408-1632 TEC | Alldatasheet
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Terminal and Splice 408- -1632 LOC B 1 of 11E2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company All Rights Reserved *Trademark TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners. 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 atwww.te.com
19 APR 11 Rev CCrimping Die Assemblies
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. Stationary Die Die Holding Screw Locator Moving Die Color Code Insulation Adjustment Spacers in Position 3 Note: Die Assembly Shown is Typical Color Code CRIMPING DIE ASSEMBLIES 46251- -2 47808- -6 69732 47806- -2 69342 69733 47807- -1 69344 69734 47808- -5 69731 69735 Figure 1 1. INTRODUCTION The die assemblies listed in Figure 1 will crimp terminals and splices for the following product families with wire sizes 26 through 10 AWG: — PIDG* terminals and splices — PIDG insulation restricting nylon terminals — PIDG STRATO- -THERM* terminals with wire sizes 22 through 10 AWG: — PLASTI- -GRIP* terminals — DIAMOND GRIP* terminals and splices These die assemblies are designed to be used with Hand Tool 69710- -1. Refer to Instruction Sheet 408- -2095 for information concerning the tool. Contact TOOLING ASSISTANCE CENTER at the number at the bottom of this page for other recommended tooling. All numerical values in this instruction sheet are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters [and inches]. Figures are not drawn to scale. Reasons for reissue of this instruction sheet are provided in Section 7, REVISION SUMMARY. 2. DESCRIPTION The die assembly consists of a moving die and a stationary die. See Figure 1. The dies and the terminals and splices are color- - coded according to wire size for easy identification. When the terminal and splice are properly crimped in the correct die assembly, 1 dot or 2 dots (depending on wire size) will appear embossed on the top and bottom of the terminal or splice. DIAMOND GRIP terminals and splices do not have a color code or crimp dot code. See Figures 2, 3, and 4. 3. CRIMPING PROCEDURE The dies are coated with oil to prevent rust and corrosion. Wipe this oil from the dies, particularly from the crimping area. 1. Install the die assembly according to the instructions included with the tool. Refer to Paragraph 2.4 for insulation crimp adjustment. 2. Strip the wire to the dimensions provided in Figure 2, 3, 4, or 5; depending on the wire size and product to be crimped. 3. Place the terminal or splice in the stationary die as shown in Figure 6, 7, or 8. Dies will not accommodate terminals with tongue width exceeding 11.91 [.469]. 4. Close the tool handles until the terminal or splice is held firmly in place. 5. For a terminal, insert a stripped wire into the insulation barrel until the wire butts against the locator. For a splice, insert the stripped wire into an insulation barrel until the wire butts against the wire stop in the splice. 6. Complete the crimp by closing the tool handles until the ratchet releases. ORIGINAL INSTRUCTIONS NOTE i NOTE i NOTE i NOTE i
PIDG Terminal andS plice and PLASTI-GRIP Terminal C B “A” Equals Strip Length “B” Equals Wire Barrel “C” Equals Insulation Barrel Finished Crimp Crimp Dot Code A C BA CRIMP WIRE STRIP LENGTH DIE ASSEMBLY WIRE SIZE (AWG) RANGE COLOR CODE CRIMP DOT CODE TERMINAL SPLICERANGE CODE CODE MIN MAX MIN MAX 47806- -2 22- -16 Red 1 47808- -6D 12- -10 Yellow 1 7 95 [ 313] 8 74 [ 344] 47808- -5D 12- -10 Lg Exp or 16- -14 HD Yellow 1 7.95 [.313] 8.74 [.344] — — Figure 2D Use only in Tool 69710- -1 PIDG Insulation Restricting Nylon Terminal C B Finished Crimp Crimp Dot Code
3 Equally Spaced Color Stripes
“A” Equals Strip Length “B” Equals Wire Barrel “C” Equals Insulation Barrel A WIRE COLOR CRIMP TERMINAL WIRE STRIP LENGTH DIE ASSEMBLY SIZE (AWG) INSULATION DIAMETER RANGE COLOR CODE CRIMP DOT CODE TERMINAL INSULATION COLOR STRIPE MIN MAX 69344 Yellow 1 Black [ ] [ ] 47807 1 Blue 2 Blue 47808 6D Yellow 1 Yellow D Use only in Tool 69710- -1 Figure 3
“A”“A” “B” GO Element “B” NO- -GO Element 50.8 [2.00] Min Typ DIE ASSEMBLY DIE CLOSURE DIM. “A”{ (Set Insulation Adjustment Spacers at Position 3) GAGE MEMBER} DIM. “B” DIAMETER DIE ASSEMBLY GO NO- -GO GO NO- -GO Die Closure Configuration “C” “D” GO Element “D” NO- -GO Element “E” 6.35 [.250] Typ DIE ASSEMBLY DIE CLOSURE DIM. “C”{ (See Insulation Adjustment Spacers at Position 1) GAGE MEMBER} DIM. “D” DIAMETER DIM. “E” WIDTH (Max) GO NO- -GO GO NO- -GO WIDTH (Max) H See Paragraph 5.3, Step 5{Die closure dimensions apply when dies are bottomed, but not under pressure.}Material - - tool steel. Figure 10
Inspection of Wire Barrel Section of Crimping Chamber Inspection of Insulation Barrel Section of Crimping Chamber Wire Barrel Crimping Section of Dies Bottomed, but Not Under Pressure Adjustment Spacers in Position 1 Insulation Barrel Crimping Section of Dies Gage Element Wire Barrel Crimping Section of Dies Bottomed, But Not Under Pressure Adjustment Spacers in Position 3 “GO” Gage Must Pass Completely Through Crimping Chamber “NO- -GO Gage May Enter Partially, But Must Not Pass Completely Through Crimping Chamber “GO” Gage Must Pass Completely Through Insulation Barrel Section of Crimping Chamber “NO- -GO Gage May Enter Partially, But Must Not Pass Completely Through Insulation Barrel Section of Crimping Chamber Gage Element If the crimping chamber conforms to the gage inspection, the dies may be considered dimensionally correct and should be lubricated with a THIN coat of any good SAE 20 motor oil. If the crimping chamber DOES NOT conform to the gage inspection, the dies must be returned for further evaluation and repair. 6. REPLACEMENT AND REPAIR Customer- -replaceable parts are listed in Figure 12. A complete inventory should be stocked and controlled to prevent lost time when replacement of parts is necessary. Parts other than those listed should be replaced by TE Connectivity to ensure quality and reliability. Order replacement parts through your 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 For customer repair service, call 1- -800- -526- -5136. 7. REVISION SUMMARY Revisions to this instruction sheet include: S Updated document to corporate requirements S New logo
PART NUMBER FOR DIE ASSEMBLY QTY PERITEM DESCRIPTION 47806- -2 47807- -1 47808- -5 QTY PER DIE ASSEMBLY
1 SCREW, Special 2- -306131- -1 2- -306131- -1 306105- -7 1
3 ANVIL, Insulation 306031- -5 306031- -4 306031- -8 1
4 ANVIL, Wire Barrel 1- -306028- -2 1- -306028- -1 2- -306028- -0 1
5 SPRING 7- -59683- -4 7- -59683- -4 7- -59683- -4 2
6 HOUSING, Locator 2- -305832- -9 2- -305832- -9 2- -305832- -9 1
7 LOCATOR 2- -304052- -8 2- -304052- -9 3- -304052- -0 1
8 RING, Retaining 1- -21046- -3 1- -21046- -3 1- -21046- -3 2
9 SPACER, Lower 2- -305832- -8 2- -305832- -8 2- -305832- -8 1
10 INDENTER, Wire Barrel 1- -306029- -2 1- -306029- -1 2- -306029- -0 1
11 INDENTER, Insulation 306030- -5 306030- -4 306030- -8 1
12 SPACER, Insulation Adjustment 306027- -7 306027- -7 1- -306027- -1 1
13 SPACER, Insulation Adjustment 306027- -6 306027- -6 1- -306027- -4 1
14 SCREW, Special 306131- -9 306131- -9 2- -306131- -5 1
15 PIN, Coiled Spring 21949- -1 21949- -1 21949- -1 2
16 PLATE, Alignment 125152- -2 125152- -2 125152- -8 1
17 SPACER 3- -305832- -1 3- -305832- -1 306192- -4 1
Figure 12 (Cont’d)
ITEM DESCRIPTION PART NUMBER FOR DIE ASSEMBLY 46251- -2 QTY PER DIE ASSEMBLY
1 SCREW, Special 3- -306624- -0 1
2 PLATE, Guide 305549- -1 1
3 ANVIL, Insulation 45933- -8 1
4 ANVIL, Wire Barrel 306244- -6 1
5 SPRING 7- -59683- -4 2
6 HOUSING, Locator 2- -305832- -9 1
7 LOCATOR 6- -304052- -4 1
8 RING, Retaining 1- -21046- -3 2
9 SPACER, Lower 2- -305832- -8 1
10 INDENTER, Wire Barrel 306245- -2 1
11 INDENTER, Insulation 45970- -4 1
12 SPACER, Insulation Adjustment 306027- -7 1
13 SPACER, Insulation Adjustment 306027- -6 1
14 SCREW, Special 306131- -9 1
15 PIN, Coiled Spring 21949- -1 2
Figure 12 (Cont’d)
PART NUMBER FOR DIE ASSEMBLY QTY PERITEM DESCRIPTION 47808- -6 69342 69344 QTY PER DIE ASSEMBLY
1 SCREW, Special 2- -306131- -2 306105- -9 1- -306131- -1 1
3 ANVIL, Insulation 1- -45932- -9 2- -45932- -0 59628- -3 1
4 ANVIL, Wire Barrel 2- -306028- -0 3- -45904- -3 2- -45904- -3 1
7 LOCATOR 3- -304052- -0 3- -304052- -1 2- -304052- -6 1
10 INDENTER, Wire Barrel 2- -306029- -0 1- -45907- -6 1- -306029- -0 1
11 INDENTER, Insulation 306030- -6 306030- -1 306030- -2 1
12 SPACER, Insulation Adjustment 1- -306027- -0 306027- -1 306027- -1 1
13 SPACER, Insulation Adjustment 306027- -9 306027- -2 306027- -2 1
14 SCREW, Special 306105- -7 2- -306131- -1 1- -306131- -1 1
16 PLATE, Alignment 125152- -3 125152- -3 125152- -3 1
Figure 12 (Cont’d)
PART NUMBER DIE ASSEMBLY QTY PER DIEITEM DESCRIPTION 69731 69732 69733 69734 69735 DIE ASSEMBLY
1 SCREW, Special 3- -306131- -3 2- -306131- -1 1- -306131- -6 1- -306131- -6 3- -306131- -4 1
3 ANVIL, Insulation 2- -45932- -8 1- -45932- -6 1- -45932- -7 1- -45932- -8 1- -45932- -9 1
4 ANVIL, Wire Barrel 3- -45904- -1 1- -45904- -8 1- -45904- -9 2- -45904- -0 2- -45904- -1 1
5 SPRING 7- -59683- -4 7- -59683- -4 7- -59683- -4 7- -59683- -4 7- -59683- -4 2
6 HOUSING, Locator 2- -305832- -9 2- -305832- -9 2- -305832- -9 2- -305832- -9 2- -305832- -9 1
7 LOCATOR 59737- -2 59737- -2 59737- -3 59737- -4 59737- -5 1
8 RING, Retaining 1- -21046- -3 1- -21046- -3 1- -21046- -3 1- -21046- -3 1- -21046- -3 2
9 SPACER, Lower 2- -305832- -8 2- -305832- -8 2- -305832- -8 2- -305832- -8 2- -305832- -8 1
10 INDENTER, Wire Barrel 1- -45907- -5 1- -45907- -0 1- -45907- -1 1- -45907- -2 1- -45907- -3 1
11 INDENTER, Insulation 2- -45931- -7 2- -45931- -1 2- -45931- -2 2- -45931- -3 2- -45931- -4 1
12 SPACER, Insulation Adjustment 1- -306027- -6 1- -306027- -6 306027- -7 306027- -7 1- -306027- -0 1
13 SPACER, Insulation Adjustment 1- -306027- -5 1- -306027- -5 306027- -6 306027- -6 306027- -9 1
14 SCREW, Special 1- -306131- -1 1- -306131- -6 1- -306105- -1 1- -306105- -1 2- -306131- -3 1
15 PIN, Coiled Spring 21949- -1 21949- -1 21949- -1 21949- -1 21949- -1 2
F i g u r e1 2( E n d )