instruction sheet 1 of 5 ? 2016 te connectivity ltd. family of companies. all rights reserved. *trademark te connectivity, te connectivity (logo), and te (logo) are trademarks. other logos, product, and/or company names m ay be trademarks of their respective owners. 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 - 100 39 01 jul 16 rev d figure 1 1. introduction the terminal crimping dies listed in figure 1 are designed to be used with hand tool 6971 0-1 to crimp pidg strato-therm terminals onto wire sizes 24 through 10 awg. refer to instruction sheet 408-2095 for information concerning the hand tool. for other compatible tooling, call the number at the bottom of thi s page. reasons for re-issue of this instruction sheet are provided in section 7, revision summary. 2. die installation and removal 1. position the stationary die in the stationary die holder and the moving die in the mov ing die holder of the tool. turn each die holding screw just enough to hold the dies in place. do not tighten the sc rews. 2. position a terminal and wire in the dies as described in steps 1 through 3 of section 3, then c lose the tool handles until the dies bottom. 3. tighten both the die holding screws while dies are bottomed. note check die alignment and tighten the die holding screws at least twice daily. 4. continue to close the tool handles until the ratchet control releases. allow the handles to open , then remove the terminal. 5. to remove the dies, loosen the die holding screws. 3. crimping 1. strip the wire to the dimension provided in figure 2. 2. place the terminal in the stationary die as shown in figure 3, then close the t ool handles until the terminal is held firmly in place. note these d ie s will not accommodate a terminal having a tongue width exceeding 11.91 mm [.469 in.]. 3. insert the stripped wire into the terminal insulation barrel until the wire butts against the locato r. proper use guidelines cumulative trauma disorders can result from the prolonged use of manually powered hand tools. h and tools are intended for occasional use and low volume applications. a wide selection of powered application equipment for extended-use, produc tion operations is available. pidg* strato-therm* terminal crimping dies crimping dies 576711, 576714, 576715, 576716, 576720, 576723, 576742 die holding screw moving die stationary die insulation adjustment spacers (shown in position 3) die holding screw color code color code
408 -10039 rev d 2 of 5 figure 2 figure 3 4. close the tool handles until the ratchet control releases. allow the handles to open, then remov e the terminal. 5. inspect the crimped terminal for the dot code on both sides of the terminal according to figure 2. caution d o not use d amaged terminals. if a damage is evident, the terminal should be cut from the wire and replaced with a new one. do not re-terminate a terminal. 4. insulation crimp adjustment 1. remove the moving die from the tool. 2. turn both insulation crimp adjustment spacers so that they fit into the notch in the side of the movi ng die for position 3 loose. see figure 1. 3. insert the moving die into the moving die holder. 4. turn the die holding screw enough to hold the moving die firmly in place. do not tighten the screw . 5. insert an unstripped wire into only the insulation barrel of the terminal. 6. position the terminal in the dies as shown in figure 3, then close the tool han dles until the dies bottom. die crimped terminal dot code wire pn color code size (awg) strip length (mm [in.]) 576711 brown 2 24 - 22 5.56 - 6.35 [.219 - .250] 576720 gray 1 20 576715 orange 2 18 576714 orange 1 16 576716 white 2 14 576742 white 1 12 576723 black 1 10 7.62 - 8.38 [.300 - .330] dot code (both sides of terminal) crimped terminal wire strip length (see table) insulation barrel wire barrel terminal wire barrel resting against locator locator insulation barrel crimping chamber wire barrel crimping chamber note: to locate terminal, pull locator down slightly.
408 -10039 rev d 3 of 5 7. tighten the die holding screw while the moving die is bottomed, then complete the crim ping cycle. 8. remove the terminal from the dies, and check the insulation grip by bending the wire back and f orth once. the terminal should retain the grip on the wire insulation. if the wire pulls out, set the i nsulation crimp adjustment to the next position as follows: a. remove the moving die from the tool. b. turn the bottom insulation adjustment spacer 90 degrees so that it fits between the moving die and the moving die holder for position 2 medium. for position 1 tight, place both adjustment spacers between the moving die and the moving die holder. c. repeat the test crimp, and adjust as necessary until the desired insulation crimp grip is obtained. 5. maintenance and inspection frequency of an inspection depends on: (1) the care, amount of use, and handling of the dies, (2) ty pe and size of terminal applied, (3) degree of operator skill, (4) presence of abnormal amounts of dust and dirt, and (5) established standards. 5.1. cleaning do not allow deposits of dirt, grease, and foreign matter to accumulate in the die closure area and on the bottoming surfaces of the dies. these deposits may prevent the dies from bottoming fully an d 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, soft cloth. 5.2. visual inspection visually inspect the die closure surfaces for broken, chipped, and pitted surfaces. although dies ma y gage within permissible limits, worn or damaged die closure surfaces are objectionable and can aff ect the quality of the crimp. 5.3. die closure inspection inspect the die closure using two plug gages. refer to figure 4 for recommended plug gage design, then proceed as follows: 1. remove traces of oil or dirt from the die crimping areas and plug gage members. 2. turn both insulation adjustment spacers of the moving die so that they fit into the notch in the side of the die (position 3 loose). see figure 1. 3. insert both dies in the tool. note some dies prevent gaging the wire barrel crimping chamber when in the tool. remove the dies, rotate the locator 180 degrees, and place the dies in a vise using light pressure. 4. when using pneumatic tools, reduce air supply pressure to a range between 103 and 138 kpa [15 an d 20 psi]. actuate the tool to bottom the dies. when using the hand tool, close the tool handles until the dies bottom. do not apply additi onal pressure to the tool handles. 5. with the dies bottomed, hold the go member in a straight alignment with the wire barrel c rimping chamber and carefully insert it without forcing it. the go member must pass completely t hrough the wire barrel crimping chamber. do the same with no-go member. the no-go member may enter partially, but must not pass completely through the wire barrel crimping chamber. see fi gure 4. 6. re -position the insulation adjustment spacers to position 1. 7. with the dies bottomed, check the insulation barrel crimping chamber using the plug gage in the s ame manner as step 5. see figure 4. if both crimping chambers meet the plug gage conditions, the dies are dimensionally correct. if either crimping chamber does not conform, contact te.
408 -10039 rev d 4 of 5 figure 4 recommended plug gage design dies wire barrel plug gage (mm [in.]) insulation barrel plug gage (mm [in.]) go no - go go no - go w (width) 576711 2.591 - 2.598 [.1020 - .1023] 2.690 - 2.692 [.1059 - .1060] 0.813 - 0.820 [.0320 - .0323] 1.217 - 1.219 [.0479 - .0480] 4.06 [.160] 576720 2.591 - 2.598 [.1020 - .1023] 2.690 - 2.692 [.1059 - .1060] 1.067 - 1.074 [.0420 - .0423] 1.471 - 1.473 [.0579 - .0580] 4.39 [.173] 576715 3.048 - 3.056 [.1200 - .1203] 3.147 - 3.150 [.1239 - .1240] 0.940 - 0.947 [.0370 - .0373] 1.344 - 1.346 [.0529 - .0530] 5.89 [.232] 576714 3.124 - 3.132 [.1230 - .1233] 3.223 - 3.226 [.1269 - .1270] 0.940 - 0.947 [.0370 - .0373] 1.344 - 1.346 [.0529 - .0530] 5.89 [.232] 576716 3.327 - 3.335 [.1310 - .1313] 3.426 - 3.429 [.1349 - .1350] 1.067 - 1.074 [.0420 - .0423] 1.471 - 1.473 [.0579 - .0580] 6.63 [.261] 576742 3.683 - 3.691 [.1450 - .1453] 3.782 - 3.785 [.1489 - .1490] 1.067 - 1.074 [.0420 - .0423] 1.471 - 1.473 [.0579 - .0580] 6.63 [.261] 576723 4.775 - 4.783 [.1880 - .1883] 4.874 - 4.877 [.1919 - .1920] 1.676 - 1.684 [.0660 - .0663] 2.080 - 2.083 [.0819 - .0820] 8.43 [.332] go gage must pass completely through crimping chamber inspection wire barrel crimping chamber insulation barrel crimping chamber no -go gage may enter partially, but must not pass completely through crimping chamber wire barrel die closure configuration insulation barrel die closure configuration no -go gage may enter partially, but must not pass completely through crimping chamber go gage must pass completely through crimping chamber dies bottomed but not under pressure spacers in position 3 crimping chamber crimping chamber spacers in position 1 dies bottomed but not under pressure go dimension no - go dimension go dimension no - go dimension w 6.35 mm [.250 in.] typ 50.8 mm [2.00 in.] min. typ
408 -10039 rev d 5 of 5 6. replacement and repa ir customer-replaceable parts are given in figure 5. to return dies for evaluation and repair, call 1- 800 -526-5136. item description dies qty per die 576711 576714 576715 576716 576720 576723 5767 42 0 1 ring, retaining 1- 21046 -3 1- 21046 -3 1- 21046 -3 1- 21046 -3 1- 21046 -3 1- 21046 -3 1- 21046 -3 2 0 2 spacer 1- 306027 -5 306027 -6 306027 -6 306027 -6 1- 306027 -5 306027 -9 306027 -6 1 0 3 spacer 1- 306027 -6 306027 -7 306027 -7 306027 -7 1- 306027 -6 1- 306027 -0 306027 -7 1 0 4 screw, special 1- 306131 -6 1- 306105 -1 1- 306105 -1 1- 306105 -1 1- 306131 -6 2- 306131 -3 1- 306 105-1 1 0 5 spacer 2- 305832 -8 2- 305832 -8 2- 305832 -8 2- 305832 -8 2- 305832 -8 2- 305832 -8 2- 305832 -8 1 0 6 spacer, locator 2- 305832 -9 2- 305832 -9 2- 305832 -9 2- 305832 -9 2- 305832 -9 2- 305832 -9 2- 305832 -9 1 0 7 screw, special 2- 306131 -1 1- 306131 -6 1- 306131 -6 1- 306131 -6 2- 306131 -1 3- 306131 -4 1- 306131 -6 1 0 8 pin, coiled 21949 -1 21949 -1 21949 -1 21949 -1 21949 -1 21949 -1 21949 -1 2 0 9 indenter, insulation 576712 -1 576712 -2 2- 45931 -2 2- 45931 -3 576712 -3 2- 45931 -4 2- 45931 -3 1 10 anvil, insulation 576713 -1 57671 3-2 576713 -4 1- 45932 -8 576713 -3 1- 45932 -9 1- 45932 -8 1 11 anvil 576718 -7 576718 -8 576718 -1 576718 -2 576718 -5 576718 -4 576718 -6 1 12 indenter, barrel 576719 -8 576719 -7 576719 -1 576719 -2 576719 -5 576719 -4 576719 -6 1 13 locator 576771 -1 576771 -1 576771 -1 576771 -1 576771 -1 576771 -5 576771 -1 1 14 spring, compression 7- 59683 -4 7- 59683 -4 7- 59683 -4 7- 59683 -4 7- 59683 -4 7- 59683 -4 7- 59683 -4 2 figure 5 7. revision summary revisions to this instruction sheet include: ? changed company name and logo ? corrected errors in figure 5 and incorporated new te logo
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