Instruction Sheet
Crimping Die Assemblies for
AMPLI-BOND*, PLASTI-GRIP*, and 408-8705
LOC B
1
of 6
E
2008 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
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
30 OCT 08 Rev A
Pre-Insulated AMPOWER* Terminals
PROPER USE GUIDELINES
CumulativeTraumaDisorderscanresultfromthe prolongeduseofmanually poweredhandtools.Hand toolsareintendedfor occasionaluseandlowvolume
applications. A wide selection of powered application equipment for extended-use, production operations is available.
Wire Strip Length (Typ)
Pre-Insulated AMPOWER Terminal
PLASTI-GRIP Terminal
AMPLI-BOND Terminal
Color Code
Color Code
Insulation Barrel
Crimping Die
Wire Barrel
Crimping Die
Socket Head
Cap Screw (Typ)
Stationary Die
(Anvil)
Moving Die
(Indenter)
WIRE WIRE STRIP LENGTH TERMINAL DIE SET
WIRE
SIZE
(AWG)
AMPLI-BOND PLASTI-GRIP
TERMINAL
COLOR
CODE
PART COLOR
(AWG) MINIMUM MAXIMUM MINIMUM MAXIMUM CODE NUMBER CODE
8 11.51 [.453] 12.29 [.484] Red 1490534-1 Red
6
11 51 [ 453]
12 29 [ 484]
15.47 [.609] 16.26 [.640] Blue 1490535-1 Blue
4
11
.
51 [
.
453]
12
.
29 [
.
484]
15.47 [.609] 16.26 [.640] Yellow 1490536-1 Yellow
2 11.51 [.453] 12.29 [.484] Red 1490410-1 Red
Figure 1
1. INTRODUCTION
This instruction sheet provides information on product
application and a maintenance and inspection
procedure for the crimping dies listed in Figure 1. The
dies are used in Hydraulic Crimping Head 1490746–1
and Hydraulic Hand Tool 1490749–1. For detailed
information on the crimping head and hand tool, refer
to the instructions packaged with these tools.
These dies are designed to crimp AMPLI–BOND and
PLASTI–GRIP terminals on wire sizes 8 to 2 AWG,
and Pre–Insulated AMPOWER terminals on wire size
2 AWG. Dies are coated with a preservative to
prevent rust and corrosion. Wipe preservative from
dies, particularly from crimping areas.
All dimensions in this document are in millimeters
[with inches in brackets]. Illustrations and figures
are for reference only and are not drawn to scale.
2. DIE INSTALLATION AND REMOVAL
(Figure 2)
Do not operate tool without dies.
Avoid personal injury. Always keep fingers clear
of dies when activating power unit.
2.1. Die Insertion
1. Refer to the chart in Figure 1 and verify that you
have the proper die set for the terminal and wire
size being used.
2. Before inserting dies in head, loosen socket
head cap screws holding insulation crimping
section of dies in place. See Figure 1. If screws are
not loosened, dies may not fit into head of tool
because of close tolerance.
3. Release the button and rock the die
back–and–forth until the nest snaps in place.
NOTE
i
CAUTION
!
DANGER
408-8705
Crimping Die Assemblies
Rev
A2
of6 Tyco Electronics Corporation
Figure 2
Upper Die
Release Knob
Stationary Die
(Anvil)
Spring-Loaded
Locator
Lower Die
Release
Button
Ram
Advanced
Moving Die
(Indenter)
4. Activate the power unit until the lower die
release button located in the ram is exposed.
5. Depress the release button and slide the
indenter into place.
6. Release the button and rock the indenter
back–and–forth until the die snaps in place.
Moving die must be properly oriented to mate
with the stationary die.
7. Tighten the socket head cap screws holding the
insulation crimp section of dies.
8. Activate the power unit to allow ram to return to
the “down” position.
9. Lift the upper release located in the C–head and
slide the anvil into place.
2.2. Die Removal
1. Lift the upper release located in the C–head and
slide the anvil out of the head.
2. Activate the power unit until the lower die
release button located in the ram is exposed.
3. Depress the release button and slide the
indenter out of the ram.
3. OPERATION
3.1. Wire Stripping and Crimping Procedure
Avoid personal injury. When operating power unit,
exercise caution while holding terminals or wire
near crimping area. Never place anything in the
dies except terminals.
1. Strip wire to dimensions listed in Figure 1. Do
NOT nick or cut conductor strands.
2. Insert stripped wire in terminal. End of wire must
be flush with or extend beyond edge of terminal
wire barrel.
3. Place terminal on dies. See Figure 3, Detail A.
Bottom of terminal tongue should face stationary
die and terminal wire barrel should rest against
spring–loaded locator.
When crimping pre-insulated AMPOWER
terminals in die 1490410-1, it will be necessary
to remove the locator. Position the terminal in
dies as shown in Figure 3, Detail B. Bottom of
terminal tongue faces stationary die and rear of
terminal tongue butts against the side of the die.
4. Hold terminal in place and activate power unit to
complete crimp. Remove crimped terminal.
If terminal sticks in die after crimping, apply a
rocking action to remove it from the die.
Figure 3
Bottom of Terminal
Tongue Faces
Stationary Die
Terminal Wire Barrel
Rests Against Locator
Detail A
AMPLI-BOND or
PLASTI-GRIP
Terminal
Detail B
Pre-Insulated
AMPOWER
Terminal in Die
1490410-1
Bottom of Terminal
Tongue Faces
Stationary Die
Locator
Removed
Rear of Terminal Tongue
Butts Against Side of Die
NOTE
i
DANGER
NOTE
i
NOTE
i
408-8705
Crimping Die Assemblies
3
of 6Rev
A
Tyco Electronics Corporation
3.2. Insulation Crimp Adjustment
This adjustment is made to both stationary and
moving dies after they have been placed in crimping
head.
Crimping Dies have four socket head cap screws
and two pin-keys for insulation crimp adjustment.
1. The dies have three insulation crimp positions.
The adjustment is made by moving a pin–key (see
Figure 1). When the pin–key is pushed all the way
in, the insulation crimping section of the die is in
the loose position; when the pin–key is halfway
out, the insulation crimping section of the die is in
the medium position; when the pin–key is all the
way out, the insulation crimping section of the die
is in the tight position.
2. To adjust the insulation crimp, loosen socket
head cap screws and push pin–key all the way in
so that insulation crimp section of the die is in the
loose position.
3. Press and hold insulation die down against the
pin–key. This will prevent the spring–loaded
pin–key from popping back.
4. Tighten socket head cap screws.
Make certain insulation crimping sections of
moving and stationary dies are both adjusted to
the same position.
5. Perform a test crimp (refer to Paragraph 3.1).
AMPLI-BOND and AMPOWER terminals provide
a grip" on wire insulation. PLASTI-GRIP
terminals provide only a support" for the wire.
6. Remove crimped terminal from dies and visually
inspect the insulation crimp portion of terminal. The
insulation crimp should “
grip
” wire insulation (when
using AMPLI–BOND or AMPOWER terminals) or
provide “
support
” for wire insulation (when using
PLASTI–GRIP terminals).
7. If the insulation crimp does not grip or support
wire insulation as described in step 6, loosen
socket head cap screws and set the pin–keys in
the medium position. Then follow Steps 3 and 4.
8. Make another test crimp over previously
crimped terminal.
9. Remove crimped terminal from dies and visually
inspect insulation crimp.
10. Repeat adjustment as necessary until desired
insulation crimp is obtained. Do NOT use a tighter
setting than required.
11. Refer to Paragraph 3.4 and Figure 4 for crimp
inspection procedure.
3.3. Color Code
Terminals and dies are color coded as listed and
shown in Figure 1. The dies have the terminal size
stamped in the wire barrel crimp sections of both the
moving and stationary dies. When crimped, the wire
size will appear on both sides of the terminal wire
barrel. The wire size appearing on the crimped wire
barrel should always agree with the wire size stamped
on the terminal tongue.
3.4. Crimp Inspection
Inspect crimped terminals by checking the features
described in Figure 4.
AMPLI-BOND terminals are shown in Figure 4.
Inspection procedure is the same for AMPOWER
and PLASTI-GRIP terminals.
Use only the terminals that meet the conditions
shown in the “ACCEPT” column. “REJECT” terminals
can be avoided through careful use of instructions in
Paragraphs 3.1 and 3.2, and by performing regular
die maintenance described in Section 4.
4. MAINTENANCE/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 the
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 training and skill, and established
company standards. These inspections should be
performed in the following sequence:
4.1. Cleaning
Do not allow deposits of dirt, grease, or foreign matter
to accumulate in the die closure area, or 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 closure surfaces for flattened,
broken, pitted, or chipped 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 5.
NOTE
i
NOTE
i
NOTE
i
NOTE
i
408-8705
Crimping Die Assemblies
Rev
A4
of 6 Tyco Electronics Corporation
Figure 4
Wire fully inserted.
1
Crimp centered on wire barrel.
2
Correct color code and die combination. (Terminal insulation
color matches color dots on dies.)
3
Wire size being used is same as wire size embossed on
terminal insulation and stamped on terminal tongue.
4
End of conductor is flush with or extends beyond end of
wire barrel of terminal.
5
Insulation barrel is in contact with wire insulation.
(AMPLI-BOND terminals have insulation grip" and
PLASTI-GRIP terminals have insulation support".)
6
Wire not fully inserted.
1
Crimp not centered on wire barrel. (Terminal was not butted
against stop plate. See Figure 4.)
2
Wrong die and terminal color code combination. See Figure 1.
3
Excessive flash or extruded insulation. (Wrong size or damaged
dies.)
4
End of conductor is not flush with or extending beyond end of
wire barrel of terminal.
5
Wire insulation pinched. (Insulation crimp too tight on
AMPLI-BOND terminals.)
6
Nicked or missing conductor strands.
7
Crimp Inspection of
AMPLI-BOND, AMPOWER and
PLASTI-GRIP Terminals
Accept Reject
3
1
24
5
4
4
6
47
5
16
3
2
Figure 5
Broken Corner
Chipped or
Flattened
Edge
Pitted
4.3. Plug Gage Inspection
Every die set is inspected and tested for proper die
closure dimensions before packaging. An inspection
should be performed periodically to check the die
closure for excessive wear. A suggested gage design
and the GO and NO–GO dimensions of the plug gage
elements are shown in Figures 6 and 7. The following
procedure is recommended for inspecting the die set.
1. Clean oil or dirt from the bottoming surfaces, die
closure surfaces, and plug gage elements.
2. Remove two socket head cap screws and
locator from moving die. See Figure 8, Detail A.
This will provide access to the wire barrel dies for
plug gaging.
3. Assemble stationary and moving dies so that
wire barrel dies are bottomed, but not under
pressure. See Figure 8.
4. 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 try to insert, without forcing,
the GO element. See Figure 8, Detail A. The GO
element must pass completely through the wire
barrel crimp die closure.
5. Try to insert the NO–GO element. The NO–GO
element may enter partially, but must not pass
completely through the wire barrel die closure.
6. Re–install locator and secure with the two
socket head cap screws.
7. Loosen socket head cap screws from both
stationary and moving insulation dies and move
pin–keys all the way out so that insulation crimping
sections of dies are in the tight position. See
Figure 8, Detail B.
8. Press and hold insulation die down against
pin–key, and tighten the socket head cap screws.
9. With wire barrel dies bottomed, inspect the
insulation crimp die closure using the proper plug
gage in the same manner as steps 3 through 5.
See Figure 8, Detail B.
10. If both wire barrel and insulation die closures
meet the plug gage conditions, the dies are
considered to be dimensionally correct.
408-8705
Crimping Die Assemblies
5
of 6Rev
A
Tyco Electronics Corporation
50.8 [2.00]
Min Typ
GO Diameter NO-GO Diameter
SUGGESTED PLUG GAGE DESIGN - WIRE BARREL CRIMP
Die Closure
Configuration
TOOL GAGE ELEMENT DIAMETER
NUMBER GO NO-GO
1490534-1 5.105-5.113 [.2010-.2013] 5.255-5.258 [.2069-.2070]
1490535-1 6.020-6.027 [.2370-.2373] 6.170-6.172 [.2429-.2430]
1490536-1 6.833-6.840 [.2690-.2693] 6.982-6.985 [.2749-.2750]
1490410-1 8.103-8.110 [.3190-.3193] 8.252-8.255 [.3249-.3250]
Figure 6
SUGGESTED PLUG GAGE DESIGN - INSULATION BARREL CRIMP
GO NO
GO
GO Dimension D"
Dimension F"
Min (Typ)
Die Closure
Configuration
NO-GO Dimension D"
Dimension E"
TOOL GAGE ELEMENT DIMENSION D" DIMENSION DIMENSION
NUMBER GO NO-GO E" F"
1490534-1 3.861-3.868 [.1520-.1523] 4.366-4.369 [.1719-.1720] 7.14 [.281] 6.35 [.250]
1490535-1 4.216-4.224 [.1660-.1663] 4.722-4.724 [.1859-.1860] 7.92 [.312] 11.18 [.440]
1490536-1 4.115-4.122 [.1620-.1623] 4.620-4.623 [.1819-.1820] 8.13 [.320] 11.94 [.470]
1490410-1 4.623-4.630 [.1820-.1823] 5.128-5.131 [.2019-.2020] 10.29 [.405] 11.94 [.470]
Figure 7
Figure 8
Detail A
Inspection of
Wire Barrel
Crimping Dies
Detail B
Inspection of
Insulation Barrel
Crimping Dies
Wire Barrel Dies
Bottomed But Not
Under Pressure
Socket Head
Cap Screws and
Stop Plate Removed
Socket Head
Cap Screws
Pin-Keys in
Tight Position
Wire Barrel Dies
Bottomed But Not
Under Pressure
GO element must pass completely through
the die closure.
NO-GO element may enter partially, but must
not pass completely through the die closure.
408-8705
Crimping Die Assemblies
Rev
A6
of 6 Tyco Electronics Corporation
5. REPLACEMENT AND REPAIR
The parts listed in Figure 9 are customer–
replaceable. A complete inventory can be stocked
and controlled to prevent lost time when replacement
of parts is necessary. Order replacement parts
through your Tyco Electronics Representative, or call
1–800–526–5142, or send a facsimile of your
purchase order to 1–717–986–7605, or write to:
CUSTOMER SER VICE (38–35)
TYCO ELECTRONICS CORPORATION
P.O. BOX 3608
HARRISBURG, PA 17105–3608
Dies may be returned for evaluation and repair. For
die repair service, contact a representative at
1–800–526–5136.
6. REVISION SUMMARY
S
Updated document to corporate requirements
S
New format
1
2
3
45
6
7
8
9
10
11
12
ITEM
DESCRIPTION
QTY PER DIE SET NUMBERS AND COMPONENT PART NUMBERS
ITEM
DESCRIPTION
DIE SET 1490534-1 1490535-1 1490536-1 1490410-1
1 Washer 4 306098-3 306098-3 306098-3 306098-3
2 Screw 4 23030-5 23030-7 23030-7 23030-7
3 Insulation Insert 2 313339-2 1490540-1 313339-1 45861-1
4 Adjustment Key 2 308947-1 313292-2 313292-1 313292-1
5 Spring 2 302380 302380 302380 302380
6 Anvil Barrel 1 1490409-1 1490409-2 1490409-3 1490409-4
7 Locator 1 307130-1 307130-1 307130-2 307130-3
8 Sleeve 2 306363 306363 306363 306363
9 Spring 2 3-304668-5 3-304668-5 3-304668-5 6-59683-8
10 Screw 2 2-21000-8 2-21000-8 2-21000-8 2-21000-8
11 Indenter Barrel 1 1490411-1 1490411-2 1490411-3 1490411-4
12 Washer 2 1-59681-8 1-59681-8 1-59681-8 1-59681-8
Figure 9
