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LOC B
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408-9786
NOMINAL WIRE SIZE
mm²
7-8
13-15
21
34-35
59-60
67-70
80-95
100-125
AWG
8
6
4
2
1/0
2/0
3/0
4/0
mm² [CIRCULAR
MILL AREA RANGE)
6.637-10.539
[13,100-20,800]
10.539-16.771
[20,800-33,100]
16.771-26.653
[33,100-52,600]
26.653-42.411
[52,600-83,700]
42.411-60.551
[83,700-119,500]
72.259-96.274
[150,500-190,000]
96.274-117.049
[190,000-231,000]
96.274-117.049
[190,000-231,000]
BS† + Butt Splice
TYPICAL
PRODUCT
33463
RTT♦
33466
RTT♦
34323
BS†
35187
PS▲
36946
PS▲
36948
PS▲
36927
RTT♦
36932
RTT♦
DIES
NEST
48126■
48128-1•
48128■
48129-1•
48129■
48130-1•
48130■
48132-1•
48132■
48133-1•
48133
48134
300430
PS▲ = Parallel Splice
• = Dies for Heavy Duty Terminals
INDENTER
48355■
48127-1•
48127■
48127-1•
48127■
48127-1•
48127■
48131-1•
48131■
48131-1•
TOOL OR
HEAD NUMBER
Head Number 69065
(408-2452)
69067 (408-2454)
Hand Tool 59973-1 (408-
6803)
48131
RTT♦ = Ring Tongue Terminals
■
= also Dies for STRATO-THERM* Heat Resistant Terminals
Figure 2
CAUTION
Ensure the latch pin is fully inserted or damage
may occur to the yoke, dies, or latch pin.
!
used with the wire size or range stamped on the
nest and indenter.
2. Center terminal or splice in nest as shown in
Figure 4. For best results, when brazed seam on
terminal or splice is visible, position seam toward
indenter.
3. Activate power unit so that ram advances and
holds terminal or splice in place. Do NOT deform
terminal or splice wire barrel.
4. Insert stripped wire into terminal or parallel splice
until end of conductor is flush with or extended
slightly beyond end of wire barrel.
5. Insert stripped wire into butt splice until end of
conductor butts against splice wire stop.
6. Activate power unit to complete the crimp.
NOTE
If the terminal sticks in the die after crimping, grasp
the wire close to the crimp and apply a rocking
motion to remove the die.
3.2. Die Removal
1. Remove latch pin and open yoke.
2. Insert blade of screwdriver under nest and pry
nest out of yoke.
3. Raise ram to full up position.
4. Insert blade of screwdriver under nest and pry
indenter out of ram.
4. WIRE STRIPPING AND CRIMPING PROCEDURE
4.1. Wire Stripping
Strip wire to dimensions listed in Figure 3. Do NOT
nick or cut wire strands.
DANGER
AVOID PERSONAL INJURY. When operating
power unit, exercise caution while holding
STOP
terminals, splices, or wire near crimping area.
i
7. For butt splice, repeat steps 5 and 6 for other wire
barrel.
4.2. Crimping Procedure
1. Ensure the wire range or size stamped on the
terminal or splice corresponds with the size being
8. Refer to Paragraph 5.1, Crimp Inspection, for
standard terminal, butt and parallel splice crimp
inspection procedure.
Rev
D
2
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408-9786
NOMINAL WIRE
SIZE
mm²
7-8
13-15
21
34-35
59-60
67-70
80-95
100-125
AWG
8
6
4
2
1/0
2/0
3/0
4/0
mm²
[CIRCULAR MILL
AREA)
6.637-10.539
[13,100-20,800]
10.539-16.771
[20,800-33,100]
16.771-26.653
[33,100-52,600]
26.653-42.411
[52,600-83,700]
42.411-60.551
[83,700-119,500]
60.551-72.259
[119,500-150,500]
72.259-96.274
[150,500-190,000]
96.274-117.049
[190,000-231,000]
STRIP LENGTHS mm [in.]
RING TONGUE TERMINALS
MIN.
8.334 [.328]
9.922 [.391]
11.509 [.453]
13.096 [.516]
18.653 [.734]
18.653 [.734]
19.050 [.750]
19.446 [.766]
MAX.
9.128 [.359]
13.255 [.522]
12.302 [.484]
13.890 [.547]
20.240 [.797]
20.240 [.797]
20.637 [.812]
20.637 [.812]
BUTT SPLICES
MIN.
10.319 [.406]
11.906 [.469]
13.493 [.531]
15.081 [.594]
15.875 [.625]
15.875 [.625]
17.463 [.688]
17.463 [.688]
MAX.
11.112 [.437]
12.700 [.500]
14.288 [.563]
15.875 [.625]
17.462 [.687]
17.462 [.687]
19.050 [.750]
10.050 [.750]
PARALLEL SPLICES
MIN
10.319 [.406]
11.112 [.437]
13.493 [.531]
15.081 [.594]
17.462 [.687]
17.462 [.687]
17.463 [.688]
10.050 [.750]
MAX.
11.112 [.437]
11.906 [.469]
14.288 [.563]
15.875 [.625]
19.050 [.750]
19.050 [.750]
19.050 [.750]
20.637 [.812]
Figure 3
Inspection Holes of
Terminal or Butt
Splice Must Face
Either Die
End of Wire Visible
Through Inspection
Hole
Center Terminal or
Splice Wire Barrel
in Next
Ends of Wires Flush
with or
Extended Beyond
End of Barrel
Brazed Seam (Typ)
Figure 4
Rev
D
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408-9786
5. INSPECTION/MAINTENANCE
DANGER
Disconnect power supply before performing
maintenance, adjustments, inspections, and
STOP
repairs.
These instructions have been approved by Design,
Production, and Quality Control Engineers to provide
documented maintenance and inspection procedures.
Through Tyco Electronics Test Laboratories and the
inspection of production assembly, the procedures
described herein have been established to ensure
quality and reliability of the crimping die assemblies.
Customer-replaceable parts are listed in Figure 2. A
complete inventory should be stocked and controlled
to prevent lost time when replacement of parts is
necessary.
5.1. Crimp Inspection
(Figure 5)
NOTE
i
The accompanying procedure is included as an aid
to the tool operator ONLY. It is not intended to serve
as a quality control procedure for qualifying finished
crimps on SOLISTRAND Terminals or Splices.
Figure 5
Rev
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408-9786
Inspect crimped terminals or splices by checking the
features described in Figure 5. 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
Paragraphs in 5.2 and 5.3.
Pitted
Broken
5.2. 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
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 No. 20 motor oil, and mate and store them in a
clean, dry area.
Figure 6
Chipped
5.3. Periodic Inspection
Regular inspections should be performed by quality
control personnel. A record of scheduled inspections
should remain with the dies or be made available to
supervisory 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:
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. If the crimping chamber
conforms to the gage inspection, the dies are
considered dimensionally correct. If not, they must
be replaced. For additional information regarding
the use of a plug gage, refer to Instruction Sheet
408-7424.
A. Visual Inspection
(Figure 6)
1. Remove all lubrication and accumulated film by
immersing the dies in a suitable degreaser that will
not affect paint or plastic.
1. 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.
6. REPLACEMENT PARTS
Order replacement dies through your TE
Representative, or call 1-800-526-5142, or send a
facsimile of your purchase order to 717-986-7605, or
write to:
CUSTOMER SERVICE (038-035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
B. Gaging the Crimping Chamber
(Figures 7 and 8)
The inspection requires the use of a plug gage
conforming to the dimensions in Figure 8. Tyco
Electronics does not manufacture or market these
gages.
Proceed as follows:
1. Mate the dies until it is evident that they have
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