?2013 tyco electronics corporation, a te connectivity ltd. company all rights reserved *trademark te connectivity, te connectivit y (logo), and te (logo) are trademarks. other logos, product and/or company names may be tradem arks of their respective owners. 1 of 6 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.te.com 408-2648 crimping dies for solistrand* and strato-therm* terminals and butt splices 17 may 13 rev c 1. introduction this instruction sheet provid es instructions on product application; and maintenance and inspection procedures for crimping dies 69930, 69931, 69932, 69954, 69955, and 69956 used in the amp-tapetronic* machine 69875; dies 68240-1, 68241-1, and 68242-1 are also used in the amp-tapetronic machine 6 9875, or the model ?k? amp-o-lectric* 565435-5, or the g-terminating machine 354500-1. these dies are used to crimp: ? solistrand terminals and butt splices on solid or stranded copper wi re sizes 22 thru 10. ? uninsulated strato-therm terminals and butt splices (with wire insulation support) on solid or stranded copper wire sizes 22 thru 10. ? uninsulated strato-therm terminals and butt splices (without wire insulati on support) on solid or stranded copper wire sizes 22 thru 10. dies are coated with preservative to prevent rust and corrosion. wipe preservative from dies, particularly from crimping surfaces. die insertion and removal an d crimping instructions are provided in the manual packaged with the terminating machine. section 2, instructions, provides personal safety and wire preparation information. section 3, cri mp inspection, features terminal and splice crimp inspection procedures which will enable you to establish and maintain a die certification program. for further instructions re lative to th e machines, tooling adjustment, tape l oading, etc., refer to the instructions packaged with the machines. note dimensions in this instruct ion sheet are in millimeters [with inches in brackets]. fi gures and illustrations are for reference only and are not drawn to scale. reasons for reissue of this instruction sheet are provided in section 5, revision summary. 2. instructions danger avoid personal injury. always disconnect machine from power supply when prefor ming adjustments, die installation or removal, and machine maintenance. always keep guards and covers in place during normal machine operation. for wire preparation, select the correct wire strip length from figure 1. do not use wires with nicked or missing conductor strands. refer to machine manual for crimp instructions. 3. crimp inspection inspect crimped terminals and splices by checking the features described in figure 2. use only the terminals and splices that meet the conditions shown in the ?accept? column. ?reject? terminals and splices can be avoided through careful use of instructions provided in the machine manual and by preforming regular die maintenance as instructed in section 4, maintenance/inspection procedure, of this instruction sheet. 4. maintenance/inspection procedure it is recommended that a maintenance/inspection program be performed periodically to ensure dependable and uniform terminations. dies should be inspected at least once a month. frequency of inspection may be adjusted to suit your requirements through experience. frequency of inspection is depend upon: 1. the care, amount of use, and handling of the dies. 2. the degree of operator skill. 3. the presence of abnormal amounts of dust and dirt. 4. your own established standards. since there is a possibility of die damage in shipment, new dies should be inspected in accordance with section 4 when received in your plant. 4.1. cleaning do not allow deposits of dirt, grease, and foreign matter to accumulate on the die closure surfaces and on the bottoming surfaces of the dies. these deposits may prevent the dies from bottoming fully and may also cause excessive wear in the die closure surfaces, thereby affecting the quality of the crimp. the dies should be wiped clean frequently with a clean cloth. 4.2. visual inspection visually inspect the die clos ure surfaces for chipped or pitted conditions. although dies may gage within permissible limits, worn or damaged die closure surfaces are objectionable and can affect the quality of the crimp. examples of possible damaged die surfaces are shown in figure 3. note i ! original instructions
408-2648 2 of 6 rev c ?crimped by foot switch control only in machine 69875. figure 1 4.3. die closure inspection every die set is inspected for proper die closure dimensions before packaging. an inspection should be performed periodically to inspect the die closure for excessive wear. die closure inspection is accomplished using go no-go plug gages. te connectivity neither manufactures nor sells plug gages. a suggested plug gage design and the go no-go dimensions of the plug gage elements are listed in figures 4 and 5. the following procedure is recommended for inspecting the die closure. terminals butt splices solistrand and strato-therm w/o insulation support solistrand flag terminal strato-therm w/insulation support ?b? equals wire barrel ?c? equals insulation barrel b b b b b c c product description wire size range (awg) die no. machine no. wire strip length (add 1.59 mm [.062 in.] to strip length when using probe in 69875 machine) terminals splices min max min max solistrand terminals and splices? 22-16 68240-1 69875, 354500-1, 565435-5 4.37 [.172] 5.16 [.203] 6.35 [.250] 7.14 [.281] 16-14 68241-1 12-10 68242-1 6.35 [.250] 7.14 [.281] uninsulated strato-therm terminals and splices? (insulation support) 22-16 69930 69875 5.16 [.203] 5.94 [.234] 5.16 [.203] 5.94 [.234] 16-14 69931 12-10 69932 8.74 [.344] 9.52 [.375] 8.74 [.344] 9.52 [.375] uninsulated strato-therm terminals and splices? (non-insulation support) 22-16 69954 4.37 [.172] 5.16 [.203] 6.35 [.250] 7.14 [.281] 16-14 69955 12-10 69956 6.35 [.250] 7.14 [.281]
408-2648 3 of 6 rev c figure 2
408-2648 4 of 6 rev c figure 3 ?die closure dimensions apply when wire barrel dies are bottomed but not under pressure. ?material - tool steel figure 4 ?material - tool steel figure 5 a. wire barrel crimp die closure 1. clean oil or dirt from the die closure surfaces, bottoming surfaces, and plug gage elements. 2. assemble dies so that wire barrel dies are bottomed but not under pressure. 3. with wire barrel dies bottomed, inspect the wire barrel crimp die closure using the proper plug gage. hold gage in straight alignment with the die closure and carefully insert, without forcing, the go element. see figure 6a. the go element must pass completely through the wire barrel crimp die closure. 4. try to insert the no-go element. the no-go element may enter partially, but must not pass completely through the wire barrel crimp die closure. see figure 6a. b. insulation crimp die closure 1. with wire barrel dies bottomed and not under pressure, set insulation crimp dies at ?gage? dimension shown in figure 6b. 2. inspect the insulation crimp die closure using the proper plug gage in the same manner as steps (c) and (d) in paragraph 4.3.a. see figure 6b. if both the wire barrel and insulation crimp die closures meet the go no -go gage conditions, the dies may be considered dimensionally correct. die set die closure dim's ?a?? gage element? dim's ?b? ?r? radius (max) go no-go go no-go 68240-1 1.168 [.0460] 1.321 [.0520] 1.168-1.176 [.0460-.0463] 1.318-1.321 [.0519-.0520] 1.575 [.0620] 68241-1 1.372 [.0540] 1.524 [.0600] 1.372-1.379 [.0540-.0543] 1.521-1.524 [.0599-.0600] 1.981 [.0780] 68242-1 1.930 [.0760] 2.083 [.0820] 1.930-1.938 [.0760-.0763] 2.080-2.083 [.0819-.0820] 2.769 [.1090] 69930 1.499 [.0590] 1.651 [.0650] 1.499-1.506 [.0590-.0593] 1.648-1.651 [.0649-.0650] 1.880 [.0740] 69931 1.905 [.0750] 2.057 [.0810] 1.905-1.913 [.0750-.0753] 2.055-2.057 [.0809-.0810] 2.184 [.0860] 69932 2.311 [.0910] 2.464 [.0970] 2.311-2.319 [.0910-.0913] 2.461-2.464 [.0969-.0970] 2.997 [.1180] 69954 1.295 [.0510] 1.448 [.0570] 1.295-1.303 [.0510-.0513] 1.445-1.448 [.0569-.0570] 1.575 [.0620] 69955 1.499 [.0590] 1.651 [.0650] 1.499-1.506 [.0590-.0593] 1.648-1.651 [.0649-.0650] 1.981 [.0780] 69956 2.108 [.0830] 2.261 [.0890] 2.108-2.116 [.0830-.0833] 2.258-2.261 [.0889-.0890] 2.769 [.1090] chipped edge pitted die set die closure dim's ?c? (dies set at ?gage? dim see figure 6b.) gage element? dimension ?d? ?e? dim go no-go go no-go 69930 0.762 [.0300] 1.27 [.0500] 0.762-0.770 [.0300-.0303] 1.267-1.27 [.0499-.0500] 4.06 [.160] 69931 0.762 [.0300] 1.27 [.0500] 0.762-.0770 [.0300-.0303] 1.267-1.27 [.0499-.0500] 4.83 [.190] 69932 1.321 [.0520] 1.829 [.0720] 1.321-1.328 [.0520-.0523] 1.826-1.829 [.0719-.0720] 7.87 [.310]
408-2648 5 of 6 rev c if you find that the crimp die closures do not conform with the go no -go gage conditions, contact your local te representative. 4.4. replacement parts customer-replaceable parts are listed in figure 7. a complete inventory should be stocked and controlled to prevent lost time when replacement of parts is necessary. order replacement parts through your te 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 5. revision summary this paragraph is reserved for a revision summary of changes and additions made to this document. the following changes were made for this revision: ? updated document to corporate requirements ? deleted product trademark name in all instances figure 6 ?a? - inspection of wire barrel crimp dies ?b? - inspection of in sulation crimp dies insulation crimping dies 1.181 [.0465] gage dim wire barrel crimp dies wire barrel dies are bottomed but not under pressure ?go? gage must pass completely through the die closure ?no-go? gage may enter partially, but must not pass completely through the die closure
408-2648 6 of 6 rev c figure 7 type a type d die sets item number 12 3 4 567 8910 part no. type screw moving die moving die ret. ring 2 req?d sta. die sta. die screw screw saddle curved washer 68240-1 a 1-59781-3 --- 308209-1 1-21046-3 308210-1 --- 1-59781-3 --- --- --- 68241-1 a 1-59781-3 --- 308209-2 1-21046-3 308210-2 --- 1-59781-3 --- --- --- 68242-1 a 1-59781-3 --- 308209-3 1-21046-3 308210-7 --- 1-59781-3 --- --- --- 69930 d 1-59781-7 310676-6 307236-5 1-21046-3 307235-5 310677-7 59781-9 3-59577-1 307275-9 24088-8 69931 d 2-59781-8 310676-2 307236-4 1-21046-3 307235-4 310677-6 59781-9 3-59577-1 307275-9 24088-8 69932 d 1-59781-3 310676-7 307236-6 1-21046-3 307235-6 310677-8 59781-9 3-59577-3 1-307275-0 24088-8 69954 a 1-59781-3 --- 1-307161-7 1-21046-3 307160-8 --- 1-59781-3 --- --- --- 69955 a 1-59781-3 --- 1-307161-8 1-21046-3 307160-9 --- 1-59781-3 --- --- --- 69956 a 1-59781-3 --- 1-307161-9 1-21046-3 1-307160-0 --- 1-59781-3 --- --- ---
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