16-14 2,050-5,180 [1.04-2.62] 12-10 5,180-13,100 [2.62-6.64] L Max. Body Color Ring Color Wire Insulation Dia.Max. Part Numbers Hand Tool Part No. .970 24.64 Tin Plated Green .065 1.65 324987 46073 .970 24.64 Tin Plated Orange .073 1.85 1-324987-0 46073 1.156 29.36 Red Green .101 2.57 324988 46074 1.156 29.36 Blue Green .120 3.05 324989 59282 1.345 34.16 Yellow Green .150 3.81 324990 58325-1 Splices without nylon wire insulation diameter adapters Wire Size Circular Mils [mm2] 24-20 320-1,290 [0.16-0.65] 22-18 509-1900 [0.26-0.96] 16-14 2,050-5,180 [1.04-2.62] 12-10 5,180-13,100 [2.62-6.64] 16-14 HD L Max. Body Color Ring Color Wire Insulation Dia.Max. Part Numbers Hand Tool Part No. .970 24.64 Tin Plated Tin Plated .100 2.54 324544 46073 1.156 29.36 Red Tin Plated .133 3.38 324548 46074 1.156 29.36 Blue Tin Plated .157 3.99 324549 59282 1.345 34.16 Yellow Tin Plated .218 5.54 324631 58325-1 1.345 34.16 Tin Plated Tin Plated .218 5.54 55685-1 58325-1 Wire Insulation Dia.Max. Adapter End Other End Part Number Hand Tool Part No. 1-324987-1 46073 Splices with nylon wire insulation diameter adapter in one end Wire Size Circular Mils [mm2] 24-20 320-1,290 [0.16-0.65] L Max. Body Color Ring Color .970 24.64 Tin Plated Orange & Tin Plated .073 1.85 .100 2.54 Tooling Tool Part No. 46073 or 46074 Tool Part No. 59282 or 58325-1 Hand tooling features the AMP 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-SEAL Tools do not require wire insulation adjustment prior to crimping. 64 Dimensions are shown for reference purposes only. Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Specifications subject to change. Technical Support Center 1-800-522-6752 www.amp.com