63318-1 Datasheet 63318-1, 62754-2 | P1-P3

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PRODUCT INFORMATION

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Application Specification

1 of 6

LOC B

Open Barrel Pigtail and Through Splices

114-2088

25 OCT 11 Rev D

All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters [and inches].

Unless otherwise specified, dimensions have a tolerance of ±0.13 [±.005] and angles have a tolerance of ±2°. Figures

and illustrations are for identification only and are not drawn to scale.

1. INTRODUCTION

This specification covers the requirements for application of open barrel pigtail and through splices. These

splices are available in end feed and side feed. The splices will accept wire sizes and combinations within the

range of 400 to a combined total of 30,000 circular mill area (CMA). The splices feature serrations that help to

hold the wire in place after crimping. All are available in strip form to be crimped using precision crimping dies

and various power assist units.

When corresponding with personnel, use the terminology provided in this specification to facilitate your inquiries

for information. Basic terms and features of this product are provided in Figure 1.

Figure 1

2. REFERENCE MATERIAL

2.1. Revision Summary

Revisions to this application specification include:

• Changed “thru” to “through”

• Changed company name and logo

2.2. Customer Assistance

Reference Product Base Part Number 61299 and Product Code 1041 are representative of open barrel pigtail

and through splices. Use of these numbers will identify the product line and expedite your inquiries through a

service network established to help you obtain product and tooling information. Such information can be

obtained through a local Representative or, after purchase, by calling PRODUCT INFORMATION at the number

at the bottom of page 1.

2.3. Drawings

Customer Drawings for product part numbers are available from the service network. If there is a conflict

between the information contained in the Customer Drawings and this specification or with any other technical

documentation supplied, the information contained in the Customer Drawings takes priority.

NOTE

End Feed Splice Side Feed Splice

Serrations

Cutoff Tab

Carrier Strip

114-2088

2 of 6

Rev D

2.4. Instructional Material

Instruction Sheets (408-series) provide product assembly instructions or tooling setup and operation procedures

and Customer Manuals (409-series) provide machine setup and operating procedures. Documents that pertain

to this product are:

408-4357 AMP-O-LECTRIC* Model “G" Terminating Machine 356462-[ ]

408-7424 Checking Terminal Crimp Height or Gaging Die Closure

408-8012 Standard-Type Side-Feed Applicators

408-8014 Standard-Type End-Feed Applicators

408-8024 Miniature Quick-Change Applicators (End-Feed Type)

408-8039 Heavy Duty Miniature Quick-Change Applicators (End-Feed Type)

408-8040 Heavy Duty Miniature Quick-Change Applicators (Side-Feed Type)

408-8053 Miniature Quick-Change Applicators

408-8059 General Preventative Maintenance for Applicators

408-9816 Handling of Reeled Products

409-5128 AMP-O-LECTRIC Model “K" Terminating Machines 1-471273-3 and 565435-5

409-5842 AMP-O-LECTRIC Model “G" Terminating Machine 354500-1

409-5852 AMPOMATOR* CLS III-G Lead-Making Machines 122500-[ ]

409-5878 AMPOMATOR CLS IV+ Lead-Making Machines 356500-[ ]

2.1. Storage

A. Shelf Life

Reeled splices should remain in the shipping containers to prevent deformation and limit exposure to

environmental elements until ready for use. Splices should be used on a first in, first out basis to avoid long

term storage contamination that could adversely affect crimp performance.

B. Ultraviolet Light

Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the splice.

C. Reeled Splices

Care must be taken to prevent twisting, bending, or other distortion that would prevent smooth feeding of the

reeled splices through automatic machine feed mechanisms. Store coil wound reels horizontally and

traverse wound reels vertically. Review reel tag data to determine if breaks in the strip are present within the

reel.

D. Chemical Exposure

Do not store splices near any chemical listed below as they may cause stress corrosion cracking in the

splices.

Where the above environmental conditions exist, phosphor-bronze splices are recommended instead of brass.

2.2. Wire Size and Preparation

Open barrel splices accept bare solid and/or stranded copper wire of various sizes and combinations. Strip

length shall be within 1.14 and 2.16 [.045 and .085] longer than the splice or as needed to ensure that all

conductors are inserted completely through the splice without any insulation extending into the crimped area.

See Figure 2.

Reasonable care must be taken not to nick, scrape, or cut any strands during the stripping operation.

NOTE

CAUTION

114-2088

3 of 6

Rev D

Do not twist multiple wires together prior to crimping.

Figure 2

2.3. Crimped Splice Requirements

Crimp features that must apply to pigtail and through splices after termination are illustrated in Figure 3.

A. Crimp Height and Width

Optimum electrical and mechanical performance is achieved by reducing the cross-sectional area of the

wires and splice by a pre-determined percentage. Crimp width is fixed by the application tooling. Crimp

height must be set and maintained as determined from the crimp height formula provided on the splice

Customer Drawing. See Figure 3.

B. Crimp Length

For optimum crimp length effectiveness, the crimp must be within the area shown in Figure 3.

Effective crimp length shall be defined as that portion of the splice, excluding bellmouths, fully formed by the

crimping tool. The crimp length must meet the dimensions provided in Figure 3.

C. Bellmouths

Bellmouths contribute to crimp effectiveness and reduce the risk of nicked and/or broken conductor strands

due to sharp material edges at the ends of the splice. Front and rear bellmouths shall conform to the

dimensions given in Figure 3.

D. Cutoff Tab

The cutoff tab shall not exceed the dimension given in Figure 3.

E. Cutoff Burr

The cutoff burr shall not exceed the dimension given in Figure 3.

F. Wire Barrel Flash

Wire barrel flash, which can be caused by incorrect set-up and/or worn and broken crimp tooling, shall not

exceed the dimension given in Figure 3.

G. Conductor Extension

Conductors must extend completely through the splice, but to the maximum dimension given in Figure 3.

H. Seam

The seam must be closed with no evidence of loose wire strands visible in the seam as given in Figure 3.

I. Tensile Strength

Crimp quality shall be judged solely on proper crimp width, crimp height, and conformance to the

requirements given in Figure 3.

NOTE

Strip Length (Refer

to Paragraph 2.2)

Strip Length (Refer

to Paragraph 2.2)

Stranded Wire Solid Wire

Conductors

Insulation

P1-P3 P4-P6

63318-1

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Terminals SPLICE 20AWG 005SST

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