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1-307275-7 [TE]

Application and Maintenance for Crimping Die Assemblies for Tape-Mounted PIDG and PLASTI-GRIP Terminals and Splices;
1-307275-7
型号： 1-307275-7
厂家： TE CONNECTIVITY    TE CONNECTIVITY
描述：

Application and Maintenance for Crimping Die Assemblies for Tape-Mounted PIDG and PLASTI-GRIP Terminals and Splices
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Instruction Sheet  
Application and Maintenance for Crimping  
Die Assemblies for Tape-Mounted PIDG*  
and PLASTI-GRIP* Terminals and Splices  
408-2423  
08 APR 14 Rev B  
Die Holding  
Screw  
Moving Die  
Wire Barrel  
Crimper  
Saddle Screw  
Saddle  
Insulation  
Anvil  
Color Code  
Dot  
Color Code  
Dot  
Insulation  
Crimper  
Wire Barrel  
Anvil  
Die Holding  
Screw  
Stationary Die  
Figure 1  
1. INTRODUCTION  
The crimping dies listed on this instruction sheet are recommended for crimping the PIDG and PLASTI-GRIP  
tape-mounted terminals and splices indicated in Figure 2. The PIDG terminals and splices are used on  
stranded copper wire, and the PLASTI-GRIP terminals and splices are used with solid or stranded copper wire.  
The dies are designed to be used in AMP-TAPETRONIC* Machine 69875. Refer to Customer Manual  
409-1993, packaged with the machine, for information concerning die installation, crimp adjustments, crimping  
procedures, and general operation of the machine.  
This instruction sheet covers die selection, crimping instructions, and die maintenance and inspection  
procedures. Read these instructions thoroughly before crimping any terminals or splices.  
NOTE  
Measurements are in millimeters [followed by inch equivalents in brackets]. Figures and illustrations are for identification only  
and are not drawn to scale.  
Reasons for reissue are provided in Section 7, REVISION SUMMARY.  
2. DESCRIPTION (Figure 1)  
Each die assembly features two stationary dies (anvils) and two moving dies (crimpers), a saddle, and  
attaching hardware. One pair of dies (one anvil and one crimper) forms a crimping chamber for the terminal or  
splice wire barrel, and the other pair of dies crimps the insulation barrel.  
Each half of the die assembly is secured in the machine by a captive screw. The dies are color coded  
according to wire size for easy identification. When the terminal or splice is properly crimped in the correct dies,  
one or two dots (depending on wire size) will appear on the top and bottom of the terminal or splice.  
This controlled document is subject to change.  
For latest revision and Regional Customer Service,  
visit our website at www.te.com.  
© 2014 TE Connectivity family of companies  
All Rights Reserved  
*Trademark  
TOOLING ASSISTANCE CENTER 1-800-722-1111  
PRODUCT INFORMATION 1-800-522-6752  
1 of 7  
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners.  
408-2423  
PLASTI-GRIP  
Butt Splice  
PIDG  
Butt Splice  
PLASTI-GRIP  
Terminal  
PIDG  
Terminal  
PIDG FASTON  
Receptacle  
Color Stripe  
on Radiation  
Resistant  
Color Stripe on 16-14  
HD and Radiation  
Resistant  
Color Stripe  
on 16-14 HD  
Crimp Dot Code  
Crimp Dot Code  
Wire Strip Length, mm [in.]  
Wire Size  
Range  
(AWG)  
Dot Code  
(Number  
of Dots)  
Insulation  
Color Code  
Die Assembly  
Part Number  
Product  
Terminal  
Splice  
Min  
4.37  
Min  
Max  
Max  
3.97  
4.76  
5.16  
26-22  
26-24  
24-20  
Yellow  
Yellow  
White  
Red  
1
1
2
1
2
1
1
1
1
1
69877  
69872, 68208-1 Lg Exp  
69878  
[5/32]  
[3/16]  
[11/64] [13/64]  
5.16  
5.95  
6.35  
[1/4]  
7.14  
[9/32]  
[13/64] [15/64]  
4.76  
[3/16]  
5.56  
[7/32]  
5.56  
[7/32]  
6.35  
[1/4]  
5.16  
5.95  
6.35  
[1/4]  
7.14  
[9/32]  
22-16  
16-14  
69872, 68208-1 Lg Exp  
69873, 68207-1 Lg Exp  
69874  
[13/64] [15/64]  
5.16 5.95  
20-16 HD [13/64] [15/64]  
6.35  
[1/4]  
9.53  
[3/8]  
PIDG and PLASTI-GRIP  
Terminals and Splices  
(Except 12-10 PIDG  
Window Splice  
Blue  
7.94  
[5/16]  
8.73  
[11/32]  
8.73  
[11/32]  
9.53  
[3/8]  
12-10  
16-14 HD  
12-10  
Yellow  
7.94  
[5/16]  
8.73  
[11/32]  
8.73  
[11/32]  
9.53  
[3/8]  
Yellow with  
Black Stripe  
69874  
7.94  
[5/16]  
8.73  
[11/32]  
8.73  
[11/32]  
9.53  
[3/8]  
Yellow  
69897 Lg Exp  
69897 Lg Exp  
68116-1₸  
7.94  
[5/16]  
8.73  
[11/32]  
8.73  
[11/32]  
9.53  
[3/8]  
Yellow with  
Black Stripe  
16-14 HD  
8
8.33  
9.13  
9.13  
[23/64]  
9.53  
[3/8]  
Red  
[21/64] [23/64]  
₸ Long tongue PLASTI-GRIP terminals only.  
Figure 2 (Part 1 of 2)  
Rev B  
2 of 7  
408-2423  
PLASTI-GRIP  
Butt Splice  
PIDG  
Butt Splice  
PLASTI-GRIP  
Terminal  
PIDG  
Terminal  
PIDG FASTON  
Receptacle  
Color Stripe  
on Radiation  
Resistant  
Color Stripe on 16-14  
HD and Radiation  
Resistant  
Color Stripe  
on 16-14 HD  
Crimp Dot Code  
Crimp Dot Code  
Wire Strip Length, mm [in.]  
Dot  
Code  
(Number  
of Dots)  
Wire Size  
Range  
(AWG)  
Insulation  
Color Code  
Die Assembly  
Part Number  
Product  
Terminal  
Splice  
Min  
Min  
Max  
Max  
4.76  
[3/16]  
5.56  
[7/32]  
5.56  
[7/32]  
6.35  
[1/4]  
Natural with  
White Stripe  
24-20  
22-16  
2
1
2
1
1
1
2
1
2
69878  
69872  
69873  
69874  
69874  
69935  
69936  
69937  
69938  
5.16  
5.95  
6.35  
[1/4]  
7.14  
[9/32]  
Natural with  
Red Stripe  
[13/64] [15/64]  
PDIG Radiation  
Resistant Terminals and  
Splices  
5.16 5.95  
[13/64] [15/64]  
6.35  
[1/4]  
7.14  
[9/32]  
Natural with  
Blue Stripe  
16-14  
12-10  
16-14 HD  
26-24  
22-20  
18-16  
14  
7.94  
[5/16]  
8.73  
[11/32]  
6.35  
[1/4]  
7.14  
[9/32]  
Natural with  
Yellow Stripe  
7.94  
[5/16]  
8.73  
[11/32]  
6.35  
[1/4]  
7.14  
[9/32]  
Natural with  
Black Stripe  
3.97  
[5/32]  
4.76  
[3/16]  
6.35  
[1/4]  
7.14  
[9/32]  
Black  
Green  
Orange  
White  
4.76  
[3/16]  
5.56  
[7/32]  
6.35  
[1/4]  
7.14  
[9/32]  
PIDG STRATO-THERM*  
Terminals  
5.16  
5.95  
6.35  
[1/4]  
7.14  
[9/32]  
[13/64] [15/64]  
5.16 5.95  
[13/64] [15/64]  
6.35  
[1/4]  
7.14  
[9/32]  
PIDG FASTON*  
Receptacles 641321-2  
(.187 Series) and  
4.76  
[3/16]  
5.56  
[7/32]  
6.35  
[1/4]  
7.14  
[9/32]  
26-24  
Yellow  
1
69877-2  
641324-2 (.110 Series)  
Figure 2 (Part 2 of 2)  
Rev B  
3 of 7  
408-2423  
3. DIE SELECTION AND INSTALLATION  
Refer to Figure 2 and select a compatible die assembly for the terminal or splice, based on the wire size being  
used.  
Refer to the Customer Manual supplied with the machine for information concerning installation of dies in the  
machine.  
When installing Die Assembly 68116-1 in Machine 69875, the terminal extractor/finger guard assembly and the  
clear plastic applicator guard must be moved out from the machine as follows:  
1. Remove the terminal extractor/finger guard assembly holding screw.  
2. Reinstall the extractor/finger assembly using the holding screw (part no. 25064-1) and six washers  
(part no. 21055-7) provided with the die assembly.  
3. Remove the clear plastic applicator (side) guard.  
4. Reinstall the guard using the two (lower) holding screws (part no. 2-21002-2) and two spacers  
(part no. 4-25272-6) provided with the die assembly.  
4. CRIMPING PROCEDURE  
1. Load the terminal or splice tape into the machine. Refer to the Customer Manual for tape loading  
instructions.  
2. Strip the wire to the dimension specified in Figure 2. Do NOT cut or nick the wire.  
NOTE  
Depending on your wire stripping machine adjustment capabilities, the wire strip length may be increased to the nearest  
0.79 mm [1/32 in.] if necessary.  
3. Insert the prepared wire into the terminal or splice until the wire is bottomed.  
DANGER  
KEEP HANDS CLEAR OF DIES during the crimping procedure.  
4. Hold the wire in position and activate the machine to crimp the terminal or splice.  
5. Inspect the crimped product for a proper termination.  
5. MAINTENANCE/INSPECTION  
5.1. Daily Maintenance  
It is recommended that a maintenance and inspection program be performed periodically to ensure dependable  
and uniform terminations.  
Frequency of inspection depends on:  
1. The care, amount of use, and handling of the dies.  
2. The presence of abnormal amounts of dust and dirt.  
3. The degree of operator skill.  
4. Your own established standards.  
The dies are inspected before being shipped; however, it is recommended that the dies be inspected  
immediately upon arrival at your facility to ensure that no damage occurred during shipment.  
Due to the precision design, it is important that no parts of these dies be interchanged except those  
replacement parts listed in Section 6.  
Rev B  
4 of 7  
408-2423  
5.2. Daily Maintenance  
1. Remove dust, moisture, and other contaminants with a clean brush, or a soft, lint-free cloth. Do NOT  
use objects that could damage the dies.  
2. When the dies are not in use, 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 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 raining and skill, and established company standards.  
The inspections should be performed in the following sequence:  
Visual Inspection  
1. Remove accumulated dirt, grease, and foreign matter by immersing the dies in a suitable commercial  
degreaser that will not affect paint or plastic material.  
2. Make sure all die holding components are in place. Refer to the parts list in Figure 4 if replacements  
are necessary.  
3. Check all bearing surfaces for wear. Remove and replace worn components.  
4. Inspect the crimp sections for flattened, chipped, cracked, worn, or broken areas. If damage is  
evident, the dies must be repaired before returning them to service. See Section 6, REPLACEMENT  
AND REPAIR, for information on obtaining customer repair service.  
Gaging the Wire Barrel Crimping Chamber  
This inspection requires the use of a plug gage conforming to the dimensions shown in Figure 3. To gage  
the crimping chamber, refer to Figure 3, and proceed as follows:  
1. Remove traces of oil or dirt from the crimping chamber and plug gage.  
2. Mate the dies until it is evident that they have bottomed.  
3. Align the GO element with the crimping chamber. Push element straight into the chamber without  
using force. The GO element must pass completely through the crimping chamber.  
4. Check the crimping chamber with the NO-GO element in the same manner as Step 3. The NO-GO  
element may start entry, but must not pass completely through the crimping chamber.  
If the dies conform to the gage inspection, they are considered dimensionally correct. If not correct, refer  
to Section 6, REPLACEMENT AND REPAIR, for information on obtaining customer repair service.  
For additional information regarding the use of a plug gage, refer to Instruction Sheet 408-7424.  
6. REPLACEMENT AND REPAIR  
The parts listed in Figure 4 are customer-replaceable parts. A complete inventory can be stocked and  
controlled to prevent lost time when replacement of parts is necessary.  
Order replacement parts through your representative, or call 1-800-526-5142, or send a facsimile of your  
purchase order to 1-717-986-7605, or write to:  
CUSTOMER SERVICE (038-035)  
TYCO ELECTRONICS CORPORATION  
PO BOX 3608  
HARRISBURG PA 17105-3608  
Dies may also be returned for evaluation and repair. For die repair service, contact a TE Connectivity  
Representative at 1-800-526-5136.  
Rev B  
5 of 7  
408-2423  
GO  
DIA  
NO-GO  
DIA  
Crimping  
Chamber  
Insulation Barrel  
Crimper  
Wire Barrel  
Crimper  
GO Element  
NO-GO Element  
GAGE DIMENSION  
DIE ASSEMBLY NUMBER  
GO Diameter  
NO-GO Diameter  
68116-1  
68207-1  
68208-1  
69872  
69873  
69874  
69877  
69877-2  
69878  
69897  
69935  
69936  
69937  
69938  
5.105 [.2010]  
3.023 [.1190]  
2.769 [.1090]  
2.769 [.1090]  
3.023 [.1190]  
4.293 [.1690]  
1.600 [.0630]  
1.600 [.0630]  
2.261 [.0890]  
4.293 [.1690]  
2.311 [.0910]  
2.667 [.1050]  
3.327 [.1310]  
3.835 [.1510]  
Figure 3  
5.258 [.2070]  
3.175 [.1250]  
2.921 [.1150]  
2.921 [.1150]  
3.175 [.1250]  
4.445 [.1750]  
1.753 [.0690]  
1.753 [.0690]  
2.413 [.0950]  
4.445 [.1750]  
2.388 [.0940]  
2.743 [.1080]  
3.404 [.1340]  
3.912 [.1540]  
7. REVISION SUMMARY  
Updated document to corporate requirements  
Changed part number in “Insul Indenter” column in Figure 4  
Rev B  
6 of 7  
408-2423  
25.4 [1.00]  
(Ref)  
15.85 [.624]  
(Ref)  
1
5
8
2
57.53 [2.265]  
(Ref)  
3
9
6
10  
4
7
Replacement Parts (Quantity is one per die Assembly, except for Item 8, Quantity for Item 8 is two.)  
SPECIAL  
SCREW  
SADDLE  
SCREW  
SPECIAL  
SCREW  
INSUL  
INDENTER  
CURVED  
WASHER  
INSUL  
ANVIL  
RTNG  
RING  
SADDLE  
INDENTER  
ANVIL  
DIE ASSY  
NO.  
1
2
3
4
5
6
7
8
9
10  
68116-1▪  
68207-1  
68208-1  
69872  
1-59781-4  
2-59781-4  
2-59781-4  
3-59781-4  
2-59781-4  
59781-1  
3-59577-8  
1-59577-5  
2-59577-9  
2-59577-9  
2-59577-9  
2-59577-8  
2-59577-7  
2-59577-7  
3-59577-0  
2-59577-8  
2-59577-7  
2-59577-9  
2-59577-9  
2-59577-9  
1-307275-7  
1-307275-0  
307275-9  
307275-9  
307275-9  
1-307275-0  
307275-9  
307275-9  
1-307275-1  
1-307275-0  
1-307275-5  
307275-9  
1-307275-6  
1-307275-6  
2-59781-5  
2-59781-6  
59781-6  
59781-6  
59781-6  
59781-5  
59781-7  
59781-7  
59781-8  
59781-5  
1-59781-8  
59781-6  
59781-6  
59781-6  
307913-1  
307276-1  
307285-2  
307285-1  
307285-2  
307276-1  
307285-3  
307285-3  
307285-4  
307276-2  
310676-3  
310676-4  
310676-5  
310676-1  
24088-8  
24088-8  
24088-8  
24088-8  
24088-8  
24088-8  
24088-8  
24088-8  
24088-8  
24088-8  
24088-8  
24088-8  
24088-8  
24088-8  
308916-1  
1-21046-3  
307914-1  
59779-3  
59779-2  
59779-2  
59779-3  
310454-1  
59782-2  
59782-2  
59782-8  
310454-1  
310674-2  
310674-3  
310674-4  
310674-1  
307915-1  
59623-5  
59623-6  
59623-6  
59623-5  
59623-4  
2-59615-0  
2-59615-0  
3-59615-0  
59623-4  
310675-2  
310675-3  
310675-4  
310675-1  
1-59619-2 1-21046-3  
1-59619-8 1-21046-3  
1-59619-7 1-21046-3  
1-59619-8 1-21046-3  
1-59619-2 1-21046-3  
1-59619-5 1-21046-3  
1-59619-5 1-21046-3  
1-59619-4 1-21046-3  
69873  
69874  
69877  
59781-4  
69877-2  
69878  
59781-4  
59781-3  
69897  
59781-1  
904765-1  
310667-2  
310667-3  
310667-4  
310667-1  
1-21046-3  
1-21046-3  
1-21046-3  
1-21046-3  
1-21046-3  
69935  
1-59781-7  
59781-2  
69936  
69937  
2-59781-0  
2-59781-0  
69938  
▪Refer to Section 3 for hardware to adapt guards.  
Figure 4  
Rev B  
7 of 7  

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