Heavy Duty Seamless Terminals & Splices
Catalog 1308674
Issued 4-02
Catalog 1308674
Heavy Duty Seamless Terminals & Splices
Introduction
Product Facts
Heavy Duty Seamless
Electrical Lugs
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Issued 4-02
High conductivity ETP copper
Utilize seamless drawn body
Flared wire barrel
Copper and tin plating
available
Sight hole versions
available for wire inspection
Multiple tongue widths
available
Bent tongues available at
angles up to 90°
Many part numbers are UL
listed
Heavy Duty Seamless
Electrical Splices
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Utilize seamless tubular body
Flared or chamfered wire
barrel entry
Dimpled wire stop for
proper placement
Tin plating
High conductivity ETP
copper material
Utilize seamless drawn body
Tin plating
Flared wire barrel
Sight hole for wire inspection
Color coding for crimp
identification
The Heavy Duty Seamless
and Copper Compression
Lug and Splice line provides
a robust terminal line for
applications in the many
industries. The product is
used in applications
including industrial and
welding equipment,
transportation/marine cable
harness, and general-
purpose harnesses. The
Heavy Duty Seamless line
utilizes deep-draw stamping
technology to create a
robust terminal without
butted seams along the
wire barrel or along the
outer edge of the ring
tongue. The Heavy Duty
Splice line offers butt splice
versions with either flared or
chamfered wire barrels for
ease of wire entry and
dimpled wire stops to assist
in proper wire placement.
The Copper Compression
Lug and Splice line is a
formed tubular line for use
on cable assemblies in
Commercial equipment and
Industrial machinery. The
thicker tongue and wire
barrel of this line provide
added strength and rigidity
for more challenging
applications.
The Battery Lug and Splice
line offers the thickest
material and strength for
your industrial equipment
and transportation harness
applications.
Tyco Electronics has
extensive drawn sleeve
capabilities to help meet
your customized electrical
sleeve needs. The company
manufactures specialized
sleeves used in general
electrical applications and
electronic components.
Tyco Electronics has the
capability to manufacture
sleeves in a range of
copper alloys and has
extensive post electro-
plating capabilities.
Contact us to review your
application and discuss the
benefits we can provide.
Need more information?
Call Technical Support at
the numbers listed below.
Technical Support is staffed
with specialists well versed
in all Tyco Electronics
products. They can provide
you with:
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Technical support
Catalogs
Technical Documents
Product Samples
Tyco Electronics
Authorized Distributor
Locations
Industrial Electrical Lugs
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Copper Compression Lugs
and Splices
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Tubular copper body
Sight hole for wire inspection
Single and double stud hole
available
Long and short crimp barrel
available
Color coding for crimp
identification
Chamfered wire barrel entry
Many part numbers are UL
listed
Capabilities to produce a
wide range of custom drawn
sleeves for electrical and
electronic applications
Drawn Sleeves
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© Copyright 2002 by Tyco Electronics
Corporation. All Rights Reserved.
AMP and TYCO are trademarks.
2
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
Catalog 1308674
Heavy Duty Seamless Terminals & Splices
Table of Contents
Product Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
Stud Hole Size Chart/UL486A Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Deep-Drawn Sleeves and Terminals
Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Sleeve Illustrations and Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Design Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Heavy Duty Seamless Lugs and Splices
Seamless Ring Lugs
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12, 13
8 AWG to 250 MCM
Seamless Ring Lugs with Sight Hole
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14, 15
8 AWG to 250 MCM
Seamless Angled Ring Lugs
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16, 17
8 AWG to 250 MCM
Seamless Angled Ring Lugs with Sight Hole
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
8 AWG to 250 MCM
Seamless Butt Splices
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
8 AWG to 4/0
Industrial Electrical Lugs and Splices
Industrial Lugs
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
8 AWG to 4/0
Industrial Butt Splices
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
8 AWG to 4/0
Copper Compression Lugs and Splices
Standard Barrel Lug with One Stud Hole
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
8 AWG to 500 MCM
Standard Barrel Lug with Two Stud Holes
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
8 AWG to 500 MCM
Long Barrel Lug with One Stud Hole
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
8 AWG to 500 MCM
Long Barrel Lug with Two Stud Holes
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
8 AWG to 500 MCM
Standard Barrel Butt Splices
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
8 AWG to 500 MCM
Long Barrel Butt Splices
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
8 AWG to 500 MCM
Design Worksheet
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Heavy Duty Starter/Battery Lugs and Splices
Super Lugs
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
4 AWG to 4/0
Super Butt Splices
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
4 AWG to 4/0
Crimp Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
AMP to Former AET Part Number Cross Reference . . . . . . . . . . . . . . . . . . . . . . . . . . .31-33
Former AET to AMP Part Number Cross Reference . . . . . . . . . . . . . . . . . . . . . . . . . . .34-36
Part Number Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37-39
Issued 4-02
3
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
Catalog 1308674
Heavy Duty Seamless Terminals & Splices
Heavy Duty Seamless Electrical Lugs
This line is made from high
conductivity Electrolytic
Tough Pitch (ETP) copper in
a unique deep drawing
process that enables the
seamless characteristics.
The seamless design
provides advantages in a
wide range of environmental
and corrosive applications.
The product incorporates
a flared wire barrel to ease
wire entry. The product has
the wire gauge stamped on
barrel for ease of
identification. Different ring
tongue pad widths and stud
hole clearances are available
for nearly any application.
Versions with sight holes in
the barrel are available to
assist in wire inspection after
crimping. Different angled
versions are available to
meet your many challenging
applications, and custom
bend angles can be quoted
upon request. The product
is available in copper or tin-
plated copper varieties.
The product is available in
wire ranges from 8 AWG to
250 MCM.
Issued 4-02
Standard
Angled Ring Tongue
Expanded Tongue
4
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
Catalog 1308674
Heavy Duty Seamless Terminals & Splices
Heavy Duty Seamless Butt Splices
This line incorporates high
conductivity ASTM B-152
tubular copper material for
a series of butt splices to
meet most applications. The
splices are available with
either flared or chamfered
barrels to ease in wire entry.
Dimpled wire stop features
are incorporated in each
barrel to assist in proper
wire placement for
crimping. All products in
this line are tin plated to
provide additional corrosion
protection.
Issued 4-02
Seamless Barrel
Dimpled Wire Stop
Flared Wire Barrel
Seamless Barrel
Dimpled Wire Stop
Chamfered Wire Barrel
5
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
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