instructions, maintenance, and inspection procedures
for the crimping dies listed in Figure 1. These dies are
used to crimp heavy--duty seamless straight ring
tongue terminals and butt splices onto solid or
stranded copper wire also listed in Figure 1.
Refer to Catalog 1308674 for information and part
numbers for the terminals and splices.
The dies are designed to be installed in a hydraulic
crimping head or hydraulic hand crimping tool.
Available heads and tools are listed in Figure 1.
NOTE
Dimensions on this instruction sheet are in
millimeters [with inches in brackets]. Figures and
illustrations are for identification only and are not
drawn to scale.
Reasons for reissue of this instruction sheet are
provided in Section 7, REVISION SUMMARY.
2. DESCRIPTION
Each die consists of a nest and an indenter (available
separately) which are retained in the crimping head or
crimping tool by retainer pins. The nest is positioned
in the yoke and the indenter is positioned in the ram.
3. DIE INSTALLATION AND REMOVAL
Refer to Figure 1 and determine the correct dies, wire
size, crimping head, and hydraulic hand tool to use.
CAUTION
Never operate the head or tool with the dies
removed.
i
!
E2011
Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
*Trademark
TOOLING ASSISTANCE CENTER 1--800--722--1111
PRODUCT INFORMATION 1--800--522--6752
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
www.te.com
1
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LOC B
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners.
ORIGINAL INSTRUCTIONS
Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools. Hand tools are intended for occasional use and low volume
applications. A wide selection of powered application equipment for extended-- use, production operations is available.
408- 10110
Hydraulic Crimping Head
Upper Die
Release Button
Yoke
Nest
“C” Head
Nest
Indenter
Indenter
“C” Head
Moving Die
Release Button
Hydraulic Hand Crimping Tool
Yoke
Stationary Die
Release Button
Ram
(Advanced)
Lower Die
Release Button
Ram
(Advanced)
Figure 2
DANGER
To avoid personal injury, make sure to exercise
extreme caution when using the head or tool.
Avoid depressing the footswitch or trigger control
when installing or removing the dies.
3. Depress the button, and slide the indenter out of
the ram.
4. CRIMPING PROCEDURE
1. Ensure that the wire range or size stamped on
the terminal or splice corresponds with the wire
size being used and the wire range or size marked
on the nest and indenter.
2. Strip the wire to the dimension given in Figure 3.
DO NOT nick or cut the wire strands.
3.1. Die Installation
1. Depress the upper die release button (head) or
stationary die release button (tool) located on the
“C”--head. See Figure 2.
2. Slide the nest into place in the “C”--head. See
Figure 2.
3. Release the button, and rock the nest back and
forth until the nest snaps into position.
4. Activate the head or tool according to the
instructions included with the head or tool until the
lower die release button (head) or moving die
release button (tool) located in the ram is exposed.
Depress the button.
5. Slide the indenter into position in the ram. See
Figure 2.
6. Release the button, and rock the indenter back
and forth until the indenter snaps into position.
7. Return ram to the down position.
Note:
Not to Scale
Strip Length
(Refer to Table)
Insulation
Conductors
NOMINAL WIRE SIZE (AWG)
8
6
4
2
1
1/0
2/0
3/0
4/0
Figure 3
STRIP LENGTH
11.43 [.450]
12.06 [.475]
13.34 [.525]
14.60 [.575]
15.87 [.625]
17.46 [.688]
17 46 [ 688]
19.05 [.750]
20.64 [.812]
3.2. Die Removal
1. Depress the upper die release button (head) or
stationary die release button (tool) located on the
“C”--head, and slide the nest out. See Figure 2.
2. Activate the head or tool according to the
instructions included with the head or tool until the
lower die release button (head) or stationary die
release button (tool) located in the ram is exposed.
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Rev D
408- 10110
3. Insert the stripped wire into the wire barrel of the
terminal or splice making sure that the end of the
wire is visible through the sight hole.
4. Center the terminal or splice in the nest as
shown in Figure 4.
DANGER
To avoid personal injury, make sure to exercise
caution when holding terminals, splices, or wire
near the crimping area.
8. For splices, insert a stripped wire into the
uncrimped wire barrel until the end of the
conductor is visible in the sight hole.
9. Inspect the crimp according to Figure 5. This is
included as an aid to the tool operator ONLY. It is
not intended to serve as a quality control
inspection for qualifying finished crimps on these
terminals and splices. Use only terminals or splices
that meet the conditions shown in the ACCEPT
column. Terminals and splices displaying the
features shown in the REJECT column can be
avoided by careful use of these instructions and by
performing the maintenance and inspection
procedures described in Section 5.
CAUTION
Damaged terminals or splices should not be
used. If a damage is evident, the terminal or
splice should be cut from the wire and replaced
with a new one. DO NOT re--terminate terminals
or splices.
Terminal or Splice
Centered in Nest
(See Detail)
!
5. MAINTENANCE AND INSPECTION
DANGER
To avoid personal injury, DISCONNECT THE
POWER SUPPLY before performing
maintenance, adjustments, inspection, or repair.
Detail
Terminal
Nest
Sight Hole
Facing Nest
Nest
Splice
Sight Hole
Facing Nest
5.1. Daily Maintenance
It is recommended that each operator of the dies be
made aware of, and responsible for, the following
steps of daily maintenance:
1. Remove dust, moisture, and other contaminants
from the dies with a clean brush, or a clean, soft,
lint--free cloth. DO NOT use objects that could
damage the dies.
2. If dies are coated with oil or preservative, wipe
them clean—particularly in the crimping
areas—before placing them in use.
3. When dies are not in use, make certain all
surfaces are protected with a THIN coat of any
good SAE 20 motor oil, then mate and store them
in a clean, dry area.
Indenter
Wire Visible
Through
Sight Hole
Indenter
Wire Visible
Through
Sight Hole
Figure 4
5. Activate the head or tool according to the
instructions included with the head or tool so that
ram advances and holds the terminal or splice in
place. DO NOT deform the wire barrel.
6. For terminals, insert the stripped wire into the
wire barrel until the end of the conductor is visible
in the sight hole. For butt splices, insert a stripped
wire into the wire barrel until the end of the
conductor is visible in the sight hole.
7. Activate the head or tool to crimp the wire
barrel.
NOTE
If the terminal or splice sticks in the die after
crimping, grasp the wire close to the crimp and
apply a rocking motion to remove it from the die.
5.2. Periodic Inspection
Periodic inspections should be performed by quality
control personnel. A record of scheduled inspections
should remain with the dies or be made available to
personnel responsible for the dies. Though
recommendations call for at least a monthly
inspection, the inspection frequency should be based
upon the amount of use, working conditions, operator
training and skill, and established company
standards. These inspections should be performed in
the following sequence.
A. Visual Inspection
1. Remove all lubrication and accumulated film by
immersing the dies in a suitable degreaser that will
not affect paint or plastic.
i
Rev D
3
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408- 10110
ACCEPT
Terminal
3
4
2
REJECT
1
4
2
1
6
1
3
4
3
2
1
2
3
4
Crimp is centered on wire barrel. Crimp may be off
center but not off end of wire barrel.
Wire size being used matches the wire range or size
stamped on terminal or splice and dies.
Wire insulation does not enter wire barrel.
End of wire is visible through sight hole of terminal or
splice.
Splice
4
1
3
5
2
1
2
3
4
5
Crimp is off end of wire barrel.
Wire size being used does not match the wire range
or size stamped on terminal or splice and dies.
Wire insulation enters wire barrel. Check that the
strip length is correct.
End of wire is not visible through sight hole of terminal
or splice. Wire was not inserted far enough.
Excessive “flash” on terminal or splice. This indicates
damaged dies or wrong wire size, splice, or tooling com-
bination was used.
Nicked or missing strands.
5
Figure 5
2. Check all surfaces for wear. Inspect the crimp
area for flattened, chipped, cracked, worn, or
broken areas. If damage is evident, the die must
be replaced. Refer to Figure 6.
Flattened
Pitted
Chipped
B. Gaging the Crimping Chamber
This inspection requires the use of a plug gage
conforming to the dimensions in Figure 7. Refer to
Figure 7, and gage the crimping chamber as follows:
1. Mate the dies until it is evident that they have
bottomed. Hold the dies in this position.
2. Align the GO element with the wire barrel
crimping chamber. Push the element straight into
the the crimping chamber without using force. The
GO element must pass completely through the
crimping chamber.
3. Align the NO--GO element and try to insert it
straight into the same crimping chamber. The
NO--GO element may start entry but must not pass
completely through.
Broken
Figure 6
4
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Rev D
408- 10110
If the crimping chamber conforms to the gage
inspection, the dies are considered dimensionally
correct. If not, the dies must be replaced. For
additional information regarding the use of a plug
gage, refer to Instruction Sheet 408--7424.
CUSTOMER SERVICE (038--035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105--3608
6. REPLACEMENT
Order replacement dies through your representative,
or call 1--800--526--5142, or send a facsimile of your
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