Instruction Sheet
Crimping Die Assemblies
59826- 1, 59827- 1, and 59828- 1
21 Mar 11 Rev B
408-- 2822
Moving
Dies
Color
Code
For complete instructions concerning the related
applicators or machines, refer to the customer
documents supplied with the respective tooling.
These documents will explain further instructions
relative to tooling adjustments, die installation, tape
loading, maintenance, etc.
Read this sheet thoroughly before installing or using
the die assemblies. Reason for revision is provided in
Section 8, REVISION SUMMARY.
NOTE
Dimensions in this document are in millimeters
and [inches]. Figures and illustrations are for
reference only and are not drawn to scale.
i
2. DESCRIPTION
These die assemblies consists of two stationary dies
and two movable dies. These features allow one set
of dies to crimp the wire barrel while crimping the
insulation simultaneously. See Figure 1.
Stationary
Dies
Refer to Catalogs 82004 and 82042 for complete
product information and features.
DANGER
APPLICATOR
(DOCUMENT)
567200-- 2
MACHINED
(DOCUMENT)
1901700-- [ ] (409-- 10078)
354500-- [ ] (409-- 5842)
1490501-- [ ] (409-- 10029)
1725900-- [ ] (409-- 10047)
1725910-- [ ] (409-- 10027)
1725950-- [ ] (409-- 10047)
1901700-- [ ] (409-- 10078)
122500-- [ ] (409-- 5852)
356500-- [ ] (409-- 5878)
Avoid personal injury. Always disconnect machine
from power supply when performing adjustments,
die installation or removal, and machine
maintenance. Always keep guards and covers in
place during normal machine operation.
DIES
3. WIRE PREPARATION AND CRIMP INSTRUCTIONS
Figure 2 lists the preferred wire strip lengths for
products discussed in this publication. However,
depending on your wire stripping machine adjustment
(strip length) capabilities, wire strip length may be
increased to the nearest 0.8 mm [.031 in.] if
necessary.
CAUTION
Do not use wires with nicked or missing
conductor strands.
59826-- 1
59827-- 1
59828-- 1
567200-- 3
687658-- 1
D
Other Tyco Electronic machines may be available. Contact the
Tooling Assistance Center number at the bottom of this page for more
information.
Figure 1
!
1. INTRODUCTION
This Instruction Sheet (IS) covers the use and care of
Crimping Die Assemblies 59826--1, 59827--1, and
59828--1. See Figure 1. These dies are used to crimp
the PIDG* and PLASTI--GRIP* FASTON* terminals
and splices listed in Figure 2 which are designed to
be used in the various applicators and machines
listed in Figure 1.
Refer to the respective machine manual for crimp
instructions.
4. COLOR AND DOT CODE
Dies, terminals, and splices are color--coded for a
given wire range as shown in Figure 2. Color coding
is used as a method of verifying that the correct
combination of die set and terminal or splice was
used.
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
www.te.com
E2011
Tyco Electronics Corporation, a TE Connectivity Ltd. Company
TOOLING ASSISTANCE CENTER 1--800--722--1111
All Rights Reserved
PRODUCT INFORMATION 1--800--522--6752
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks.
*Trademark. Other logos, product and/or Company names may be trademarks of their respective owners.
1
of 7
LOC B
408- 2822
Typical PIDG Type
Terminals and Splices
“C”
“B”
“C” “B”
Typical PLASTI- GRIP Type
Terminals and Splices
“C” “B”
Window
Indent
“C”
“B”
Wire Stop
Wire Stop
FASTON Receptacle
FASTON Receptacle
“B” Equals Wire Barrel
“C” Equals Insulation Barrel
“B” Equals Wire Barrel
“C” Equals Insulation Barrel
DIE SET
PRODUCT
NUMBER
INSULATION
AND COLOR
COLOR
CODE DOT
CODE
59826-- 1
(Red)
Red
WIRE STRIP LENGTH
PRODUCT
PIDG and PLASTI-- GRIP Terminals and Splices
TERMINALS
MIN
MAX
SPLICES
MIN
MAX
WIRE SIZE
mm
2
[AWG]
0.3-- 1.3
[22-- 16]
0.3-- 0.8
[22-- 18]
1.3-- 2.0
[16-- 14]
0.5-- 1.3
[20-- 16] HD
1.3-- 2.0
[16-- 14]
3.0-- 5.0
[12-- 10]
1.3-- 2.0
[16-- 14] HDG
3.0-- 5.0
[12-- 10]
5.16 5.95 6.35 7.14
[.203] [.234] [.250] [.281]
7.54 8.33
PIDG and PLASTI-- GRIP FASTON ReceptaclesU
---
---
[.297] [.328]
PIDG and PLASTI-- GRIP Terminals and Splices
5.16 5.95 6.35 7.14
[.203] [.234] [.250] [.281]
7.54 8.33
[.297] [.328]
---
---
59827-- 1
(Blue)
Blue
PIDG and PLASTI-- GRIP FASTON ReceptaclesU
PIDG Terminals and PLASTI-- GRIP
Terminals and Splices
PIDG and PLASTI-- GRIP FASTON ReceptaclesU
59828-- 1
(Yellow)
Yellow
7.94 8.73 8.73 9.53
[.313] [.344] [.344] [.375]
7.94 9.53
[.313] [.375]
---
---
UCrimp
using foot petal control only.
GYellow
with black stripe product insulation color code.
Figure 2
2
of 7
Rev
B
408- 2822
ACCEPT
PIDG Type Terminals
and Splices Shown
7
4
5
3
4
REJECT
2
PIDG and PLASTI- GRIP
Terminals and FASTON
Receptacles
2
3
2
Wire Range
Stamped Here
4
2
Wire Range
Stamped Here
6
7
6
7
4
Wire Stop
Wire Stop
5
2
Wire Range
Stamped Here
PIDG Butt Splices
5
4
3
2
Wire Range
Stamped Here
3
Wire Stop
1
1
1 Correct product insulation color and die set combination.
2
Wire size is within wire range stamped under terminal
tongue or on center of splice.
1
2
3
4
5
6
7
Wrong product insulation color and die set combination.
Wire size is not within wire range stamped on terminal
tongue or splice.
Crimp not centered on wire barrel. See machine manual
for terminal positioning and crimp location adjustments.
End of conductor is not flush with or extending beyond
end of wire barrel. (Check for correct strip length.)
Excessive flash or extruded insulation, (wrong die set,
terminal, or splice combination, or damaged dies.)
Wire insulation entered wire barrel.
Nicked or missing conductor strands.
3 Crimp centered on wire barrel.
4
5
End of conductor is flush with, or extends slightly beyond
end of terminal wire barrel.
End of conductor against wire stop of splice, or at least
flush with, or extended slightly beyond wire barrel.
6 Wire insulation does not enter wire barrel.
7 No nicked or missing conductor strands.
Figure 3
Rev
B
3
of 7
408- 2822
5. CRIMP INSPECTION
Inspect crimped terminals and splices by checking the
features described in Figure 3.
Use only the terminals and splices that meet
conditions shown in the “ACCEPT” column.
“REJECT” terminals and splices can be avoided
through careful use of instructions provided in the
machine manual and by performing regular die
maintenance as instructed in Paragraph 6 of this
Instruction Sheet.
2. Check the die alignment and tighten the die
holding screws regularly.
3. Make certain the dies are protected with a THIN
coat of any good SAE No. 20 motor oil. Do
NOT
oil
excessively.
4. When the dies are not in use, store them in a
clean, dry area.
6.3. Periodic Inspection
Regular inspections should be performed by quality
control personnel. A record of scheduled inspections
should remain with the dies and/or be supplied to
supervisory personnel responsible for the dies.
Though recommendations call for at least one
inspection a month, the inspection frequency should
be based on the amount of use, ambient working
conditions, operator training and skill, and established
company standards. These inspections should be
performed in the following sequence:
6. DIE MAINTENANCE/INSPECTION PROCEDURE
DANGER
Disconnect power supply from tooling before any
inspection, maintenance, adjustment, or repair.
TE Connectivity recommends that a
maintenance/inspection program be performed
periodically to ensure dependable and uniform
terminations. Frequency of inspection may be
adjusted to suit your requirements through
experience.
Frequency of inspection depends on:
1. The care, amount of use, and handling of the
dies.
2. Type and size of products being crimped.
3. Skill level of the operator.
4. Presence of abnormal amounts of dust and dirt.
5. Your own established standards.
6.4. Visual Inspection
1. Remove all lubrication and accumulated film by
immersing the dies in a suitable commercial
degreaser that will not affect paint or plastic
material.
2. Make sure all die holding screws, retaining
rings, and die components are in place. Refer to
the parts list in Figure 8 if replacements are
necessary.
3. Check all bearing surfaces for wear. Remove
and replace worn components.
4. Inspect the crimp area for flattened, chipped
cracked, worn, or broken areas. Although dies may
gage within permissible limits, worn or damaged
die closure surfaces are objectionable and can
affect the quality of the crimp. See Figure 4. If
damage is evident, the dies must be repaired
before returning them to service (See Paragraph 7,
DIE REPLACEMENT AND REPAIR).
6.1. Initial Die Inspection
The dies are thoroughly inspected before shipping.
The dies should be inspected immediately upon
arrival at your facility to ensure the dies have not
been damaged during shipment, and that they
conform to Figure 7. If the dies are damaged upon
arrival, retain the shipping container, file a claim with
the carrier, and notify TE immediately.
6.5. Die Closure Inspection
Every die set is inspected for proper die closure
dimensions before packaging. However, inspection of
die closure for excessive wear is required periodically.
Die closure inspection is accomplished using plug
gages.
TE neither manufactures nor sells plug gages. A
suggested plug gage design and the GO and NO--GO
dimensions for plug gage elements are given in
Figures 5 and 6. For additional information concerning
the use of a plug gage, refer to Instruction Sheet
408--7424.
Clean oil or dirt from the die closure surfaces,
bottoming surfaces, and plug gage elements.
6.2. Daily Maintenance
It is recommended that each operator of the dies be
made aware of — and responsible for — the following
four steps of daily maintenance.
1. Remove dust, moisture, and other contaminants
from the dies with a clean brush, or a soft, lint--free
cloth. Do
NOT
use objects that could damage the
dies.
4
of 7
Rev
B
408- 2822
2. With wire barrel crimp dies bottomed, inspect
the wire barrel crimp die closure using the proper
plug gage. Hold gage in straight alignment with the
die closure and carefully insert, without forcing, the
GO element. The GO element must pass
completely through the wire barrel crimp die
closure.
3. Try to insert the NO--GO element. The NO--GO
element may enter partially, but must not pass
completely through the wire barrel crimp die
closure.
Chipped Edge
Pitted
B. Insulation Crimp Die Closure
(Figure 7B)
1. With the wire barrel crimp dies bottomed and
not under pressure, adjust the dies to meet the
“gage dimension” as shown in Figure 7B.
2. Inspect the insulation crimp die closure using
the proper plug gage in the same manner as steps
6.5.A. (2) and (3).
If both the wire barrel and insulation crimp die
closures meet the plug gage conditions, the dies are
considered to be correct and should be lubricated with
a THIN coat of any good SAE No. 20 motor oil. If not,
the dies must be repaired before returning them to
service (See Paragraph 7, DIE REPLACEMENT AND
REPAIR).
Figure 4
A. Wire Barrel Crimp Die Closure
(Figure 7A)
1. Assemble dies so that wire barrel crimp dies are
bottomed but not under pressure.
Die Closure
Configuration
“C” Dim.
Suggested Plug Gage Design - Wire Barrel
GO Dim.
“B”
NO-- GO Dim.
“B”
“C” Dim.
“A” Dim.
Break Edges
0.51 [.020] x 45 (Typ)
25.4 [1.00] Min. (Typ)
DIE SET
59826--1
59827--1
59828--1
DIE CLOSURE DIM’S “A”{
GO
1.98 [.078]
2.33 [.092]
3.25 [.128]
NO-- GO
2.18 [.086]
2.54 [.100]
3.45 [.136]
GAGE ELEMENT} DIM’S “B”
GO
1.98--1.99 [.0780--.0783]
2.33--2.34 [.0920--.0923]
3.25--3.26 [.1280--.1283]
NO-- GO
2.18--2.19 [.0859--.0860]
2.53--2.54 [.0999--.1000]
3.45--3.46 [.1359--.1360]
“C” DIM
4.49 [.185]
5.33 [.210]
6.85 [.270]
{
Die closure dimensions apply when wire barrel crimp dies are bottomed but not under pressure.
}
Material -- Tool Steel
Figure 5
Rev
B
5
of 7
京公网安备 11010802033920号
Copyright © 2005-2026 EEWORLD.com.cn, Inc. All rights reserved
电子工程世界
