Tyco Electronics 408-10050 User manual

©2010 Tyco Electronics Corporation, Berwyn, PA
All Rights Reserved
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Instruction Sheet
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.tycoelectronics.com
1of 6
LOC B
Crimping Dies for SOLISTRAND*
Terminals and Splices 408-10050
28 DEC 10 Rev C
PROPER USE GUIDELINES
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.
Figure 1
1. INTRODUCTION
This instruction sheet provides instruction on
application and maintenance and inspection
procedures for dies that crimp SOLISTRAND ring
tongue terminals, butt splices, and parallel splices.
These dies are used to crimp product on solid or
stranded copper wires. The dies are used in Battery
Operated Hand Tool 1901343-1, -2, -3, and -4
(Customer Manual 409-10070). Read these
instructions, and all applicable references, before
inserting any die assemblies and crimping any
terminals. See Figure 2.
Dimensions on this document are in metric units
with [U.S. customary units in brackets}. Figures and
illustrations are for reference only and are not
drawn to scale.
2. DESCRIPTION (Figure 1)
Each die assembly consists of a nest and an indenter,
ordered separately, which are retained in the crimping
head by set screws. The nest is positioned in the yoke
of the crimping head and the indenter is positioned in
the ram of the tool, in all applications.
3. DIE INSTALLATION AND REMOVAL
Refer to Figure 2 and determine the correct die
assembly and wire size for the terminal splice part
number.
AVOID PERSONAL INJURY. Exercise extreme
caution when using the tool.
3.1. Die Installation
1. Pivot the latch arm away from the yoke to open
the crimp head.
2. Loosen the set screw in the yoke.
3. Insert the shank of the nest into the yoke and
tighten the set screw.
4. Extend the ram until the set screw is visible.
5. Loosen the set screw in the ram.
6. Insert the shank of the indenter into the ram and
tighten the set screw.
7. Return the ram to the down position.
8. Pivot the latch arm and yoke toward each other
until the locking flange secures the latch arm to the
yoke.
Nest
Indenter
Yoke
Yoke Screw
Nest
Shank
Push Nest
Into Yoke
Push Indenter
Into am
Adapter
Latch
Arm
Locking
Flange
Nest Indenter
Indenter
Shank
NOTE
i
DANGER
STOP

408-10050
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Rev C
Figure 2
Always make sure the yoke and latching arm are
secured by the locking flange before cycling the
tool.
3.2. Die Removal
1. Pivot the latch arm away from the yoke to open
the head.
2. Loosen the set screw in the yoke and remove the
nest.
3. Raise the ram to full up position.
4. Loosen the set screw in the ram and remove the
indenter.
Figure 3.
NOMINAL WIRE SIZE mm2(CIRCULAR MIL AREA
RANGE)
TYPICAL
PRODUCT
DIES
mm2AWG NEST INDENTER
7 - 8 8 6.637-10.539
[13,100-20,800]
33463
RTT•• 1901001-1• 1901002-2•
13 - 15 6 10.539-16.771
[20,800-33,100]
33466
RTT•• 1901000-1• 1901002-1•
21 4 16.771-26.653
[33,100-52,600]
34323
BS••• 1901000-2• 1901002-1•
34 - 35 2 26.653-42.411
[52,600-83,700]
35187
PS•••• 1901000-3• 1901002-1•
• Also used for STRAO-THERM* Heat Resistant Uninsulated Terminals. •• RTT = Ring Tongue Terminals ••• BS = Butt Splice
•••• PS = Parallel Splice.
CAUTION
!
NOMINAL WIRE
SIZE
mm2 (CIRCULAR
MILL AREA)
STRIP LENGTHS
mm [In.]
mm2AWG
RING TONGUE
TERMINALS BUTT SPLICES PARALLEL SPLICES
MIN. MAX. MIN. MAX. MIN. MAX.
7 - 8 8 6.637-10.539
[13,100-20,800]
8.334
[.328]
9.128
[.359]
10.319
[.406]
11.112
[.437]
10.319
[.406]
11.112
[.437]
13 - 15 6 10.539-16.771
[20,800-33,100]
9.922
[.391]
13.225
[.522]
11.906
[469]
12.700
[.500]
11.112
[.437]
11.905
[.469]
21 4 16.771-26.653
[33,100-52,600]
11.509
[.453]
12.302
[.484]
13.493
[.531]
14.288
[.563]
13.493
[.531]
14.288
[.563]
34 - 35 2 26.653-42.411
[52,600-83,700]
13.06
[.516]
13.890
[.547]
15.081
[.594]
15.875
[.625]
15.081
[.594]
15.875
[.625]

408-10050
3of 6
Rev C
4. WIRE STRIPPING AND CRIMPING PROCEDURE
4.1. Wire Stripping
Strip the wire to the dimensions listed in Figure 3. Do
NOT nick or cut the wire strands.
AVOID PERSONAL INJURY. When operating the
tool, exercise caution while holding the terminals,
splices, or wire near the crimping area.
4.2. Crimping Procedure
1. Ensure the wire range or size stamped on the
terminal or splice corresponds with the size being
used with the wire size or range stamped on the
nest and indenter.
2. Pivot the latch arm away from the yoke to open
the head.
3. 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.
4. Holding the terminal or splice in place, pivot the
latch arm and yoke toward each other until the
locking flange secures the latch arm to the yoke.
Always make sure the yoke and latching arm are
secured by the locking flange before cycling the
tool.
5. Activate the tool so that ram advances and holds
terminal or splice in place. Do NOT deform terminal
or splice wire barrel.
6. IInsert stripped wire into terminal or parallel
splice until end of conductor is flush with or
extended slightly beyond end of wire barrel.
7. Insert stripped wire into butt splice until end of
conductor butts against splice wire stop.
8. Activate the tool to complete the crimp.
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 the terminal or
splice.
9. Pivot the latch arm away from the yoke to open
the head.
10. Remove the crimped terminal or splice from the
tool.
11. For butt splice, repeat steps 2 through 10 for
other wire barrel.
12. Refer to Paragraph 5.1, Crimp Inspection, for
standard terminal, butt and parallel splice crimp
inspection procedure.
5. INSPECTION/MAINTENANCE
Remove battery from tool before performing
maintenance, adjustments, inspections, and
repairs.
Figure 4
DANGER
STOP
CAUTION
!
NOTE
i
DANGER
STOP
Terminal
Butt
Splice
Parallel
Splice
Inspection Holes of
Terminal or Butt Splice
Must Face Either Die
End of Wire Visible
Through Inspection Hole
Ends of Wires Flush with or
Extended Beyond the End
of the Barrel
Center Terminal or Splice
Wire Barrel in the Nest

408-10050
4of 6
Rev C
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)
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.
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.
Figure 5
NOTE
i

408-10050
5of 6
Rev C
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.
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:
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.
Figure 6
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.
B. Gaging the Crimping Chamber (Figure 7 and Figure 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
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. 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.
6. REPLACEMENT PARTS
Order replacement dies through your Tyco Electronics
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
7. REVISION SUMMARY
Revisions to this instruction sheet include:
•Logo update
•Updated format to current corporate requirements.
Pitted
Broken
Chipped
‡ Trademark of Society of Automotive Engineers

408-10050
6of 6
Rev C
Figure 7
Figure 8
Dies Bottomed but
Not Under Presssure
“GO” Element Must Pass
Completely Through the
Die Closure
“NO-GO” Element May
Enter Partially, But Must
NOT Pass Completely
Through the Die Closure
DIES DIE CLOSURE DIM. “A” GAGE ELEMENT DIM. “B” DIM.
“C”
RADIUS
“R”
NEST INDENTER GO NO-GO GO NO-GO
1901001-1 1901002-2 2.54
[.1000]
2.692
[.1060]
2.54 - 2.692
[.1000 - .1003]
2.689 - 2.692
[.1059 - .1060]
2.92
[.312]
3.18
[.1225]
1901000-1 1901002-1 3.911
[.1540]
4.1115
[.1620]
3.911 - 3.919
[.1540 - .1543]
4.112 - 4.115
[.1619 - .1620]
11.09
[.437]
4.34
[.171]
1901000-2 1901002-1 4.699
[.1850]
4.902
[.1930]
4.699 - 4.706
[.1850 - .1853]
4.899 - 4.902
[.1929 - .1930]
11.09
[.437] 5.54
1901000-3 1901002-1 5.410
[.2130]
5.613
[.2210]
5.410 - 5.418
[.2130 - .2133]
5.610 -5.613
[.2209 - .2210]
11.09
[.437]
6.35
[.250]