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not to be used for splices figure 1 these crimping die assemblies listed in figure 1 crimp terminyl* terminals and splices onto wire sizes 8 through 1/0 awg. refer to figure 1 to ensure compatibility of crimping die, head or tool, and wire size. for detailed information about the head or tool, refer to the instructions packaged with the head or tool. $! $ ! %$ !& % # %# & %$ (% &$%!#) & %$ #%$ &#$ &$%#%! $ # !# %%! ! ) # !% #( %! $ each crimping die consists of a stationary die (nest) and a moving die (anvil). the stationary die features a locator. each die contains a color code dot that matches the color code of the terminal and splice. when mated, the dies form a crimping chamber. .,:7* ! !% !"#% %!! (%!&% % $ ! '! "#$! &#) #$ )#& "#$$&# %! !$ !# ! %#! $! % "!(# & % #! "!(# $&"") !# $% !# #!' $ (& +/0"))"0(,+ 1. depress the upper release button located in the chead and slide the nest into place. 2. release the button and rock the die back and forth until the nest snaps in place. 3. activate the power unit until the lower die release button located in the ram is exposed. 4. depress the release button and slide the indenter into place. 5. release the button and rock the indenter backandforth until the die snaps in place. 6. return the ram to the down position. ! '! %! % $ $&# %% % !' $%%! #) $ # "#!"#) !# % (& &*,1") ensure that the possibility of accidental activation of the hydraulic power unit has been eliminated, and proceed as follows: 1. depress the upper release button located in the chead and slide the nest out of the head.

(#%'#&" #! ))!% $#!) !/ )" 1) &!-+)(%, )+*)+-%)( 2. activate the power unit until the lower die release button in the ram is exposed. 3. depress the release button and slide the indenter out of the ream. figure 2 **!+ %! !&!,! .--)( )&)+ ) ! )- )0!+ %! !&!,! .--)( +%'*%(# ! )/%(# %! --%)(+1 %! (#%'#&" !(%#&$) "
! 1. strip wire to the dimensions listed in figure 3. do not nick or cut the wire strands. 2. select the proper colorcoded terminal for the wire size. the wire size stamped on the terminal tongue and on the crimping die must match the wire size selected. 3. insert stripped wire fully into terminal wire barrel. the end of the conductor must not protrude more than 1.60 mm [.063 in.] beyond the edge of the wire barrel. 4. place the terminal in the stationary die with the edge of the wire barrel resting against the locator and the bottom of the terminal tongue facing the stationary die. see figure 4. 5. holding wire in place, activate tool or power unit to complete crimp. "
" " 6. inspect the crimp according to section 5. %+! -)*
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1. strip wires to the dimensions listed in figure 3. do not nick or cut the wire strands. 2. select the proper colorcoded splice for the wire size. the wire size stamped on the splice and on the crimping die must match the wire size selected. 3. insert the stripped wire into the wire barrel of the end of the splice to be crimped until the wire bottoms against the wire stop within the splice. 4. place the splice in the stationary die. grasp the end of the splice to be crimped and point the opposite end toward the top of the head yoke at approximately a 30 angle. rotate the end of the splice to be crimped into the die. position the edge of the window indent against the locator. refer to figure 5. 5. holding wire in place, activate tool or power unit to complete first wire barrel crimp. 6. when crimp is completed, remove the latch pin, open the yoke and remove the splice.

7. to crimp the other half of splice, reposition uncrimped end of splice in the stationary die and follow the same procedure used to crimp the first half of splice. 8. inspect the crimp according to section 5.
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1. strip wires to the dimensions listed in figure 3. do not nick or cut the wire strands. 2. select the proper splice, adapter, and crimping die for the wire size. see figure 6. note that the end of the splice containing the adapter has a different color code. use the crimping die for the larger wire size to crimp both ends of the splice. for example, use crimping die 14905981 (for wire size 6 awg) to crimp both ends of the splice with stepdown adapter for stepping down from wire size 6 to 8 awg.

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figure 6 3. insert stripped wire into the wire barrel of the end of the splice to be crimped until the wire bottoms against the wire stop within the splice. refer to figure 3. 4. remove crimping head latch pin, and open yoke. 5. place the splice in the stationary die. grasp the end of the splice to be crimped and point the opposite end toward the top of the head yoke at approximately a 30 angle. rotate the end of the splice to be crimped into the die. position the edge of the window indent against the locator. refer to figure 5. 6. holding the splice in place, close the yoke and insert the latch pin. " ! ! 7. holding the wire in place, activate tool or power unit to complete first wire barrel crimp. 8. when crimp is completed, remove the latch pin, open the yoke and remove splice. "
" " 9. to crimp the other half of splice, reposition uncrimped end of splice in the stationary die and follow the same procedure used to crimp the first half of splice. 10. inspect the crimp according to section 5. inspect crimped terminals and splices by checking the features described in figure 7. use only the terminals and splices that meet the conditions shown in the aaccepto column. "
" ! ! " each crimping die is thoroughly inspected before packaging. since there is a possibility of damage during shipment, the crimping die should be inspected immediately upon arrival at your facility. 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. !&'0 !&).$)!)#$ it is recommended that each operator of the dies be made aware ofeand responsible forethe following steps of daily maintenance: 1. remove dust, dirt, and other contaminants with a clean brush, or a soft, lintfree cloth. do not use objects that could damage the dies. 2. make certain the dies are protected with a thin coat of any good sae 20 motor oil. do not oil excessively. 3. when the dies are not in use, mate them and store in a clean, dry area. &-/!' )-+$#.&*) 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 components are in place. if replacements are necessary, refer to the replacement parts listed in figure 10. 3. check components for wear. remove and replace worn components.

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( )! 0$+ )(.-)+ ()- !&.,# 0$-# )+ 1- ($(" ,&$"#-&2 2)( ( )! - +'$(& 0$+ ++ & $+ ()- $(, +- !.&&2 )+ 0+)(" ,-+$* & ("-# ., +$'* ()- (- + )( - +'$(& 0$+ ++ & +'$(& 0$+ ++ & 0, ()- .-- "$(,- &)-)+ 0# ( +$'* $+ ,$3 ()- -# ,' , 0$+ ,$3 ,-'* )( - +'$(& -)(". ,*&$ )2 ( 0$+ ++ & +)(" )&)+ ) 0$+ ,$3 ( -))&$(" )'$(-$)( ., ( )! 0$+ )(.-)+ ()- /$,$& )(.-)+ $ ()- .-- "$(,- 0$+ ,-)* )+ 0, ()- !&.,# 0$-# )+ 1- ( ,&$"#-&2 2)( ,*&$ 0$+ ++ & +$'* ()- (- + )( ,*&$ 0$+ ++ & " )! 0$()0 $( (- $ ()- .-- "$(,- &)-)+ 0# ( +$'* $% )+ '$,,$(" 0$+ ,-+(, *&$ 0, + / +, $( $ &)-)+ 0, ()- )+$ (- 0$-# 0$()0 $( (- 0# ( +$'* 1 ,,$/ 4!&,# )+ 1-+. 0$+ $(,.&-$)( $ 0, $-# + '" )+ $()'*-$& 0# ( +$'* 4. inspect the crimp area for flattened, chipped, cracked, worn, or broken areas. if damage is evident, the dies must be repaired before returning them to service (see section 7, replacement and repair). the die closure inspection is accomplished using plug gages. a suggested gage design and the go and nogo diameters of the plug gage elements are shown in figure 8. the following procedure is recommended for inspecting the die closures.

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figure 8 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 crimping chamber. push element straight into the crimping chamber without using force. the go element must pass completely through the crimping chamber as shown in figure 9. 3. align the nogo element and try to insert it straight into the crimping chamber. the nogo element may start entry but must not pass completely through as shown in figure 9. if the crimping chamber conforms to the gage inspection, the crimping die is considered dimensionally correct and should be lubricated with a thin coat of sae 20 motor oil. if not, the dies must be repaired before returning them to service (see section 7, replacement and repair). for additional information concerning the use of a plug gage, refer to instruction sheet 4087424. figure 9 *$&)$'" #& * % & ', % & ', % & ', &-+, )++ (&)% , %/ ,#*(-"# ,# *$&)$'" #& * % & ', &/ ', * )*,$%%/ -, &-+, '(, )++ (&)% , %/ ,#*(-"# ,# *$&)$'" #& * %-" " *$&)$'" #& *
the parts listed in figure 10 are customer replaceable. a complete inventory can be stocked and controlled to prevent lost time when replacement of parts is necessary. order replacement parts through your tyco electronics representative, or call 18005265142, or send a facsimile of your purchase order to 17179867605, or write to: customer service (3835) tyco electronics corporation p.o. box 3608 harrisburg, pa 171053608 dies may be returned for evaluation and repair. for die repair service, contact a representative at 18005265136. updated document to corporate requirements added new part number to table in figure 1
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