Aerospace Tooling and Equipment

Aerospace Toolingand Equipment

Aerospace Tooling and EquipmentPages1 Crimping Equipment 21.1 Tooling available by Product Family 21.2 Premium CERTI-CRIMP andCERTI-CRIMP II Tools 5 Hand Tools 6 Power Assist Options 101.3 SDE Premium Crimp Tooling 13 SDE Hand Tools 14 Power Assist Options 171.4 Tools for MIL Indent Crimping 181.5 Power Assist Equipment 20 Battery Tool 1.5 t 20 Battery Tool 4 t 21 SDE Electric Terminator withCERTI-CRIMP Adapters 22 626 and Micro PneumaticTool System 231.6 Hydraulic Equipment 281.7 Insertion / Extraction Tools 381.8 Hand Tool Control Gauges 391.9 Service and Calibration 402 Wire Processing Equipment 412.1 Stripping Machines 412.2 Cutting and Stripping Machines 422.3 4/8 Indent Stripper Crimperwith Touch Sensor 432.4 AM03 Universal Stripper Crimper 442.5 Micrograph Cross-SectionLaboratories 45 Micrograph Laboratory 45 Portable Micrograph Laboratory 463 Test Equipment 473.1 High Voltage Test Equipment 473.2 Cable Test Systems 514 Appendix - Useful Information 524.1 Wire Range Limits 524.2 Computing CMA 534.3 Wire Range and Colour Codes 544.4 Terminal Styles 57For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe1

Aerospace Tooling and Equipment1 Crimping Equipment1.1 Tooling available by Product FamilyInsulated TerminalsHand ToolsPower ToolsConnector/TerminalStyleWire Range(AWG)PremiumCERTI-CRIMPandCERTI-CRIMP IISDEPremium DiesBatteryTool 1.5 tBatteryTool 4 tHydraulicEquipment626PneumaticToolElectricTerminatorSection 1.2 Section 1.3 Section 1.5 Section 1.5 Section 1.6 Section 1.5Sections1.3, 1.5PIDGPLASTI-GRIPPIDGSTRATO-THERMwith TEFLON orPEEK InsulationTERMINYLAMPLI-BONDTerminals andSplicesTerminals andSplices (Radiationresistant)Terminals andSplices (Insulationrestricting nylon)Spare Wire capsSplicesTerminalsTerminals andSplicesTerminalsTerminals andSplices26 to 24 X X X22 to 18 X X X X X16 X X X X14 X X X X X12 to 10 X X X X X24 to 14 X X12 to 10 X X26 to 14 X X12 to 10 X X22 to 14 X X12 to 10 X X26 to 24 X X22 to 14 X X X12 to 10 X X8 X X26 to 24 X X X22 to 14 X X X X X12 to 10 X X X X X8 X X X6 X4 to 4/024 to 16 X X X X14 X X X X12 to 10 X X X X8 X6 X4 to 4/08 X X6 to 4/0TEFLON is a trademark of E.I. DuPont deNemours and Co.2For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe

Aerospace Tooling and EquipmentUn-Insulated TerminalsHand ToolsPower ToolsConnector/TerminalStyleWire Range(AWG)PremiumCERTI-CRIMP SDEand Premium DiesCERTI-CRIMP IIBatteryTool 1.5 tBatteryTool 4 tHydraulicEquipment626PneumaticToolElectricTerminatorSOLISTRANDCOPALUMSTRATO-THERMTerminals & SplicesTerminals(with and withoutinsulation support)Section 1.2 Section 1.3 Section 1.5 Section 1.5 Section 1.6 Section 1.526 to 24 X X22 to 18 X X X12 to 10 X X X8 to 6 X X X4 to 2 X0 to 600 MCM X16 to 10 X8 X X6 to 500 MCM X22 to 14 X X X12 to 10 X X X8 to 2/0 XTERMI-FOIL 8 XAMPOWER 1/0 to 1500 MCM XSections1.3, 1.5ContactsHand ToolsPower ToolsConnector/TerminalStyleWire Range(AWG)PremiumCERTI-CRIMPandCERTI-CRIMP IISDEPremiumDiesMIL IndentToolingBatteryTool 1.5 tBatteryTool 4 tHydraulicEquipment626PneumaticToolElectricTerminatorSection 1.2 Section 1.3 Section 1.4 Section 1.5.1 Section 1.5 Section 1.6 Section 1.5Sections1.3, 1.5Screw-machinedContactsXAMPLIMITE Size 22 DF 28 to 22 X XD-SUBSize 20 DF 28 to 20 X X X XAMPMODU IV 26 to 20 X X X XLocking Clip 26 to 22 X X X XAMPMODU Mini Tandem Spring 32 to 28 X X X XMTE Pin 32 to 22 X X X XShort Point 32 to 20 X X X XCommercial 30 to 14 X X X XUniversal 24 to 14 X X X XMATE-N-LOK Universal II 24 to 14 X X X XMini Universal 20 to 16 X X X XMini Universal II 26 to 16 X X X XMR Connector Contacts 26 to 18 X X X XCPC Type II X X X XType III+ 30 to 14 X X X XFor more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe3

Aerospace Tooling and EquipmentCoaxial ConnectorsHand ToolsPower ToolsConnector/TerminalStyleWire Range(AWG)PremiumCERTI-CRIMPandCERTI-CRIMP IISDEPremium DiesBatteryTool 1.5 tBatteryTool 4 tHydraulicEquipment626PneumaticToolElectricTerminatorSection 1.2 Section 1.3 Section 1.5 Section 1.5 Section 1.6 Section 1.5Sections1.3, 1.550 Ohm BNC 26 to 24 X X X X50 Ohm SMB 22 to 18 X X X XRaychem SplicesHand ToolsPower ToolsConnector/TerminalStyleWire Range(AWG)PremiumCERTI-CRIMPandCERTI-CRIMP IISDEPremium DiesBatteryTool 1.5 tBatteryTool 4 tHydraulicEquipment626PneumaticToolElectricTerminatorSection 1.2 Section 1.3 Section 1.5 Section 1.5 Section 1.6 Section 1.5Sections1.3, 1.5MiniSeal 26 to 12 X XDuraSeal 26 to 12 X X4For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe

Aerospace Tooling and Equipment1.2 Premium CERTI-CRIMP and CERTI-CRIMP II Hand ToolsDesigned to exactingspecificationsRatchet control providescomplete crimping cycleFor most military, UL and CSAapplicationsManufactured using the highestquality materialsRequires minimum skillRepairableCalibrated; recalibrationrecommended every 6 monthsor 5,000 cyclesProduced under a QualityManagement System certifiedto ISO 9001CERTI-CRIMP Hand Tools aretop-of-the-line, premium, handoperatedtools for crimping abroad array of terminals, contactsand special wiring devices availablefrom Tyco Electronics. They aredesigned to exacting specificationsto produce consistent, high-qualityterminations. A potential servicelife of over 50,000 cycles is possible,depending on operator care.Other features include insulationcrimp adjustment for differentinsulation thicknesses, a locatorfor properly positioning and supportingthe terminal or contact inthe tool, a wire stop, and colorcoding and/or wire size informationon the head of the tool or on thehandles.All CERTI-CRIMP Hand Tools featurethe reliable ratchet control.The ratchet will not release untilthe handles are fully closed andthe dies bottomed. This helpseliminate partial crimps.CERTI-CRIMP Hand Tools are wellsuited for low production runs,prototype work, and repairs almostany application requiring consistent,highly-reliable terminations.CERTI-CRIMP Hand Tools aredesigned to meet all featurerequirements listed on applicableTyco Electronics ApplicationSpecifications.(Check appropriate product catalogsfor qualification to militaryspecifications, UL recognition andCSA certification.)Calibration:Recommended every 6 month or 5000 crimp cycles.See section 1.9 of this catalogue for your nearest calibration centre.Produced under a Quality Management System.Certified to ISO 9001.For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe5

Aerospace Tooling and EquipmentHand ToolsCERTI-CRIMP IIStraight Action Hand Tools(SAHT) Dies close in a straight line Contact locator and support Wire stop Insulation crimp adjustment(4 positions) Ejects crimped contact Approx. weight 0.59 kg[1.3 lb]Heads are compatible with:BatteryKitsMicroPneumaticPneumatic6-26ElectricTerminatorDouble Action HT Yes Yes Yes NoHeavy Head HT Yes No Yes NoCERTI-CRIMP IIStraight Action HTCERTI-CRIMP IIStraight Action HTLarge DieYes Yes Yes YesYes No Yes YesDouble ActionHand Tool (DAHT) Dies travel in arc-like path Locator on tools forFASTON, MATE-N-LOK,PIDG and PLASTI-GRIPterminals Insulation adjustment ontools for FASTON,MATE-N-LOK, PIDG andPLASTI-GRIP terminals Approx. weight 0.54 kg[1.2 lb]Battery Tool forCERTI-CRIMP II,Straight Action (SAHT) andDouble Action (DAHT) Light weight and fullymobile power assist option Compatible with allstandard die setsHeavy Head Hand Tool(HHHT) Designed to terminatemost large coaxial cableand heavy-gage wire Dies close in a straight line Locator and wire stopwhen applicable Insulation adjustment ontools for AMPLI-BOND,PIDG and PLASTI-GRIPterminals Approx. weight 0.95 kg[2.1 lb]626 and Micro PneumaticTool for CERTI-CRIMP II,Straight Action (SAHT) andDouble Action (DAHT) Effortless crimping for abroad range of terminals Either bench-mounted orhandheld for working incramped quarters6For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe

Aerospace Tooling and EquipmentPremium CERTI-CRIMP and CERTI-CRIMP IITerminal to Tool ReferenceInsulated Terminals Sleeve Wire Range Insulation RangeTerminal Type Style Colour / Stripe mm² AWG Diameter [mm]Hand ToolType and P/NDAHTHHHTYellow 0.1-0.4 26-22 2.08 max 46121White 0.16-0.65 24-20 2.54 max 47907-1Red 0.26-0.96 22-18 3.18 max 47386Terminals and SplicesGreen 0.5-1.42 20-16 HD 3.81 maxBlue 1.04-2.62 16-14 4.32 max47387Yellow / Black 1.04-2.62 16-14 HDYellow 2.62-6.64 12-106.35 max 59239-4PIDGTerminals and Splices(Radiation Resistant)Translucent / White 0.16-0.65 24-20 2.54 max 47907-1Translucent / Red 0.26-0.96 22-18 3.18 max 47386Translucent / Blue 1.04-2.62 16-14 4.32 max 47387Translucent / Black 1.04-2.62 16-14 HD6.35 max 59239-4Translucent / Yellow 3.0-5.0 12-10Yellow / Black 0.15 26 0.66-1.446121Yellow / Blue 0.24 24 0.79-1.4Red / Green 0.38 22 0.97-1.4Terminals and Splices(InsulationRestricting Nylon)Red / Red 0.6 20 1.17-2.79Red / White 0.96 18 1.42-2.79Blue / Blue 1.42 16 1.6-3.3Blue / Green 2.15 14 1.98-3.3Yellow / Yellow 3.37 12 2.41-5.08Yellow / Brown 6.11 10 3.02-5.08473864738759239-4Spare Wire Caps(Nylon)Red 0.3-0.85 22-18 3.15 max 47386Blue 1.4-2.0 16-14 3.78 max 47387Yellow 3.0-6.0 12-10 5.33 max 59239-4Terminals & Butt Splice Yellow 0.1-0.41 26-22 2.03 max 46121Butt Splice45160Red 0.26-1.65 22-16 4.32 maxParallel Splice 45449PLASTI-GRIPButt Splice45575-1Blue 1.04-2.62 16-14 5.46 maxParallel Splice 45450Butt Splice12-1059489Yellow 2.62-6.647.62 maxParallel Splice 16-14 HD 59270For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe7

Aerospace Tooling and EquipmentPremium CERTI-CRIMP and CERTI-CRIMP IITerminal to Tool ReferenceInsulated Terminals Sleeve Wire Range Insulation RangeHand ToolType and P/NDAHTTerminal Type Style Colour / Stripe mm² AWG Diameter [mm]HHHTCERTI-CRIMP IIPLASTI-GRIPTerminalsRed 0.26-1.65 22-16 5.08 max 47386Blue 1.04-2.62 16-14 6.35 max 47387Yellow 2.62-6.64 12-10 7.62 max 59239-4Red9.14 maxButt Splice Red 6.64-10.5 86.35 max69959AMPLI-BOND Red 9.58 maxBrown 0.25-0.4 24-22 0.89-1.9 576778Grey 0.6 20 1.14-2.03 576779PIDGSTRATO-THERMwith PTFE orPEEK InsulationTerminals(thin-wall insulation)Brown 0.25-0.4 24-22 0.89-1.91901611-1Grey 0.6 20 1.14-2.031.0 18576780Orange1.2 16 1.4-2.675767811.0-1.2 18-16 1901600-1Beige2.0 145767822.3-3.183.0 12 576783Black 5.0 10 2.6-5.44 576784Uninsulated Terminals - no insulation supportWire RangeHand ToolType and P/NTerminal Type Terminal Style mm 2 AWG0.1-0.41 26-220.2-0.6 24-20DAHTHHHT693630.26-1.65 22-16SOLISTRANDTerminals and Splices(except Flat Tongue Terminals)1.04-2.62 16-14499352.62-6.64 12-101.65-4.17 14-12 495926.64-10.50 8 69355For Battery Tool Kit with Adapter for CERTI-CRIMP II options see Section 1.58For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe

Aerospace Tooling and EquipmentPremium CERTI-CRIMP and CERTI-CRIMP IITerminal to Tool ReferenceTerminals Wire Range Insulation RangeHand ToolType and P/NTerminal Type Terminal Style mm² AWG Diameter [mm] CERTI-CRIMP IIAMPLIMITE D-SubAMPMODUSize 20 DFSize 22 DF0.08-0.24 28-24 0.76-1.000.2-0.6 24-20 1.27-1.520.09-0.15 28-260.2-0.39 24-2291503-10.76-1.27 91520-1MODU IV0.12-0.24 26-241.02-1.52 91517-11.32-0.38 220.12-0.51 26-20 1.22 max91516-10.2-0.6 24-20 1.75 maxLocking Clip 0.12-0.38 26-22 0.97-1.57 91533-1Mini TANDEM SPRINGRecptacleMTE Pin0.03-0.09 32-28 1.52-0.64 1901786-1SHORT POINT Recept.MTE Pin0.12-0.38 26-22 0.91-1.42 91531-1MATE-N-LOKMR ConnectorCPC M SeriesSHORT POINTReceptacleCommercialUniversalUniversal IIMini-UniversalMini-Universal IIMR Contacts0.03-0.09 32-280.64-1.52 91518-10.12-0.38 26-220.2-0.6 24-20 0.64-1.52 91551-10.05-0.38 30-22 0.89-1.491515-10.05-0.6 30-20 1.02-1.910.2-0.6 24-201.52-2.54 91512-10.81-0.96 180.5-2.1 20-14 2.54-3.3 91504-10.2-0.38 24-220.51-0.96 20-182.54 max 91510-10.51-0.96 20-181.2-2-1 16-143.30 max 91500-10.51-0.96 20-1891508-15.08 max1.2-2.1 16-14 91506-10.5-0.96 20-18 2.0-3.01.42 16 2.49-3.20.12-0.24 26-24 1.19-1.600.32-0.38 22 1.5-1.750.32-0.6 22-20 1.5-2.010.81-0.96 18 2.11-2.390.5-0.89 20-18 2.0-3.21.42 16 2.49-3.20.12-0.38 26-220.5-0.96 20-1891536-191529-191522-191594-11.27-2.79 91526-1Type II Terminal PN Specific 91539-1Type III+0.05-0.38 30-22 0.89-1.491515-10.05-0.6 30-20 1.02-1.910.2-1.6 24-202.03-2.54 91523-11.81-1.42 18-160.2-0.6 24-20 1.14-1.7891505-11.81-1.42 18-16 2.03-2.540.81-1.42 18-161.94-2.14 142.03-2.54 91519-1For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe9

Aerospace Tooling and EquipmentPower Assist Options for CERTI-CRIMP IIStraight Action Hand ToolsCERTI-CRIMP II Tool Adapter can be used with thefollowing tools Battery Tool 626 or Micro Pneumatic Electric TerminatorBattery Tool Heads can be removed from HandTools, or the head only is available as a [-3] option.Example P/N 91503-1; handles can be removed oralternatively P/N 91503-3 (head only) can bepuchased and used in the shown Power-Assistoptions.626 or Micro Pneumatic Tool withCERTI-CRIMP II Tool AdapterCERTI-CRIMP II ToolAdapter for 626 or MicroPneumatic ToolP/N 1583527-1For more information on the 626 and MicroPneumatic System see Section 1.5Battery Tool Kit with Adapter forCERTI-CRIMP II Hand ToolEU Power Plug P/N 1213805-4GB Power Plug P/N 1213805-6These tools have the standard retract switch coveredover to best ensure complete crimp cycle.The switch is fully functional with the cover removed.Electric Terminator withCERTI-CRIMP II Tool AdapterCERTI-CRIMP IITool AdapterP/N 1213660-1for Electric TerminatorFor more information on the Electric Terminator seeSection 1.510For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe

Aerospace Tooling and EquipmentPower Assist Options for Double Action andHeavy Head Hand Tools626 or Micro Pneumatic ToolCrimping Head forLarge Tool Holder (LTH)Crimping Head forSmall Tool Holder (STH)Crimping Heads for 626 or Micro Pneumatic ToolLarge Tool Holder LTH P/N 356302-1Small Tool Holder STH P/N 356303-1DAHT Adapter to MicroPneumatic Hand ToolHHHT Adapter to MicroPneumatic Hand ToolAdapters to Micro Pneumatic ToolDAHT Adapter P/N 1213563-1HHHT Adapter P/N 525432-1HHHT = Heavy Head Hand ToolDAHT = Double Action Hand ToolFor more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe11

Aerospace Tooling and Equipment626 or Micro Pneumatic Terminal to Tool Reference ToolTerminal TypePIDGTerminals and SplicesPLASTI-GRIP TerminalsWire RangeCrimping Headsmm² AWG 626 (LTH) 626 (STH) Micro1.3-2.0 HD 16-14 HD679300-13.0-6.0 12-100.12-0.3 26-22 314537-10.3-1.3 22-16 31470-31.3-2.0 16-14 314269-1PLASTI-GRIPButt Splices0.3-1.3 22-16 314868-11.3-2.0 16-14 314869-10.9-8.0 ECV 18-8Closed End SpliceInsulated0.9-6.0 CES 18-100.3-2.0 22-14 354422-10.3-1.3 VS 22-16 217205-10.3-6.0 EC 22-10 354422-2PIDG STRATO-THERMTerminals and Splices0.3-6.0 22-10 217206-10.3-6.0 22-10 679301-18.0 8 1338757-1SOLISTRANDUninsulatedTerminals and Splices13.0 6 1338758-10.3-3.0 22-14 189989-10.3-1.3 22-16 314516-11.3-2.0 16-14 314517-12.0-3.0 14-12 314518-112For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe

Aerospace Tooling and Equipment1.3 SDE Premium Crimp ToolingSDE (Standard Die Envelope) is a new, flexibleapproach to crimp tooling, that allows use of the samedies on tooling across a range of application platforms.Dies are interchangeable in tools from portable handtools - manual or battery-powered - to pneumatic handtools and electric bench terminators. It is a family oftools that you can take from bench to production orinto the field, without the need for dies fitted to eachkind of tool.You can be sure your dies will fit your long-term needs,because they are completely compatible with all toolsin the SDE system. They move with you as your needsgrow.Fast FactsThese versatile hand tools are ideallysuited for R&D, networking applications,and on-site maintenance work.• User-adjustable ratchet control fora complete crimping cycle• Emergency ratchet release• Angled head, providing a comfortablehand and wrist position• Over 100 interchangeable SDE diesets to crimp a broad range ofconnectors• Able to handle multiple wire andterminal sizes in one die set• Precision construction of durablehigh-carbon steel• Extra strength pivot pins for maximumdurability• Engineered and manufactured usingprocesses independently certified tointernationally recognized qualitystandards ISO-9001:2000 andTelecommunications IndustryStandard TL 9000.For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe13

Aerospace Tooling and EquipmentSDE Hand ToolsPRO-CRIMPER IIIHand ToolPart No. 354940-1The PRO-CRIMPER III Hand Toolcombines the versatility of generalpurpose service tools with thereliability and ease of use of manypremium grade tools. It is ideallysuited for R&D prototyping, networkingapplications, and commercial,industrial, and institutionalmaintenance work.The precision design and manufacturingtechniques that go into thistool ensure reliable, repeatable performance.The new handles and headdesign result in increased usablelifecycle.Versatile. As part of the SDE familyof tools, the system accommodatesdozens of interchangeable dies in anever-expanding range, includingthose for open-barrel contacts andterminals. Many die sets have multiplecavities for crimping more thanone wire or terminal size at the sametime.Dependable. The tool is constructedof durable high-carbon steel withextra strength pivot pins, for maximumreliability and long-life precision.Locators are included withpin-and-socket style tools. They helpproperly locate the contact in thedie set, provide a wire stop, andhelp minimize contact rotation andbending during crimping.Convenient. User convenience andcomfort features are evident throughout.User-adjustable ratchet controlis provided for complete crimpcycling that helps eliminate partialcrimps. An emergency ratchetrelease allows the user to open thetool jaws at any time during the crimpcycle. To reduce handle force, thelinkage was designed to match theforces required to crimp our largestinsulated terminal. The result is dramaticallyless hand force than comparabletools. The angled head andspecially designed handles providecomfortable operation.Quality. Every tool crimps with precision,because every tool incorporatesthe traditional quality of allTyco Electronics products.SDE DAHand ToolPart No. 1213745-1This tool is specifically designed forclosed barrel SDE dies. It incorporatesall the convenient operationalfeatures of the SDE family.• Excellent mechanical advantage,enhancing user comfort• Adjustable ratchet withemergency releaseSDE PEW 12Hand ToolPart No. 9-1478240-0The unique geometry of this toolresults in a comfortable, easy-tousehandle design that isunmatched in the market.• Easy accessibility for space-constrainedapplications• Large crimp jaw arc, minimizing“roll” in open barrel applications• User-adjustable ratchet controland emergency ratchet release• Compatible with over 100 interchangeableSDE dies14For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe

Aerospace Tooling and EquipmentSDE Premium Crimp ToolingTerminal to Tool ReferencePart NumberProductFamilyCatalogNumberTyco ElectronicsProductRG/U CableWire SizeTerminationType/StyleP/N 354940-1withSDE Die SetSDE Die SetOnlyRD 316, 180, 195, Belden 8218 “O”/Commercial — 58539-150 OhmBNC and TNC“O”/Commercial 58433-1 58435-158, 62, 59Hex/Commercial 58433-2 58436-1Belden 9248, 9114 “O”/Commercial — 58539-1174, 188, 316, 179, 161, 187 “O”/Commercial 318450-1 318450-262, 59 “O”/Commercial — 58435-1Belden 9907, 89907, Comm/Scope 2104 “O”/Commercial 318452-1 318452-2174, 188, 316, 179, 161, 187 Hex/Commercial — 58436-362, 59, Belden 9104, 9112 “O”/Commercial & Military — 58537-150 Ohm BNCBelden 8281, 9141Hex/Commercial — 58436-2“O”/Commercial & Military — 58538-1180, 195, Belden 8218, 9248, 9114 “O”/Commercial — 58539-158 “O”/Military — 220189-375 OhmBNC and TNC62, 59 “O”/Commercial — 58536-16, Belden 8281 “O”/Commercial — 58538-1CoaxialConnector8207475 Ohm BNC“O”/Commercial 318451-1 318451-2179, 161, 187Hex/Commercial 58531-2 58425-262, 59 Hex/Commercial 58531-1 58425-1Double Braid 59, Belden 8281, 9141 Hex/Commercial 58531-3 58425-3Belden 9248, 9114 “O”/Commercial — 58536-1Belden 8218 “O”/Commercial — 58174-150 and 75 Ohm BNC 6, Belden 8281 “O”/Commercial — 58538-150 Ohm N58, 62, 59 Hex/Commercial 58433-2 58436-18, 213, 11, 216, 9, 214 Hex/Commercial 58501-1 58485-1Miniature UHF 58 Dual Crimp 58506-3 220196-150 Ohm SMB174, 316, 188, 179, 161, 187,RD 316, 188 Double BraidHex/Commercial 58500-1 58489-1Hex/Military 58499-1 58483-1178, 196, 174, 316, 188, 179, 161, 187 Hex/Commercial — 58046-150 and 75 OhmConsumer BNC58, 62, 59 “F” / “O” 58558-1 58558-2174, 316, 188, 179, 161, 187 “F” / “O” 58559-1 58559-258, 6, 7, 6.6, 8.2, 9.8[0.259, 0.324, 0.384] Dia.Hex/Commercial 58621-1 58621-2Series FCATV PlugsBraid-Pic BraidTermination58, 6,7,7.4, 8.7 [0.290, 0.343] Dia.59,69.1 [0.360] Dia.Hex/Commercial 58622-1 58622-2Hex/Commercial 58663-1 58663-258, 62, 59 — — 220195-1For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe15

Aerospace Tooling and EquipmentSDE Premium Crimp ToolingTerminal to Tool ReferenceProductFamilyCatalogNumberTyco ElectronicsProductCable orWire SizeP/N 354940-1withSDE Die SetSDE Die SetOnlyFSMA and ST-Style (S.S.)Connectors (504XXX Series only)ST-Style FC Type, D4 andAMP SC Connectors3.0 mm Jacket Dia. 58551-1* 58552-13.0 mm Jacket Dia. 58433-4* 58424-1ST-Style (Ceramic) Connectors 3.8 mm Jacket Dia. — * 503890-182164 and 296355FC Type and AMP SC Connectors(Next Generation)3.0 mm Jacket Dia. 503911-1** 503910-1Fiber OpticConnectorsFSD, FSD MC and RSD Connectors;FSD Breakout KitLightCrimp XTC Connectors(Ceramic/Polymer/S.S.)DUALAN and LDD 58519-1* 58510-13.0 mm Jacket Dia. 503568-1* 503567-1LightCrimp SC (Ceramic) Connectors 3.0 mm Jacket Dia. 503699-1* 503698-11307099LightCrimp Plus AMP SC 3.0 mm Jacket Dia. 492623-1*** 492622-1LightCrimp Plus ST-Style 3.0 mm Jacket Dia. 492782-1*** 492783-1— Multimate Contacts1 mm Plastic Fiber,2.2 mm Jacket Dia.217211-1 217211-2Request catalog for detailed product information.* Tool Frame Part No. 58532-1** Tool Frame Part No. 58588-1*** Tool Frame Part No. 58532-2SDE Premium Die-Sets for PIDG and PLASTI-GRIP TerminalsPart Number Description AWG / mm 2 /other91963-2PIDG, PLASTI-GRIP Terminals & Splices - equivalent crimp to 47387Qualifications: Mil-T-7928; LUL RSE 024 pt6 and EE6161Marks the applied product with a two dot indent code.16-14 / 1.5-2.520-16 / 0.6-1.5 HD91964-2PIDG, PLASTI-GRIP Terminals and Splices - equivalent crimp to 47386Qualifications: Mil-T-7928; LUL RSE 024 pt6 & EE6161Marks the applied product with a two dot indent code.22-16 / 0.4-1.591965-2PIDG, PLASTI-GRIP Terminals & Splices - equivalent crimp to 59239-4Qualifications: Mil-T-7928; LUL RSE 024 pt6 and EE6161Marks the applied product with a two dot indent code.12-10 / 4.0-6.0Only the most popular options are listed here, please use our online search by terminal PN to find the right tool for yourapplication, and contact us where information is unclear or missing - there may well be something available for yourrequirement.16For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe

Aerospace Tooling and EquipmentPower Assist Options for SDE Premium ToolingSDE 626 Pneumatic Tool• P/N 1213855-1Complete all pneumatic unit• P/N 679304-1SDE Head onlyFor more information on the 626 Systemsee Section 1.5SDE Battery Tool Kits• P/N 1725837-4SDE Shoulder DiesOPEN head (EU Power Plug)• P/N 1725837-6SDE Shoulder DiesOPEN head (UK Power Plug)For more information on the Battery Tool Kitssee Section 1.5SDE Electric Terminator• P/N 1490076-2Portable Bench-top Unit with SDE Head andFoot Switch• P/N 1673663-2Adapter only for SDE DiesFor more information on the Electric Terminatorsee Section 1.5For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe17

Aerospace Tooling and Equipment1.4 Tools for Mil Indent CrimpingTurrets - accurately position Contacts in the ToolPart Number DescriptionP/N 601967-2Turret TH1A [M22520/1-02] for ARINC ContactsP/N 601967-3Turret TH163 [M22520/1-04] for MS27490; MS27655P/N 601967-4Turret TH4 [M22520/1-03] for MS17803; MS21097;OSI2814 ContactsP/N 601967-5Universal Head UH2-5 [M22520/1-05]AF8P/N 601967-1Base Tool (AF8) without TurretP/N 2031846-1Pneumatic AF8 (WA27F) without TurretFeatures 4/8 indent Crimp to Military standard M22520/1-01 Ratchet mechanism ensures complete crimp cycle 8 Position Dial select Indent Depth control Many Turrets available Ergonomic non-slip handlesP/N 601967-6Turret TP45 [M22520/1-06]for OSI2814 type M size 16 & 22P/N 601967-7Turret TP85 [M22520/1-07]for MS18232; MS18233 ContactsP/N 601967-8Turret TH199S [M22520/1-08]for MS3343; MS90460; MS90461 ContactsP/N 1-601967-2Single Position Head TP465 [M22520/1-11]for M39029Partial listing only. For the full range please visit our online Hand Tool Catalogue atwww.tooling.tycoelectronics.com/europe/catalogue.aspthen go to the Tools for Screw-machined Contacts section.DMC is a trademark of Daniels Manufacturing Corp.18For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe

Aerospace Tooling and EquipmentTools for Mil Indent CrimpingPositioners - accurately position Contacts in the ToolPart Number DescriptionP/N 601966-2Positioner K1S [M22520/2-02]for TERMI-BLOK ContactP/N 601966-3Positioner K60S [M22520/2-03]for MS3343; MS90461 ContactsP/N 601966-4Positioner K41 [M22520/2-06]for Size 22 ContactsAFM8P/N 601966-1Base Tool (AFM8) without PositionerP/N 2031845-1Pneumatic AFM8 (WA22) without PositionerFeatures4/8 indent Crimp to Military standard M22520/2-01Ratchet mechanism ensures complete crimp cycle8 Position Dial select Indent Depth controlMany Positioners availableErgonomic non-slip handlesP/N 601966-6Positioner K13-1 [M225202/2-08]for ARINC size 20 ContactsP/N 1-601966-1Positioner K339 [M22520/2-16]for M39029/17 ContactsP/N 1-601966-3Positioner K40 [M22520/2-07]for MS27490; MS27655 ContactsP/N 1-601966-4Positioner K43 [M22520/2-10]for MS27490; MS27491; MS27492 and more ContactsP/N 1-601966-6Positioner K370 [M22520/2-12]for ARINC COAXICON size 15 ContactsP/N 966254-1Positioner K42 [M22520/2-09]for ARINC size 22 ContactsPartial listing only. For the full range please visit our online Hand Tool Catalogue atwww.tooling.tycoelectronics.com/europe/catalogue.aspthen go to the Tools for Screw-machined Contacts section.DMC is a trademark of Daniels Manufacturing Corp.For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe19

Aerospace Tooling and Equipment1.5 Power Assist EquipmentBattery Tool 1.5 tTyco Electronics only recommends the use of handtools for prototyping, service and repair, as continueduse can cause operators to experience RSI(Repetitive Strain Injury).We are continually adding to our power-assist rangeto minimise this risk. All electric, all pneumatic andnow battery powered options. With the vastimprovement of battery life and small motor power,the practicality and convenience of battery poweredtools is now well known.These tools have the standard retract switch coveredover to best ensure complete crimp cycle. The switchis fully functional with the cover removed.All Battery tools come together with a battery chargerand will be supplied in a durable plastic case.Battery Tool Kit with Adapter for HHHTEU Power Plug P/N 1901235-4GB Power Plug P/N 1901235-6Battery Tool Kit with Adapter for DAHTEU Power Plug P/N 1213840-4GB Power Plug P/N 1213840-6For HHT and DAHT, heads can be removed fromhand tools and used with the above kits.Typical C-Head SAHT DiesMoving DieInsulation AdjustmentSpacersBattery Tool Kit with Adapter for C-Head SAHTStationary DieEU Power Plug P/N 1213819-2GB Power Plug P/N 1213819-5LocatorHHHT = Heavy Head Hand ToolDAHT = Double Action Hand ToolSAHT = Straight Action Hand ToolsDie Holding Screw20For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe

Aerospace Tooling and EquipmentBattery Tool 4 tOver 100 Crimps per chargeCompact only 356 mm long and weighs 160 kg (3.4lbs)Kits are supplied in a durable carry case and include:• Battery tool• 4 t Latched Head• Battery Charger 230 V• Two BatteriesSpares:• Battery P/N 1725839-1• Battery Charger EU Power Plug P/N 1725840-2• Battery Charger GB Power Plug P/N 1725840-5Crimping Tool (with Battery Installed)Length356 mm [14 in]Width60 mm [2 3/8 in]Depth80 mm [3 1/8 in]Mass Weight (w/Battery)1.6 kg [3.4 lb]Sound Level75 dB(A) at 1 mVibration

Aerospace Tooling and EquipmentSDE Electric Terminator with CERTI-CRIMP Tool AdaptersThis all electric portable bench-top Terminator is fast,effortless and ideal for low to medium volume production.P/N 167377-2 Electric TerminatorP/N 679304-1 SDE Head AdapterP/N 1213860-1 CERTI-CRIMP II Straight Action Head AdapterP/N 1901556-1 C-Head SAHT AdapterP/N 1673664-1 Optional Foot SwitchMain powered unit - nor air requiredSwitchable 110 V or 240 V supplyCycle CounterTwo stage crimp cycle optionDimensions [mm] 390 x 260 x 200Weight 13 kgPIDG and STRATO-THERM Die Sets for Electric Terminatorwith C-Head SAHT AdapterColor AWG Die SetBrown 24-22 P/N 576711Grey 20 P/N 576720Orange 18 P/N 576715Orange 16 P/N 576714White / Beige 14 P/N 576716White / Beige 12 P/N 576742Black 10 P/N 57672322For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe

Aerospace Tooling and Equipment626 and Micro Pneumatic Tool SystemMaximize your productivity whileminimizing your effort - replaceyour manual hand tools with the626 Pneumatic Tool System.Terminating wires from0.12–13.0 mm 2 [26–6 AWG] hasnever been easier. And you cancontinue to use most, if not all, ofyour existing Tyco Electronicscompatible crimp heads and diesets.The 626 System WorksWhere and HowYou Need ItUsing 626 adapters, tools previouslyrestricted to prototype or limitedproduction applications can nowbe used in low to medium benchproduction and harness assemblyoperations.Because the 626 crimp head canbe rotated to any angle, you canAdapter HoldersPart No. 189928-1Part No. 356304-1 (w/ratchet)Fast FactsEffortless crimping for a broadrange of terminals, either benchmountedor hand-held for workingin cramped quarters.• Lightweight tool eliminatesphysical force required by handtools• Hand- or foot-switch operation• Termination wire range from0.12–13.0 mm 2 [26–6 AWG], pluscoaxial and fiber optic cable• Works with existing TycoElectronics compatible crimpheads and die sets• Ratchet control option providescomplete crimp cycle, eliminatingpartial crimps• Use rotating head assembly toreach difficult termination locations• Engineered and manufacturedusing processes independentlycertified to internationallyrecognized quality standardsISO-9001:2000 and TelecommunicationsIndustryStandard TL 9000The powerful 626 Pneumatic ToolSystem makes crimping as easy aspressing a hand or foot switch.Besides reducing operator fatigue,this means you do not have todesign your production bencharound your tool.Include the fully adjustable BenchMount Assembly with the footswitch, and you are completelyfree to concentrate on aligningthe wire and terminal. Now you cancrimp faster and with fewer mistakes.Certi-Crimp II,SAHT AdapterPart No. 1583527-1Heavy Head Hand ToolAdapter,Part No. 525432-1also work on those difficult terminationsin confined equipmentcabinets or enclosures.Looking for the complete crimpcycle control provided by themechanical ratchet in premiumCERTI-CRIMP hand tools? Theavailable 626 System ratchet toolholders produce a complete crimpcycle by simply pressing a switch.Dies will fully bottom before youcan open the jaws to release thecrimped product.For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe23

Aerospace Tooling and Equipment626 and Micro Pneumatic Tool System626 Pneumatic System Power UnitProtect Your ToolInvestmentOutside DiameterLength45 mm [1.8 in]225 mm [8.88]for foot actuated unit230 mm [9.00 in]for hand actuated unitThe 626 System’s power unitworks with a variety of adaptersand tool holders, so you can continueto work with your existingcrimp heads and die sets.Grip SpanMassAir PressureMicro Pneumatic System Power Unit55 mm [2.19 in] over button/handle0.60 kg [1.32 lbm]for foot actuated unit600-700 kPa [90-100 psi]Air Displacement 0.00018 m 3 [11.14 in 3 ]Air Supply HoseCycle TimeOutside DiameterLengthGrip SpanMass3.05 m [10 ft] long4.8 mm [3/16 in] I.D.with 1/8 in NPT fitting0.7-0.8 s (for 16-14 AWG[1.3-2 mm 2 ] PIDG Terminals)45 mm [1.8 in]146.5 mm [5.75 in]55 mm [2.19 in] over button/handle0.70 kg [1.5 lbm]Big Return in a MicroPackageDoes your crimping applicationdemand even more accessibilityand flexibility than the 626 Systemoffers?The Micro Pneumatic Tool Systemterminates wires in the 0.12-2 mm 2[26-14 AWG] range,* but with asmaller and lighter power unit.Weighing in at only 0.7 kg [1.5 lb]and just 146.5 mm [5.75 in] long, thehand-actuated Micro System iscompatible with three differenthead systems.* With the exception of theSOLISTRAND tool head combination,which crimps 0.3-2 mm 2[22–10 AWG] combinations.Air Pressure600 - 700 kPa [90-100 psi]Die InterchangeabilityAir Displacement 0.00018 m 3 [11.14 in 3 ]Air Supply HoseCycle Time3.05 m [10 ft] long4.8 [3/16 in] I.D.with 1/8 in NPT fitting0.7-0.8 s (for 16-14 AWG)[1.3-2 mm 2 ] PIDG Terminals)For the ability to change diesquickly when needs change,whether from one terminal type toanother or from tool to tool whenworkload and environment change,consider the SDE family of toolsand dies.For more information, seeCatalog 1773379.24For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe

Aerospace Tooling and Equipment626 and Micro Pneumatic Tool SystemSDE Compatible KitComplete tool withhand-held power unitP/N 1213855-10.3 - 6.0 mm 2(22-10 AWG)Tool and Adapter Holders*Large ToolHolderSmall ToolHolderAdapter HolderLength(with Head Assembly)100 mm [3.88] 70 mm [2.75] 70 mm [2.75]Weight(with Head Assembly)0.76 kg [1.68 lb]0.44 kg[0.96 lb]0.44 kg [0.96 lb]P/N 356302-1 356303-1 356304-1*Measurements are averages.For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe25

Aerospace Tooling and Equipment626 and Micro Pneumatic Tool SystemConfigurations and Ordering InformationThe basic 626 and Micro Pneumatic Tool Systems require a power unit, a tool holder, a head assembly, anda die set, when applicable. Tool holder assemblies (i.e., tool holder and cam) accept the crimping heads,adapters, and die sets listed in section 1.2Power Unit Tool Holders Crimping Heads Adapters626 SeriesLarge Tool HoldersPart No. 189767-1Part No. 356302-1 (w/ratchet)Hand Actuated Power UnitPart No. 189721-1PRO-CRIMPER III ToolDie Set AdapterPart No. 679304-1Foot Actuated Power UnitPart No. 189722-1(-2 required for C Head Adapter)Small Tool HoldersPart No. 189766-1Part No. 356303-1(w/ratchet)2614 SeriesAdapter HoldersPart No. 189928-1Part No. 356304-1(w/ratchet)CERTI-Crimp II,SAHT AdapterPart No.1583527-1 Power Units with a -1suffix can be convertedto -2 by orderingBooster Addition Kit,Part No. 189720-1. 3.05 m [10 ft] Air SupplyHose (Part No. 38111)included with eachpower unit.Double ActionHand ToolHandle AssemblyDAHT Adapter(Including cam)Part No. 1213563-1(See pages 5 & 6.)Heavy HeadHand Tool AdapterPart No. 525432-126For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe

Aerospace Tooling and Equipment626 and Micro Pneumatic Tool SystemConfigurations and Ordering InformationPower UnitTool HoldersAdaptersAdapter HoldersPart No. 356304-1 (w/ratchet)Hand Actuated Power UnitPart No. 1490567-1CERTI-CRIMP II,SAHT AdapterPart No. 1583527-1Small Tool HoldersPart No. 1673611-1 (w/ratchet)2614 SeriesCrimp HeadFor more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe27

Aerospace Tooling and Equipment1.6 Hydraulic EquipmentFast Facts• Standard 68,950 kPa [10,000 psi]rated hydraulic pumps andheads• Interchangeable AMP-designU-dies for crimp force up to14 t [125 kN]• U-die stroke options of 1 in[25 mm] and 1.5 in [38 mm]• Termination range varies byproduct type• Integrated head/die for crimping7-34 mm 2 [#8-2 AWG]SOLISTRAND terminals• Heads compatible withshank-dies available for largerwires requiring crimp forcegreater than 14 t [125 kN]• Portable power, using a handheldtool with rechargeablebattery, or a Portable BatteryHydraulic Unit for standardcrimping system• Electric & manual hydraulicpumps for crimping at fixedlocations• Produced under a QualityManagement System certifiedto ISO 9001. A copy of thecertificate is available uponrequest.Tyco Electronics continues thequality tradition of AMP crimpingtools with a new line of industrystandard68,950 kPa [10,000 psi]hydraulic compression crimp heads,pumps, and interchangeable U-dies.A new battery-powered pump andtool options provide unprecedentedportability for any crimpingapplication.The U-dies, made with the AMPdesign precision and performanceyou have come to expect, are wellsuited for applications requiring acrimp force of up to 14 t [125 kN].For wire sizes requiring more than14 t [125 kN], Tyco Electronicsoffers five heavy-duty AMP crimphead configurations that are compatiblewith shank dies.There are four light-duty crimphead options, including three in theU-die format. U-dies are availablein two types, with 25 mm [1 in] and38 mm stroke [1.5 in], respectively.The two 12 t [101 kN] head optionshave 25 mm [1 in] stroke.The 14 t [125 kN] head is for largerproducts that call for a 38 mm [1.5in] stroke. Also available is an integratedhead/die for crimping #8 to#2 SOLISTRAND terminals. Theheavy-duty heads are available infive different configurations.Note: These heads are notcompatible with 8,200 psi[56,540 kPa] tooling.The basic 68,950 kPa [10,000 psi]hydraulic tool system requires apump, hose (multiple lengths areavailable with all configurations),crimp head, and crimp die.There is a Tyco Electronics hydraulicpump to meet the demands of anycrimping application. For maximumportability, the hand-heldcrimping tool with rechargeablebattery is an effective solution.U-Die Line up, including #8–#2SOLISTRAND tool head, for 68,950kPa [10,000 psi] systems providingup to 14 t [125 kN] of crimp forceShank-Die Line up, for wiring sizesrequiring more than 14 t [125 kN] ofcrimp forceHeavy-Duty Crimp Head (U-Die).Or, to power a standard crimpingsystem at any location, order thePortable Battery Hydraulic Unit.For fixed crimping locations, youcan choose between a 110 V or220 V Electric Hydraulic Pump(with optional remote hand control),or manual foot and handhydraulic pumps.28For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe

Aerospace Tooling and EquipmentSelecting a Hydraulic System?Have you remembered a... Pump Hand or Foot control Hose Crimp Head Crimp DieHydraulic Tooling Selection Guide - 70,000 kPa / 10,000 psiPumps, and Hose OptionsThe Heavy-duty Pump is designed for continuous use.ORWITHLight Duty Electric Hydraulic PumpP/N 523199-1 (220 V) 1, 2Heavy Duty Electric Hydraulic PumpP/N 1804700-2 (220 V) 1, 2Hydraulic Hoses 3P/N 1583662-1 - 1.8 m / 6 ftP/N 1583662-2 - 3.0m / 10 ftP/N 1583662-3 - 6.1 m / 20 ftHeavy-Duty Crimp Heads (Shank Dies) ( > 25,000 cycles)8 - 4/0 A22 t output force 16 lbsP/N 1752877-1IS 408-89564/0 AWG-1000 MCM26 t output force 29 lbsP/N 1752786-1IS 408-89588 - 4/0 AWG33 t output force 28 lbsP/N 1752787-1IS 408-891412-10 AWG - 350 MCM18 t output force 13 lbsP/N 1752868-1IS 408-8959Medium-Duty Crimp Heads & Hand Tools (U-Dies)Shank DiesU-DiesAMPLI-BOND 8 AWG-4/0 AWGAMPOWER 6 AWG-1500 MCMAMPOWER QuickDisconnect1/0 AWG-600 MCMInsulation Piercing10 AWG (Cu)-3/0 AWG)COPALUMSealed COPALUM 10 AWG-3/0 AWGBar COPALUM 10 AWG (Cu)-400 MCMSOLISTRAND 8 AWG-600 MCMSTRATO-THERM 8 AWG-2/0 AWGTERMINYL 1/0 AWG thru 4/0 AWGAMPLI-BONDAMPOWERSOLISTRANDTERMINYL8 AWG - 2 AWG6 AWG - 4/0 AWG8 AWG - 4/0 AWG8 AWG - 1/0 AWG12 t output force1.5” stroke; 50,000 cycleCompression HeadU-Die CompatibleP/N 1901821-1IS 408-1011212 t output force1” stroke TitaniumCompression HeadU-Die CompatibleP/N 1490747-1IS 408-8715SOLISTRAND (Integrated Crimp Dies)#8-#2 AWG SOLISTRAND Compression Head(No crimp dies required)P/N 1673672-1 / IS 408-891014 t output force1.5” strokeHeavy-DutyCompression HeadU-Die CompatibleP/N 1976230-1IS 408-1014514 t output force1.5” strokeCompression ToolU-Die CompatibleP/N 1976230-1IS 408-87171” stroke HandCompression ToolU-Die CompatibleP/N 1490748-1IS 408-8716#8-#2 AWG SOLISTRAND Compression Tool(No crimp dies required)P/N 59975-1 / IS 408-67581 Foot Pump 523199-2 ORHand Pump 1583661-1 can be substituted asmanual options for Electro-Hydraulic Pumps2 Includes male screw-to-connect, 3 /8" NPT quickcouplers3 Includes female screw-to-connect, 3 /8" NPTquick couplersFor more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe29

Aerospace Tooling and EquipmentDies, Hand Tools and Hydraulic HeadsConfiguration OptionsThe Tyco Electronics hydraulic crimping tool line offers a wide array of die, hand tool, and hydraulic headconfigurations.Use the following tables to determine the configuration that best matches your requirements.The tables are color-coded to help you identify the new 68,950 kPa [10,000 psi] rated configurations thatcorrespond to previous 56,540 kPa [8,200 psi] tooling.TERMINYL Terminals and SplicesHydraulic Crimp Tooling 10,000 psi Operating PressureDYNA-CRIMP Tool System 8,200 psiOperating PressureHand Tools(U-Die)Hydraulic Heads(U-Die)Hydraulic Heads(Shank-Die)Hand ToolHydraulic Heads(Shank Die)Wire Sizein AWG [mm 2 ]1490748-1 1490749-11901820-11490747-11901821-11976230-11752877-1 1752787-1 59974-1 § 69051 § 69066 58422-18 [7-8.5] 1490597-1 1490597-1 1490597-1 1490597-1 47820 § 47820 §6 [13-15] 1490598-1 1490598-1 1490598-1 1490598-1 47821 § 47821 §4 [21] 1490599-1 1490599-1 1490599-1 1490599-1 47822 § 47822 §4HD 69463 69463 69463 694632 [34-35] 1490406-1 1490406-1 47823 § 47823 §1/0 [50-60] 1490700-1 1490700-1 47824 47824 47824 478242/0 [67-70] 47825 47825 47825 478253/0 [80-95] 47915 47915 47915 479154/0 [100-125] 47918 47918 47918 47918AMPLI-BOND and PLASTI-GRIP Terminals and SplicesHydraulic Crimp Tooling 10,000 psi Operating PressureDYNA-CRIMP Tool System 8,200 psi Operating PressureHand Tool(U-Die)Hydraulic Head(U-Die)Hydraulic Heads(Shank Die)Hand ToolHydraulic Heads(Shank Die)Wire Sizein AWG [mm 2 ]1490749-11901821-11976230-11752877-1 1752787-1 59974-1 § 69051 § 69066 58422-18 [7-8.5] 1490534-1 1490534-1 48858-1 48858-1 48752-1 § 48752-1 § 48858-1 48858-16 [13-15] 1490535-1 1490535-1 48859-1 48859-1 48753-1 § 48753-1 § 48859-1 48859-14 [21] 1490536-1 1490536-1 48860-1 48860-1 48754-1 § 48754-1 § 48860-1 48860-12 [34-35] 1490410-1 1490410-1 48861-1 48861-1 48755-1 § 48755-1 § 48861-1 48861-11/0 [50-60] 48756-1 48756-1 48756-1 48756-12/0 [67-70] 48757-1 48757-1 48757-1 48757-13/0 [80-95] 48758-1 48758-1 48758-1 48758-14/0 [100-125] 48759-1 48759-1 48759-1 48759-1§These products will bediscontinued30For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe

Aerospace Tooling and EquipmentDies, Hand Tools and Hydraulic HeadsConfiguration OptionsAMPLI-BOND and PLASTI-GRIP Large Expansion TerminalsWire Sizein AWG [mm 2 ]Hydraulic Crimp Tooling10,000 psi Operating PressureHydraulic Heads(Shank Die)DYNA-CRIMP Tool System8,200 psi Operating PressureHydraulic Heads(Shank Die)1752877-1 1752787-1 69066 58422-18 [7-8.5] 47236-1 47236-1 47236-1 47236-16 [13-15] 47237-1 47237-1 47237-1 47237-14 [21] 47238-1 47238-1 47238-1 47238-12 [34-35] 47239-1 47239-1 47239-1 47239-11/0 [50-60] 47378-1 47378-1 47378-1 47378-1Stationary DieMoving DieSelf-Contained Die Use Adapter 69760 Use Adapter 69834§These products will bediscontinuedSOLISTRAND TerminalsHydraulic Crimp Tooling 10,000 psi Operating PressureDYNA-CRIMP Tool System 8,200 psi Operating PressureHand Tool(DiesIncluded)HandTools(U-Die)HydraulicHeads(U-Die)Hydraulic Heads(Shank Die)HandToolHydraulicHeadsHydraulic Heads(Shank Die)Wire Sizein AWG[mm 2 ]59975-1 1490748-11490749-11901820-11901821-11490747-11976230-1673672-1 1752868-1 1752788-1 1752786-1 59973-1 §69065 §69067 §69097 § 69069 § 69099 58445-1 690828 [7-8.5] 1490413-11490414-11490413-1 1490414-1 6921648126 §48355 §48126 §48355 §46146 §46145 § 692166 [13-15] 1490413-2 1490413-2 1490414-2 1490414-2 6921748128 §48127 §48128 §48127 §46134 §46133 § 692174 [21] 1490413-3 1490413-3 1490414-2 1490414-2 6921848129 §48127 §48129 §48127 §46135 §46133 § 692182 [34-35] 1490413-4 1490413-4 1490414-2 1490414-2 4543348130 §48127 §48130 §48127 §46136 §46133 § 454331/0 [50-60]1490413-5 1490413-5 1490414-3 1490414-3 4543648132 §48131 §48132 §48131 §46138 §46137 §454362/0 [67-70]1490413-6 1490413-6 1490414-3 1490414-3 4543948133 §48131 §48133 §48131 §454393/0 [80-95]1490413-7 1490413-7 1490414-3 1490414-3 4544248134 §48131 §48134 §48131 §454424/0 [100-125]1490413-8 1490413-8 1490414-3 1490414-3 45445300430 §48131 §300430 §48131 §45445250-300 MCM[127-152]48816 69911 48816 69911300-350 MCM[152-177]400 MCM[203]500-600 MCM[253-304]48817 69912 48817 6991248818 69913 48818 6991348819 69914 48819 69914For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe31

Aerospace Tooling and EquipmentDies, Hand Tools and Hydraulic HeadsConfiguration OptionsHeavy Duty SOLISTRAND TerminalsHydraulic Crimp Tooling10,000 psi Operating PressureDYNA-CRIMP Tool System8,200 psi Operating PressureWire Sizein AWG [mm 2 ]Hand Tools(U-Die)Hydraulic Heads(U-Die)Hand ToolsHydraulic Heads(Shank Die)1490748-1 1490749-11901820-1, 1901821-11490747-1, 1976230-1 59973-1 § 69065 § 69067 §8 [7-8.5]1490413-9 1490413-2 1490413-9 1490414-2 48128-1 §48127-1 §48128-1 §48127-1 §6 [13-15]1-1490413-0 1490414-2 1-1490413-0 1490414-2 48129-1 §48127-1 §48129-1 §48127-1 §4 [21]1-1490413-1 1490414-2 1-1490413-1 1490414-2 48130-1 §48127-1 §48130-1 §48127-1 §2 [34-35]1-1490413-2 1490414-3 1-1490413-2 1490414-3 48132-1 §48131-1 §48132-1 §48131-1 §1/0 [50-60]1-1490413-3 1490414-3 1-1490413-3 1490414-3 48133-1 §48131-1 §48133-1 §48131-1 §SOLISTRAND Flag TerminalsHydraulic Crimp Tooling10,000 psi Operating PressureDYNA-CRIMP Tool System8,200 psi Operating PressureWire Sizein AWG [mm 2 ]Hand Tools(U-Die)Hydraulic Heads(U-Die)Hand Tool(Shank Die)Hydraulic Heads(Shank Die)1490749-1 1901821-1, 1976230-1 1752868-1 69067 § 690998 [7-8.5]1752680-8 1752681-2 1752680-8 1752681-2 48506-1 48505-1 48506 §48505 §48506-1 48505-1 6 [13-15]1752680-7 1752681-3 1752680-7 1752681-3 48508-1 48507-1 48508 §48507 §48508-1 48507-1 4 [21]1752680-6 1752681-3 1752680-6 1752681-3 48509-1 48507-1 48509 §48507 §48509-1 48507-1 2 [34-35]1752680-5 1752681-3 1752680-5 1752681-3 48510-1 48507-1 48510 §48507 §48510-1 48507-1 1/0 [50-60]1752680-4 1752681-1 1752680-4 1752681-1 48652-1 48511-1 48652 §48511 §48652-1 48511-1 2/0 [67-70]1752680-3 1752681-1 1752680-3 1752681-1 48805-1 48511-1 48805 §48511 §48805-1 48511-1 3/0 [80-95]1752680-2 1752681-1 1752680-2 1752681-1 48806-1 48511-1 48806 §48511 §48806-1 48511-1 4/0 [100-125]1752680-1 1752681-1 1752680-1 1752681-1 48807-1 48511-1 48807 §48511 §48807-1 48511-1 Stationary DieMoving DieSelf-Contained Die Use Adapter 69760 Use Adapter 69834§These products will bediscontinued32For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe

Aerospace Tooling and EquipmentDies, Hand Tools and Hydraulic HeadsConfiguration OptionsAMPOWER Quick Disconnect TerminalsWire Sizein AWG [mm 2 ]Hydraulic Crimp Tooling10,000 psi Operating PressureHydraulic Heads(Shank Die)DYNA-CRIMP Tool System8,200 psi Operating PressureHydraulic Heads(Shank Die)1752868-1 1752786-1 690991/0 [50-60] 68361-1 / 68200-1 68361-1 / 68200-12/0 [67-70] 68253-1 / 68201-1 68253-1 / 68201-13/0 [80-95] 59867-1 59867-1 4/0 [100-125] 68304-1 68304-1 250 MCM [127] 68203-1 68203-1350 MCM [177] 68204-1 68204-1400 MCM [203] 68332-1 68332-1 500 MCM [253] 68206-1 68206-1 600 MCM [304] 46757-3 46757-3With locatorDual CrimpInsulation Piercing Crimp COPALUM Terminals and SplicesWire Size in AWG [mm 2 ]Hydraulic Crimp Tooling10,000 psi Operating PressureDYNA-CRIMP Tool System8,200 psi Operating PressureHand Tool(U-Die)Hydraulic Head(U-Die)Hydraulic Heads(Shank Die)Hydraulic Heads(Shank Die)Al Cu 1490749-11901821-11976230-11752868-1 1752786-1 69099 690828 [7-8.5] 10 (5-6] 1490714-1 1490714-1 68084 680846 [13-15] 8 [7-8.5] 1490715-1 1490715-1 68085 680854 [21] 6 [13-15] 1490716-1 1490716-1 68086 680862 [34-35] 4 [21] 1490717-1 1490717-1 68130 681301/0 [50-60] 2 [34-35] 1490718-1 1490718-1 68131 681312/0 [67-70] 1/0 [50-60] 68132 681323/0 [80-95] 2/0 [67-70] 68133 681334/0 [100-125] 3/0 [80-95] 318106-1 68129 318106-1 68129For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe33

Aerospace Tooling and EquipmentDies, Hand Tools and Hydraulic HeadsConfiguration OptionsAMPOWER Terminals and SplicesHydraulic Crimp Tooling10,000 psi Operating PressureDYNA-CRIMP Tool System8,200 psi Operating PressureWire Sizein AWG[mm 2 ]Hand Tools (U-Die)Hydraulic Heads(U-Die)Hydraulic Heads(Shank Die)HandToolHydraulic Heads(Shank Die)1490748-1 1490749-1 1901820-11490747-11901821-11976230-11752868-1 1752788-1 1752786-1 59973-1 §69065 §69067 §68073-2 69099 58445-1 690826[13-15]4[21]2[34-35]1/0[50-60]2/0[67-70]3/0[80-95]4/0[100-125]250 MCM[127]300 MCM[152]350 MCM[177]400 MCM[203]500 MCM[253]600 MCM[304]1583092-1 1583092-1 1583092-1 1583092-1 69133-1 69133-11583093-1 1583093-1 1583093-1 1583093-1 69134-2 69134-21583094-1 1583094-1 1583094-1 1583094-1 46765-3 46321-3 § 46321-3 § 46765-31583095-1 1583095-1 1583095-1 1583095-1 46766-2 46322-2 § 46322-2 § 46766-21583096-1 1583096-1 1583096-1 1583096-1 46767-2 46323-2 § 46323-2 § 46767-21583097-1 46749-2 46324-2 § 46324-2 § 46749-21583098-1 46750-2 46325-2 § 46325-2 § 46750-246751-2 46326-2 46751-2 46326-246752-2 46752-246753-2 69653 46753-2 6965346754-2 46754-246755-2 46755-246756-2 46756-2600 HD 59870-1 59870-1700 MCM[355]800 MCM[405]900 MCM[456]1000 MCM[507]1250 MCM[634]1500 MCM[761]46757-2 46757-246758-2 46758-246759-2 46759-246760-2 46760-268114-168282-11976230-1 only34For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe

Aerospace Tooling and EquipmentDies, Hand Tools and Hydraulic HeadsConfiguration OptionsSealed Crimp COPALUM Terminals and SplicesWire Size in AWG [mm 2 ]Hand Tool(U-Die)Hydraulic Crimp Tooling10,000 psi Operating PressureHydraulic Head(U-Die)Hydraulic Heads(Shank Die)DYNA-CRIMP Tool System8,200 psi Operating PressureHydraulic Heads(Shank Die)Al Cu 1490749-1 1901821-1 1976230-1 1752877-1 1752787-1 69066 58422-18 [7-8.5] 10 (5-6] 1490555-1 1490555-1 68006 68006 68006 680066 [13-15] 8 [7-8.5] 1490556-1 1490556-1 68007 68007 68007 680074 [21] 6 [13-15] 1490557-1 1490557-1 68008 68008 68008 680082 [34-35] 4 [21] 68009 68009 68009 680091/0 [50-60] 2 [34-35] 68010-1 68010-1 68010-1 68010-12/0 [67-70] 1/0 [50-60] 314964-1 68011-1 314964-1 68011-13/0 [80-95] 2/0 [67-70] 59877-1 59877-14/0 [100-125] 3/0 [80-95] 314948-1 314948-1Bar Crimp COPALUM Terminals and SplicesWire Size in AWG [mm 2 ]Hand Tool(U-Die)Hydraulic Crimp Tooling10,000 psi Operating PressureHydraulic Head(U-Die)Hydraulic Heads(Shank Die)DYNA-CRIMP Tool System8,200 psi Operating PressureHydraulic Heads(Shank Die)Al Cu 1490749-11901821-11976230-11752868-1 1752786-1 69099 690828 [7-8.5] 10 [5-6] 1490572-1 1490572-1 68043 680436 [13-15] 8 [7-8.5] 1490573-1 1490573-1 68044 680444 [21] 6 [13-15] 1490574-1 1490574-1 68045 680452 [34-35] 4 [21] 1490575-1 1490575-1 68046 680461/0 [50-60] 2 [34-35] 68047 680472/0 [67-70] 1/0 [50-60] 68048 680483/0 [80-95] 2/0 [67-70] 68049 680494/0 [100-125] 3/0 [80-95] 68050 68050250 MCM [127] 4/0 [100-125] 68034 68034300 MCM [152] 250 MCM [127] 68035 68035400 MCM [203] 300 MCM [152] 68036 68036500 MCM [253] 400 MCM [203] 68037 68037For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe35

Aerospace Tooling and EquipmentDies, Hand Tools and Hydraulic HeadsConfiguration OptionsSTRATO-THERM Terminals and SplicesWire Size inAWGWire Size inmm 2Hydraulic Crimp Tooling10,000 psi Operating PressureHydraulic Head(Shank Die)DYNA-CRIMP Tool System8,200 psi Operating PressureHydraulic Head(Shank Die)1752868-1 690998 7-8.5 69211-1 69211-16 13-15 69212-1 69212-14 21 69213-1 69213-12 34-35 69214-1 69214-11/0 50-60 69215-1 69215-12/0 67-70 69254-1 69254-136For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe

Aerospace Tooling and EquipmentHydraulic Equipment Options and more detailed Informationfor 70,000 kPa / 10,000 psiElectric Hydraulic Pumps, heavy dutyP/N 1804700-2 (220 V)suitable for continuous use Two speed cycle reduces cycle time for improved productivity Footswitch and 1.8 meter hose included Pump shuts down after pressure-switch setting is reached Easy to read integrated oil level sight glass Totally enclosed fan-cooled motor - ideal for use in any environment Quiet operation 70-79 dB(A) Swivel wheels provide easy manoeuvrabilityPortable Electric Hydraulic Pump, light dutyP/N 523199-1 (220 V) Lightweight and compact design 10 kg Large Carry-handle for easy portability Two speed cycle reduces cycle time for improved productivity 24 V DC remote motor control, 3m length for operator safety Starts under full load High strength moulded shroud Supplied with male quick coupler (no hose supplied)Pressure Gauge options:P/N 523200-1 Pressure GaugeP/N 523200-2 Digital Pressure GaugeP/N 523200-3 1/4" Adapter (required when using either Gauge)Hydraulic Foot Pump, manualP/N 523199-2 Pump action operation Clicker valve pressure regulation Supplied with male quick-couplingHydraulic Hand Pump, manualP/N 1583661-1This pump action unit allows hyraulic heads via optionallength hydraulic hoses a degree of positional flexibilty.Battery-Hydraulic Tool Kit 12 t 'U' DieP/N 1213875-2Kit Includes: Complete Kit with Crimp ToolEU Power Plug Battery Charger 220 V Suitable for all 'U' Dies (PN 1213873-2)with the exception of Rechargeable Battery'U' Die Assy (14 t) (PN 1213872-1) Rotating Head 320° Carry Case with strap Excellent powerto weight ratio circa 10,000 Cycles3-WayMultidirectional ValveP/N 1901782-1 (Manual)P/N 1901783-1 (Electric)For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe37

Aerospace Tooling and Equipment1.7 Insertion and Extraction ToolsInsert discrete terminals into connector housings orremove them, without causing damage to either theterminal, housing or yourself.To reference the relevant tool(s) to your Terminal P/Nplease visitwww.tooling.tycoelectronics.com/europe/Handtools.asp38For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe

Aerospace Tooling and Equipment1.8 Hand Tool Control GaugesTo reference the relevant gauge(s) to your Hand Tool Gauges are available for most closed barrel crimp toolsplease visitfor regular wear checks.www.tooling.tycoelectronics.com/europe/Handtools.asp However, factory recalibration is recommended every6 months or 5,000 cycles. See section 1.9For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe39

Aerospace Tooling and Equipment1.9 Service and CalibrationMost premium tools and some commercial tools canbe economically serviced and repaired. Our toolingService Centres hold spares for all commonly usedtools along with the specialist equipment and skillsrequired to re-calibrate after repair.Tyco Electronics recommends that for hand tools acalibration check is carried out every 6 months orevery 5,000 crimp cycles, whichever the sooner.We calibrate and provide certificates for the followingTyco Electronics / AMP equipment: Premium tools complete Interchangeable dies (independent of the optionalequipment they are used in) Any equipment that has measurable parameters.We will be pleased to quote for any of the aboveoptions or to service all other types of equipment.Only Tyco Electronics authorised Service Centreslisted below have the necessary access to engineeringdrawings and specialised equipment required for ourrepair and calibration processes.Tyco Electronics uses crimp height as the primarymeasure of crimp quality integrity, and does notrecognize pull-off values alone as a measure.If you would like more information on this subject,why not get in touch with your Country Contact whowill be happy to arrange a visit to present explanatoryinformationwww.tooling.tycoelectronics.com/europe/Contact.aspApproved Service CentreTyco Electronics AMP GmbHReparatur ServiceAmpèrestr. 7-1163225 LangenGermanyTel +49 (0)6103 709 1534Fax +49 (0)6103 709 3076email gherzog@tycoelectronics.com40For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe

Aerospace Tooling and Equipment2 Wire Processing Equipment2.1 Stripping MachinesAVG 0160 Cable Strip and Twist MachineThe AVG 0160 is a stripping and twisting machine for wires withinsulation such as PVC, TEFLON, Silicon, Fiberglass, Rubber etc.The machine can cover a wire size range from 0.03 mm 2 up to 6 mm 2with an adjustable stripping length from 0.5 mm up to 29 mm.The machine utilizes rotary stripping blades for a smooth, 360°cutting of the insulation.P/N 1481003-1JacketStrip 8400 Jacket Stripping MachineThe JacketStrip 8400 enables automatic jacket stripping of round cablesup to 26 mm in diameter and a stripping length of 200 mm. After thecable jacket has been cut, the piece of insulation is removed using a strongelectric motor (full/partial or window strip can be selected).Pneumatically operated clamping jaws guarantee optimal cable retentionduring the stripping process. All functions of the machine are electronicallymonitored and diagnosed by means of a LCD display.P/N 1-528453-7UniStrip 2015/2100 Stripping MachinesThe pneumatically operated stripping machine UniStrip 2015 primarilyprocesses stranded wires and single wires. Due to the minimal distancebetween the acryl safety cover and the stripping blades, this machinecan perform stripping on extreme short cables.The UniStrip 2100 is an electrically driven stripping machine.Ease of operation, fast cycle times, a powerful yet silent motor drive aswell as a vast cable processing range are the main features of this machine.UniStrip 2015 P/N 1-528453-0UniStrip 2100 P/N 528453-8UniStrip 2500 Stripping MachineThis pneumatically driven stripping machine comes standard withV-blades, with no blade changeover necessary. Through the use ofspecial blades, the range of applications can be expanded to include flatribbon cable, double-stranded wire, thin multistranded wire or demandingisolations. The adjustable way-back prevents the conductor frombeing damaged during the stripping process.P/N 528453-7CoaxStrip 5300 - Programmable Coaxial Cable Stripping MachineThe Coax Strip 5300 is a semi-automatic, programmable multi-stepstripping machine for coaxial, triaxial, multi-conductor cable and singleconductor wire.This benchtop unit can easily process coaxial and triaxial cables up to7 mm (0.276”) outer diameter and strips lengths up to 30 mm (1.18”).PN 1-528453-5TEFLON is a trademark of E.I. duPont deNemours and Co.For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe41

Aerospace Tooling and Equipment2.2 Cutting and Stripping MachinesThe Kappa family strippers are ideal for cutting individual and special wires to length and stripping them.They can strip in sections, allowing them to strip even extremely long length in perfect quality. The machinescover an extraordinarily broad range of cross sections.Kappa 310, 320, 321, 330 and 350 strippers support a variety of processing options such as wire markingwith hot-stamp or ink jet markers.Hot stamp marking can even be done on the Kappa 310 stripper, the entry-level model.New KAPPA Generation: Dynamic, flexible cuttingand stripping unit New intelligent sensors New electronic and software Optional TOPWIN softwareKAPPA 350 MachineKAPPA 330 MachineKAPPA, KAPPAWIN and TOPWIN are trademarks of KOMAX AG.42For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe

Aerospace Tooling and Equipment2.3 4/8 Indent Stripper Crimper with Touch Sensor SystemFast Facts• Modular open design• Fast and simple tool kit changes• Fast changeover times• Variety of tool kits• Touch sensor system• Wire sizes from 0.14 - 2.5 mm• Insulation diameter0.35 - 2.5 mm• Jacket strip length 30 mm• Strip length 2.0 - 10 mm• Electric power supply:115 V / 230 V• Compressed air: 500-700 kPa• Cycle time: 2.5 seconds• Weight: Approx. 60 kg• Dimensions machine [mm]W x H x D = 530 x 620 x 800The machine is suitable for strippingand crimping loose piececontacts to accepted MIL specificationswith 4/8 indent crimpform.The machine feeds, sorts andseparates the contacts prior tothe stripping an crimping process.A variety of contact specific toolkits is available or can be createdto suit almost all screw machinedcontacts.The machine is easy to operateand can be changed from onecontact to another quickly andeasily.The touch sensor is a safety systemdesigned to monitor when thestripping blades contact the conductorduring insulation stripping.If the blades make contact withthe conductor then the machinewill not crimp the contact.The system allows for partial or fullmonitoring or can be turned offcompletely.The touch sensor system is particularlyuseful when stripping wireswhere a non-contact situationis required.Application specific equipment:Please address your request toyour local Tyco Electronics representative.The relevant GATD contact can befound on the website below.For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe43

Aerospace Tooling and Equipment2.4 AM03 Universal Stripper CrimperFast Facts• Stripping range 0.14-2.50 mm 2[AWG 26-14]• Special version up to 4 mm 2• Programmable adjustment forstripping and crimping depth• Data memory 50 programs• Rapid and reliable crimpingprocess• Insertion wire length:min. 32 mm• Drive: Electro-pneumatic• Electrical connection:230 V, 50 Hz, 120 VA• Pneumatic connection:550 kPa (5.5 bar)• Dimensions [mm]WxDxH = 500x500x460• Weight: 40 kgThe AM03 Universal StripperCrimper processes loose pieceturned male and female pin contacts.As standard the machine uses the4/8 ident crimp corresponding toMIL 22520/1-01.The adjustment of the strippingand crimping depth is motorised.Different values for up to 50 programscan be memorised.Adjustment and programmingcan be made though the keyboard.The LCD display shows all importantdata, functions and errors.The machine can also be convertedfor different contacts by usingspecific tool kits.All tools are quick and easilyexchangeable.Machine Components Basic machine Oscillating conveyor Tool unit equipped with4/8 ident crimping dies Motorised adjustment unit forstripping and crimping Stripping unit with V-knifes Contact specific toolingfeeding tube Singling unit Contact holder Contact stopper Wire centraliserA crimp quality monitoring systemis available as an option.AM03 Basic Machinewithout KitsPN 0528375-844For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe

Aerospace Tooling and Equipment2.5 Crimp Quality Control EquipmentMicrograph LaboratoryFeatures Quick process flow of 5 to 10 minutes No cross section potting Evaluation according to DIN and different electrical and physical parameters PC specific software for micrograph evaluationThe micrograph laboratory is designed for Tyco Electronics crimp terminalsystems but is not restricted to them.With a modified sample holder, cross sections of competitors products arealso possible.The flexibility of the CSL allows cross sections of a variety of crimp terminals.Better than conventional processes the new cutting method makes pottingand long drying times a thing of the past. So processing time can bereduced dramatically.For special requirements an optional impregnation module is available. With itthe cutting area can be lightly fixed.If you need more detailed information please contact your local representative.The relevant contact can be found on the website below.Our GATD team will be very pleased to assist you.PN X-528000-XFor more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe45

Aerospace Tooling and EquipmentPortable Micrograph Laboratoryfor Crimp Terminal SystemsFeatures Compact, easy to operate Optional electrolyte Etching module Easy fixation station for sampleholder Secure mechanism for Optic duringtransportation 1.3 Mpixels USB 2.0 Camera withSL Vision II Evaluation andDocumentation moduleThe flexibility of the CSL allowscross sections of a variety of crimpterminals.Nowadays quick and significantprocess monitoring gains increasingimportance as a competitive factor.The CSL brings you a decisiveadvantage in order to evaluate thequality of your crimp connectionssimply and safely, fast and economicallypriced.The Micrograph Laboratory isdesigned for Tyco Electronics crimpterminal systems but is notrestricted to them.With a modified sample holder,cross sections of competitors productsare also possible.Due to the mobility you can use theCSL everywhere. Thereby you areable to decide on the release forproduction, e.g. after a tool change,in best time and on site. You willloose less of your value scoopingproduction time.PN 1-528000-246For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe

Aerospace Tooling and Equipment3 Test Equipment3.1 High Voltage Test EquipmentTyco Electronics offers a comprehensive range of automatic testequipment for wiring harnesses and associated systems.Overall maintenance procedures require a 100% electrical inspectionby means of high voltage testing.The automatic test equipment provides up to 500,000 test points in2-wire or 4-wire Kelvin measurement.Capability ranges from a simple harness to the most complex highdensity back planes can be analyzed in an unrivaled accuracy, qualityand reliability.19” Rack Based SystemStandard test systems are built into19” cabinets with test point numbersvarying from 32 to over 500,000.Test voltages can range from 10 V DCto 25 kV DC.AC voltages are optional upon request.19” racks can also be built asmoveable units.Portable SystemEspecially for harsh environments, Tyco Electronicsoffers portable systems in ruggedized, waterproofcases.Systems come completely with PC and ticket printer.The test voltage of 500 V DC can be supplementedwith 250 V AC.Remote ControlPOCKETMEGWhen it comes to planning a testenvironment, hooking-up a largeunit under test or when troubleshootingon larger applicationsneeds to be performed, theoperator will benefit frombeing able to move around theapplication while at the same timehaving full control over the test software.Using WiFi communication and data transfer protocol,POCKETMEG wireless PDA offers full remote controland operator interaction with the automatic test system.The operator can move around the unit under test, withPOCKETMEG wireless PDA in hand, while receiving testprogress information, test results and pictorial guides andinstructions. Productivity and test speed can be drasticallyimproved.MK and POCKETMEG are trademarks of MK Test Systems, Ltd.For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe47

Aerospace Tooling and EquipmentElectrical Test SoftwareWINDOWS-based Test Software is truly intuitiveand easy to use. Test programs use familiar from-toconnections, drop-down menus and tick boxes, sooperator training time is minimal. Operator guidanceis highly visual; pictorial prompts, links to photographsand manuals produce an immediate graphic messageof nature and location of fault.Automatic Program Generation (APG), coupled witha state of the art data import facility, dramaticallycuts programming time and virtually eliminates theneed for analysis by the operator. This means that theworld’s most powerful testing solution is also theeasiest to use and most cost-effective solution for you.Typical Systems and Applications2-Wire SystemsT 100 Low voltage, high speed testing 2-wire continuity measurement to 0.1 Ohm 50 V AC optionT 10000 2-wire continuity measurement to 0.1 Ohm 10,000 V DC testing to 1,000 MOhm 5,000 V AC option4-Wire SystemsF 1500 4-wire continuity measurement to 0.001 Ohm 1,500 V DC testing to 1,000 MOhm 1,000 V AC optionF 2500 4 wire continuity measurement to 0.001 Ohm 2,500 V DC testing to 1,000 MOhm 1,500 V AC optionDual SystemsD 1500 2/4 dual-wire continuity measurement to 0.001 Ohm 1,500 V DC testing to 1,000 MOhm 1,000 V AC optionD 2500 2/4 dual-wire continuity measurement to 0.001 Ohm 2,500 V DC testing to 1,000 MOhm 1,500 V AC optionSpecial Variants and ModulesIntrinsically Safe System For use in hazardous areas in which explosive gasatmosphere is likely to be present 4-wire continuity measurement to 0.001 Ohm 200 V DC testing to 200 MOhmWINDOWS is a trademark of Microsoft Corp.MK is a trademarks of MK Test Systems, Ltd.48For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe

Aerospace Tooling and EquipmentAdvantages of the powerful Test Systems Product RangeSpecific Build OptionsBuilt to your specific requirements,supplied, installed and commissioned atyour site, we offer the optimum inquality, accuracy and reliability - thecomplete turnkey solution.System ControlSetting new standards with its simpleto use, yet powerful, menu driven software.Test files for complex harnesssystems are created with ease, usingone of a variety of Auto Create facilities,confirming it’s place at the forefrontof automatic testing technology.QualityA comprehensive diagnostics systemallows verification of the switchingmatrix, programmable power suppliesand all measurement circuits. Thisincludes verification of external testfixtures. All diagnostics give clearresults with an optional dated reportand archive file. Diagnostics can beconfigured to run before every test,daily, weekly, monthly, etc.In addition to the diagnostics tools,the operation of power supplies,switching matrix and measurementcircuits is being monitored duringnormal testing.Calibration is designed to be carriedout by your on-site engineers makinguse of the in-built calibration programand calibration card which is suppliedwith the system. This is a simple andfast operation and is completed in amatter of minutes.Resistance MeasurementsThe range of test systems can be supplied in three formats either 2-wire,4-wire, or a Dual systems capable of performing both 2- and 4-wiremeasurement. The fundamental difference is explained as follows:2-Wire MeasurementThe 2-wire technique is typically used in automotive wiring, computercables and other low specification applications to verify that an itemis wired correctly and not to verify the integrity or performance of acable. When measuring low resistance measurements using the 2-wiretechnique, the test lead or test interface wiring will be in series withthe device under test. With a constant test current of 1 A flowingthrough the circuit a Volt drop of 6.010 V is measured, therefore displayinga resistance of 6.01 Ohm. All contact resistances and test leadresistances are added into the test value. In this typical example themeasurement error is >60,000%.4-Wire MeasurementThe 4-wire measurement technique is found in some higher specificationATE, more commonly known as Kelvin measurement. When measuringlow resistance measurements using the 4-wire technique the testlead or test interface wiring will be automatically nulled out.With a constant test current of 1 A flowing through the circuit a Voltdrop of 0.010 V is measured, therefore displaying a resistance of 0.01 Ohm.Most Aerospace and Defense companies have adopted the 4-wirecontinuity measurement technique as the industry standard.Additional ServicesTyco Electronics test systems offertest interface fixture, harnesses andjigs as part of a complete package. Ifyou would like to take advantage ofthis service, contact us with fulldetails of your requirement.For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe49

Aerospace Tooling and EquipmentAdvantages of the powerful Test Systems Product RangeThe 4-wire Kelvin resistance measurement techniquein the typical manufacturing environment will allowthe test system to detect faults such as:Incorrect wire gaugeDirty contactsBad ground / shield connectionsPoorly mated or loose connectionsIncorrect fuse / breaker installationsIncorrect or malfunctioning componentsWhen combined with specialist Kelvin probes andour continuous scanning features, and used in thecorrect environment the system can be used todetect faults such as:Wire with broken strandsBad crimp connectionsDry solder jointsIntermittent connection faults…. and other events that can only be detected withconsistent milliohm resistance measurement andaccuracy.50For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe

Aerospace Tooling and Equipment3.2 Cable Test SystemsCT15 and CT30 Cable Testers by TSKThe cable testers CT15 and CT30 are based on a universal measuring board which allows for a greater flexibilityso that these units can also be combined with TSKs modular test table systems like TS1300.Fast Facts• Continuity and short circuittesting• Resistance testing, testing ofdiodes and capacitors• Programme creation fromqualified sample(Autoprogram)• Pin number function• USB interface (CT15) resp.Ethernet data transfer to PC• Programme creation onCS WIN (CS WIN Licenserequired)• 7 resp. 8 freely programmableI/Os• Extended range of powersource to 200 mAStandard Equipment USB, serial port, parallel port resp.Ethernet (for CT30) Keyboard, Mouse, VGA(for CT30)CT15 Cable Tester:Slots for 3 test point cards internally,up to 384 test pointsFully compatible with CT20 andCT30 testersCT30 Cable Tester:Slots for 512 test points internallyadditional 2048 test points in extrahousingFully compatible with CT15 testerDesigned especially for the electricaltest of simple cables to complexwire harnesses these cable testerssets standards in technology andprice.The large graphic display and theergonomic keypad enable easyhandling for both operator andsetter.The logical software structureenables simple and easy operationand programming.A programme can be created at thetester directly or via a connectedPC with the CS WIN Software.TSK CT15 and CT30 Cable Testers are products of TSK Quality Solutions.For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe51

Aerospace Tooling and Equipment4 Appendix - Useful Information4.1 Wire Range LimitsA reliable terminaton includes: Good Electrical Performance, Cross-Sectional Area Reduction, andMechanical Strength.Termination Quailty is determined by measuring the Crimp Height of the crimped terminal. The proper crimpheight, accompanied by careful visual inspection, assures that the termination will meet or exceet specifiedrequirements, provided that the wire and tooling beeing used are correct.A quality termination occurs when the terminal is crimped within the Crimp Design Range.Mechanical Strength & Electrical Performance Related toCrimping Force & the Cross-Sectional Area of ReductionIncreasing Mechanical Strengthand Electrical Performance(Decreasing Millivolt Drop and Resistance)Decreasing Cross-Section Area(Current Carrying Capability)Increasing Crimping ForceDecreasing Crimp Height52For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe

Aerospace Tooling and Equipment4.2 Computing CMASTRANDED WIREROUND WIRE1. Multiply Diameter (D) of oneStrand (in mils) by itself.2. Multiply the result by the totalnumber of Strands.CMA = D 2 x N1. Multiply the Diameter (D)in mils by itself.CMA = D 2SQUARE OR RECTANGULAR WIREWhole numbersExamples:.0150” = 50.100” = 100.250” = 250.500” = 5001. Multiply the Width (W) of theWire Cross-Section in mils by theThickness (T) of the Wire Cross-Sectionin mils.2. Multiply the result by 1.273.CMA = W x T x 1.273CMA Table (Typical Values)Wire Size CMA Wire Size CMA Wire Size CMA Wire Size CMA26 250 18 1,620 10 10,400 2 66,40024 475 16 2,580 8 16,500 1/0 106,00022 750 14 4,110 6 26,300 2/0 133,00020 1,200 12 6,530 4 41,700 3/0 168,0004/0 212,000For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe53

Aerospace Tooling and Equipment4.3 Wire Range and Colour CodesThe Wire Range stamped on a Terminal indicates the smallest and largestacceptable Single Wire.When two or more Wires are used, the total Cross-Sectional Area should be withinthe Range listed in the CMA Range Column.54For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe

Aerospace Tooling and EquipmentWire Range and Colour CodesSOLISTRAND Terminal Uninsulation Support Sleeve / Size 26 to 600 MCMBrazed Seam“W” CrimpCross Section ofCrimped Terminal“W” CrimpDIAMOND GRIP Uninsulated Terminal with Metal Insulation Support Sleeve / Size 26 to 10InsulationGrip NotchesSleeveBodyDiamond GripTerminalCrimped DiamondGrip TerminalCross Section ofCrimped TerminalPIDG Terminal Insulated with Metal Insulation Support Sleeve / Size 26 to 10InsulatingSleeveMetal InsulationSupport SleeveInsulationRestrictingTypePIDG TerminalBodyFunnel TypeTETRA-CRIMPTerminals“CC” or Confined Crescent CrimpPLASTI-GRIP Terminal Insulated with Insulation Support / Size 22 to 2/0Vinyl PlasticSleeveFunnel EntrySize 22-8Size 22-2/0AWGBodyPLASTI-GRIPTerminalTETRA-CRIMP TerminalCross Section ofCrimped TerminalAMPLI-BOND Terminal Vinyl-Insulated with Insulation Grip / Size 8 to 4/0MetalRingDimple for AddedTensile StrengthVinyl InsulationSleeve (Bonded)UnplatedCopperSleeveBody (BrazedSeam)AMPLI-BONDTerminalCrimp Code“C” or Confined CrimpTERMINYL Terminal Nylon Insulated / Size 8 to 4/0NylonInsulationSleeveBody(Brazed Seam)“C” or ConfinedCrimpCrimp CodeCross Section ofCrimped TerminalFor more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe55

Aerospace Tooling and EquipmentWire Range and Colour CodesAMPOWER Terminal UninsulatedAMPOWERTerminalCrimp Codeon TopSight HoleNo SightHoleCopperTubingForming &Stamping“C” CrimpStandard — Wire Size 6 - 1000 MCMLong-Barrel — Wire Size 2 - 1000 MCMSTRATO-THERM Terminal UninsulatedSOLISTRAND TerminalSize 22 to 1/0DIAMOND GRIP TerminalSize 22 to 10Heat Resistant STRATO-THERMTerminals and SplicesTemperatures to 650°F (343°C)High Temperature STRATO-THERMTerminals and SplicesTemperatures to 1200°F (649°C)SOLISTRANDNickelPlatedCopperNickelDIAMOND GRIPNickel Plated Copper Bodywith Nickel SilverDiamond Grip SleeveNickel Bodywith Nickel SilverDiamond Grip SleevePIDG STRATO-THERM Terminal Insulated with Metal Insulation Support Sleeve / Size 26 to 10TEFLON insulatedSleeveMetal InsulationSupport Sleeve(Nickel-platedCopper) Copper Body (Goldor Nickel Plated)Dot Code“C” or Confined CrimpPIDGSTRATO-THERMTerminalWireSizeSleeveColor CodeDotCode26-24 Black 22-20 Green 18-16 Orange 14 White 12-10 Black PIDG Terminal Insulation-RestrictingSize 26 to 10 AWGStandard SplicesStripe ColorCodingCopper SleeveFunnel Ramp Entry and InsulationRestriction Sleeve (Limits Terminalto One Wire Size Only)Nylon InsulationCOPALUM Terminal and Splice Uninsulated Terminals for Aluminum WireUnsealed Wire Size 16 to 500 MCM Aluminum andCopperInsertBodySealed Wire Size 8 to 4/0Aluminum 10 to 3/0 CopperInsertBodyTerminalInsertSpliceClosed-End SplicesWire Size 22 to 10 NylonWire Size 22 to 6 VinylNylonInsulation(Translucent )(black)Parallel Splice(Brazed)Nylon Closed-End SpliceVinyl Insulation(VariousColors)Parallel Splice(Brazed)Vinyl Closed-End SpliceInsulation Expanded and Clinched)TEFLON is a trademark of E.I. DuPont deNemours and Co.56For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe

Aerospace Tooling and Equipment4.4 Terminal StylesMulti-studAMP, AMPLI-BOND, AMPLIMITE, AMPMODU, AMPOWER, CERTI-CRIMP, CERTI-SEAL, COAXICON, COPALUM,DIAMOND GRIP, DUALAN, DURASEAL, DYNA-CRIMP, ERGOCRIMP, FASTON, FSD, LIGHTCRIMP, LIGHTCRIMP PLUS,MATE-N-LOK, MINISEAL, PIDG, PLASTI-GRIP, PRO-CRIMPER, RSD, SOLISTRAND, STRATO-THERM, TERMI-BLOK,TERMI-FOIL, TERMINYL, TETRA-CRIMP, XTC, TE Logo and Tyco Electronics are trademarks.Other products, logos and company names mentioned herein may be trademarks of their respective owners.For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe57

Aerospace Tooling and EquipmentEMEAAustria - Slovenia - Croatia - SerbiaMontenegro - Bosnia - MacedoniaHerbert WiesingerPhone: +43 1 90560 1236herbert.wiesinger@tycoelectronics.comCzech & SlovakiaNedzad InsanicPhone: +42 724 818 993ninsanic@tycoelectronics.comFrance - Morocco - TunisiaDominique VergerPhone: +33 134208770dverger@tycoelectronics.comProduct Information Center FrancePhone: +33 134208943Fax: +33 134208623Pic.france@tycoelectronics.comGermany, Bulgaria, Latvia,Lithuania, Romania and TurkeyRalf CustodisPhone: +49-6251-133-3027rcustodis@tycoelectronics.comProduct Information Center GermanyPhone: +49 (0) 6251 1331999Fax. +49 (0) 6251 1331998germany-pic@tycoelectronics.comFinland and EstoniaPetri LaihoTel: +358 9 512 34 224plaiho@tycoelectronics.comAMERICASUSA–Harrisburg, PATooling Assistance CenterPhone: +1-800-722-1111Canada – TorontoKen NakamuraPhone: +1-416-580-8129knakamura@tycoelectronics.comTooling Assistance CenterPhone: +1-800-722-1111Brazil – Braganca Paulista, Sao PauloCelco C. LimaPhone: +55-11-3404-6011cclima@tycoelectronics.comMexico – Mexico CityTooling Assistance CenterPhone: +1-717-986-3434Great Britain & IrelandGarry FaulknerPhone: +44 1237428673gfaulkner@tycoelectronics.comHungaryTibor RomanyPhone: +36 1289 1000tromany@tycoelectronics.comIndiaMuppidathy VPhone: +91 9890600513muppi@tycoelectronics.comItalyEnrico RaccaPhone: +39 0114012272eracca@tycoelectronics.comMoroccoTarik HachemPhone: +212 5 23 32 35 18thachem@tycoelectronics.comNetherlands - Belgium - LuxembourgHenk van HasselPhone: +31 736246108hhassel@tycoelectronics.comProduct Information Center NetherlandsPhone: +31 736246999Fax: +31 736246931picbenelux@tycoelectronics.comPolandPawel WieckowskiPhone: +48 601522935pwieckowski@tycoelectronics.comASIA / PACIFICChina – ShanghaiSean RongPhone: +86-21-24071576sean.rong@tycoelectronics.comHong KongCharlie CheungPhone: +852-27388894charlie.cheung@tycoelectronics.comJapan – TokyoMr. Tanaami HirokazuPhone: +81-44-900-5027tanaami.hirokazu@tycoelectronics.comKorea – SeoulSuh, Kyung HongPhone: +82- 53-850-0083kh.suh@tycoelectronics.comProduct Information Center PolandPhone: +48 224576704Fax: +48 224576720jmatasz@tycoelectronics.comRussia, Belarus & UkraineIvan LyapinPhone: +7 9104523571ivan.lyapin@tycoelectronics.comSweden, Denmark and NorwayPekka AlakuljuPhone: + 46 8 50725000palakulju@tycoelectronics.comSouth AfricaFrikkie SwartPhone: +27 415034500frikkies@tycoelectronics.comSpain & PortugalJosé Manuel VázquezPhone: +34 932 910 396jmvazquez@tycoelectronics.comProduct Information Center SpainPhone: +34 932910330Fax: +34 932017879pic.spain@tycoelectronics.comSwitzerlandPatrick EigenmannPhone: +41 798167094p.eigenmann@tycoelectronics.comTunisiaNaoufel AbdelwahedPhone: +216 71 75 50 34nabdelwahed@tycoelectronics.comMalaysia – Kuala LumpurT.C ToPhone: +60-378053055 Ext. 7794tc.to@tycoelectronics.comSingaporeS.O.LimPhone: +65-64164567solim@tycoelectronics.comTaiwanKenneth ShyrPhone: +886-2-87682788-371kenneth.shyr@tycoelectronics.comThailand – BankokWichan BunrodPhone: +66-2-955-0500 Ext. 228wichan.br@tycoelectronics.comVietnam – Ho Chi MinhHuynh Thien TriPhone: +84-89105972tthuynh@tycoelectronics.comIn the interest of continuous improvement Tyco Electronics reserves the right to modify, discontinue or replace any products.58For more detailed information please visit our websitewww.tooling.tycoelectronics.com/europe

Tyco Electronics AMP GmbHAmpèrestr. 12-1464625 Bensheim / GermanyPhone +49-(0)6251-133-0Fax +49-(0)6251-133-1600www.tycoelectronics.comTyco Electronics AMP GmbH certifiedacc. ISO 14001 and ISO/TS 16949:2002© 2008 Tyco Electronics Ltd.2-1773444-1 issued 03-2010 in Germany