408-8704

Crimping Die Assemblies

Rev A

2 of 7

Tyco Electronics Corporation

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

Upper Die

Release

Button

Color

Code

Dot

Lower Die

Release

Button

Crimping

Head

Moving Die

Stationary

Die

4. CRIMPING PROCEDURE

4.1. Crimping Terminals

Avoid personal injury. When operating tool or

power unit, exercise caution while holding

terminals or wire near the crimping area.

1. Strip wire to the dimensions listed in Figure 3.

Do not nick or cut the wire strands.

2. Select the proper color–coded 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.

Do NOT turn or twist the wire or terminal during

insertion.

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.

If terminal sticks in die after crimping, apply a

rocking action to the terminal to remove it from

the die. Wipe light oil on the dies to prevent

sticking, or use spray dry lubricant.

6. Inspect the crimp according to Section 5.

Typical Splice

Wire Stop

Typical Terminal

Window Indent

Wire Strip

Length

Wire Strip

Length

WIRE

WIRE STRIP LENGTH

WIRE

SIZE

(AWG)

TERMINYL TERMINAL AND SPLICE

(AWG)

TERMINAL

SPLICE

8

7.96-9.53 [.313-.375]

15.48-17.07 [.609-.672]

6

11.18-12.70 [.440-.500]

19.45-20.24 [.766-.797]

4

11.18-12.70 [.440-.500]

19.45-21.03 [.766-.828]

2

11.43-13.08 [.450-.515]

21.83-30.18 [.859-1.188]

1/0

18.54-20.24 [.730-.797]

28.58-30.18 [1.125-1.188]

2/0

18.54-20.24 [.730-.797]

28.58-30.18 [1.125-1.188]

3/0

19.05-20.64 [.750-.813]

28.58-30.18 [1.125-1.188]

4/0

19.45-21.03 [.766-.828]

28.58-30.18 [1.125-1.188]

Figure 3

DANGER

CAUTION

!

NOTE

i