Instruction Sheet
Crimping Head Cross Reference
for Pneumatic Tools
11 APR 11
Rev E
408-- 2498
“626” Pneumatic Tooling Systems
Crimps The Following Products:
PLASTI-- GRIP* Terminals
PIDG* Terminals
Relay Tab
SOLISTRAND* Terminals
STRATO-- THERM* Terminals
COPALUM* Terminals
TERMI-- FOIL* Terminals
AMPLI-- BOND* Terminals
Closed End Splices
Pneumatic Tool 69015
Wire Size Range: 8 - 1/0 AWG
Crimps The Following Products:
PLASTI-- GRIP* Terminals
SOLISTRAND* Terminals
STRATO-- THERM* Terminals
COPALUM* Terminals
AMPOWER* Terminals
AMPLI-- BOND* Terminals
Figure 1
1. INTRODUCTION
The tools shown in Figure 1 are capable of crimping a
wide variety of products on solid or stranded wire
sizes 26 through 1/0. The various configurations of
the “626” Pneumatic Tooling Systems are identified in
Figure 2. All of these systems accept any of the Tool
Holder Assemblies and their associated Crimping
Heads/Adapters, as indicated. The remainder of this
instruction sheet contains tables which provide cross
referencing information on the tool, crimping head,
products crimped, and wire size ranges. In addition,
instruction sheet numbers for all crimping heads and
pneumatic tools and an explanation of product
insulation barrel expansions are provided.
Reasons for reissue are provided in Section 5,
REVISION SUMMARY.
NOTE
Dimensions are in millimeters [with inch
equivalents in brackets]. Figures and illustrations
are for reference only and are not drawn to scale.
i
E2011
Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
*Trademark
TOOLING ASSISTANCE CENTER 1--800--722--1111
PRODUCT INFORMATION 1--800--522--6752
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
www.te.com
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LOC B
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners.
ORIGINAL INSTRUCTIONS
Wire Size Range: 26 - 6 AWG
408- 2498
2. TOOL, PRODUCT, AND WIRE SIZE RANGE CROSS REFERENCE CHART
TOOL AND WIRE SIZE RANGE
PRODUCT
PIDG
PLASTI--GRIP
Relay Tab
SOLISTRAND
STRATO--THERM
COPALUM
AMPOWER
AMPLI--BOND
Closed End Splice
TERMI--FOIL
“626”
(Customer Manual - 409-- 5862)
26--14
22--14
16--14
22--6
22--10
16--10
--
8
22--8
8
69015
(Instruction sheet - 408-- 1310)
--
6
--
8--1/0
8--1/0
8--4
2
6
--
--
3.
PIDG
AND
PLASTI-- GRIP
TERMINAL AND SPLICE INSULATION BARREL EXPANSION
WIRE SIZE
RANGE
26--22
22--16
26--22
22--16
22--16
22--16
WIRE INSULATION DIAMETER RANGE
MINIMUM
MAXIMUM
1.3 [.050]D
2.0 [.080]D
1.3 [.050]D
2.0 [.080]
2.7 [.105]
2.7 [.105]
2.7 [.105]D
16--14
16 14
2.7 [.105]
2.9 [.115]
3.8 [.150]
3.8 [.150]D
12--10
12 10
3.8 [.150]
3.8 [.150]
4.3 [.170]
1.7 [.065]
2.9 [.115]
2.1 [.082]
3.2 [.125]
3.6 [.140]
5.1 [.200]
2.9 [.115]
3.8 [.150]G
4.3 [.170]
6.4 [.250]
3.8 [.150]
5.8 [.230]
6.4 [.250]
7.6 [.300]
PRODUCT INSULATION
BARREL EXPANSION
2.1 [.082] MAX
3.2 [.125] MAX
2.1 [.082] MAX
3.2 [.125] MAX
3.6 [.140] MAX
5.1 [.200] MAX
3.8 [.150] MAXG
3.8 [.150] MAXG
4.3 [.170] MAX
6.4 [.250] MAX
5.8 [.230] MAXz
5.8 [.230] MAX
6.4 [.250] MAX
7.6 [.300] MAX
TOOL INSULATION CRIMP
EXPANSION
(SM. EXP){
(SM. EXP){
(STD. EXP){
(STD. EXP){
(STD. EXP){
(LG. EXP){
(SM. EXP){
(STD. EXP){
(STD. EXP){
(LG. EXP){
(SM. EXP){
(STD. EXP){
(STD. EXP){
(LG. EXP){
D
Indicates wire diameter sizes smaller than this dimension may be used.
{
(SM EXP) = Small Expansion; (STD EXP) = Standard Expansion; (LG EXP) = Large Expansion. Small expansion
is sometimes expressed as “tight insulation support” in TE Connectivity catalogs.
EXAMPLE: When using a wire within 26-
-22 AWG range, and wire insulation diameter is 1.27 to 1.65 mm
[.050 to .065 in.], product insulation barrel crimp description must be 2.08 mm [.082 in.] Max and crimping tool
insulation barrel crimp must be small expansion.
G
Use 3.56 mm [.140 in.] for PLASTI-
-GRIP
z
Use 5.08 mm [.200 in.] for PLASTI-
-GRIP
Rev E
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