Instruction Sheet
1 of 12
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PRODUCT INFORMATION
1-800-522-6752
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408-2281
07 MAR 19 REV CS
Figure 1
CRIMPING DIE
ASSEMBLY
HYDRAULIC
CRIMPING HEAD
HYDRAULIC CRIMPING HEAD
(INSTRUCTION SHEET)
68006
68007
68008●
68008-1
68009
68010
68010-1■
68010-2
314964-1▲
58422-1
69066
1752787-1
1752877-1
408-9535
408-2453
408-8914
408-8956
59877-1
68011-1
314948-1
1976441-1
1976442-1
1976443-1
2217781-1
2217855-1
2280034-1
2280035-1
2844065-1
2844065-2
2844425-2
2844430-1
2844430-2
58422-1
1752787-1
408-9535
408-8914
●Superseded by 68008-1 ■Superseded by 68010 ▲Low Pressure Crimp Die Set
Table 1
Crimping Die Assemblies for
COPALUM* Sealed Terminals
and Splices
Stationary Die
(Nest)
Shank
Alignment Dot
Front of Die
Assembly
Alignment Dot
Shank
Moving Die
(Anvil)
ORIGINAL INSTRUCTIONS
408-2281
Rev CS
2 of 12
1. INTRODUCTION
The crimping die assemblies are designed to be installed into the hydraulic crimping heads listed in Table 1
and are used to crimp COPALUM sealed terminals and splices. Read these instructions thoroughly before
crimping any terminals or splices.
Reasons for reissue of this instruction sheet are provided in Section 8, REVISION SUMMARY.
NOTE
Dimensions in this instruction sheet are in millimeters [with inches in brackets]. Illustrations are for reference only and are not
drawn to scale.
2. DESCRIPTION
Each crimping die assembly consists of a stationary die (nest) and moving die (anvil). Each die features an
alignment dot on the front of the die. See Figure 1.
3. DIE ASSEMBLY INSTALLATION
For information concerning die installation and general performance of the hydraulic crimping head, refer to the
instruction sheet packaged with the crimping head.
DANGER
To avoid personal injury, ALWAYS DISCONNECT electrical and air supply to power unit before installing the hydraulic
crimping head or die assembly.
In order to achieve proper mating of the dies during installation, ensure that:
— the shanks of the dies are offset to the same surface of the die, but that the alignment dots align and
face the operator
— the anvil moves and the nest is stationary
CAUTION
DO NOT mix dies from different or the same die assemblies (because of inconsistent wearing) — it is important that the dies
are used as the set.
DANGER
To avoid personal injury, make sure to close the yoke of the hydraulic crimping head and fully insert the pin. When operating
the power unit, be careful when handling terminals, splices, or wire near the crimping area of the die assembly.
4. CRIMPING PROCEDURE
Select the die assembly and terminal or splice, and prepare the wire as follows:
1. Refer to Figure 2/Table 2 to select the appropriate die assembly and terminal or splice according to
the wire.
NOTE
For aluminum-to-aluminum application, butt splices will accept the same wire size at either end. For aluminum-to-copper
application, the copper wire size must be smaller to compensate for differences in the electrical properties of copper and
aluminum. This also applies when using copper wire in a terminal as listed in Table 2.
2. Cut the end of the wire perpendicular to the wire; DO NOT distort the shape of the wire. It is
recommended to chamfer the edge around the group of wires. See Figure 2. The chamfer will aid in
the insertion of the wire into the terminal or splice.
3. Strip the wire to the length indicated in Figure 2/Table 2. DO NOT nick or cut the wire strands. The
strip length for the wire will depend on the number of insulation layers covering the wire.
There are two approved methods for crimping the terminals and splices using these die assemblies and
hydraulic crimping heads. Proceed as follows:
408-2281
Rev CS
3 of 12
4.1. Terminal
IMPORTANT: To ensure a quality crimp, gage the die assembly at the beginning of a run, after changing a die
assembly — and then periodically during the run. Refer to paragraph 6.2 for gaging instructions.
Figure 2
Terminal (RT)
Butt
Splice (BS)
Wire
Die
Assy
Crimping
Head
Single
Hole
Double
Hole
Bent
Aluminum
Copper
Insulation
Range
Strip Length
±1.59 [1/16]
mm2
(CMA)†
AWG
mm2
(CMA)†
AWG
A
(Insul)
B
(Wire)
277147-[ ]
---
---
277156-[ ]
8.60
(16,564)
8
4.80
(9,354)
10
4.62-5.08
[.182-.200]
22.23
[7/8]
11.11
[7/16]
68006
58422-1
69066
1752787-1
1752877-1
277148-[ ]
55832-[ ]
---
277157-[ ]
14.60
(28,280)
6
8.80
(16,983)
8
5.72-6.35
[.225-.250]
22.23
[7/8]
12.70
[1/2]
68007
135148-[ ]
136059-[ ]
277149-[ ]
55833-[ ]
1958119-[ ] 90º
277158-[ ]
21.90
(42,420)
4
13.80
(26,818)
6
7.01-7.75
[.276-.305]
25.40
[1]
17.45
[11/16]
68008-1
134848-[ ]
135563-[ ]
277150-[ ]
277155-[ ]
55835-[ ]
55935-[ ]
2300438-[ ] 90º
277159-[ ]
35.00
(67,872)
2
22.00
(42,615)
4
8.64-9.65
[.340-.380]
31.75
[1 1/4]
19.10
[3/4]
68009
134452-[ ]
134593-[ ]
277151-[ ]
1577118-[ ]
55837-[ ]
136994-[ ] 70º
696632-[ ] 90º
1958195-[ ] 45º
277160-[ ]
55.50
(107,464)
1/0
34.30
(66,500)
2
10.79-11.94
[.425-.470]
32.54
[1 9/32]
25.40
[1]
68010
1958110-2●
---
---
---
---
---
11.18-11.94
[.440-.470]
134594-[ ]
277152-[ ]
696972-[ ]
55839-[ ]
1958038-[ ] 90º
2289812-[ ] 90º
2317551-[ ] 45º
277161-[ ]
71.30
(138,168)
2/0
53.90
(104,500)
1/0
12.70-13.97
[.500-.550]
34.93
[1 3/8]
25.40
[1]
314964-1▲
69066,
1752877-1
68011-1
58422-1
1752787-1
277153-[ ]
696767-[ ]
696974-[ ]
55840-[ ]
2325332-[ ] 60º
2327315-[ ] 45º
277162-[ ]
87.20
(168,872)
3/0
68.60
(133,000)
2/0
13.21-16.38
[.520-.645]
34.93
[1 3/8]
25.40
[1]
59877-1
184113-[ ]
55995-[ ]
55841-[ ]†
696786-[ ]
---
---
110.94
(214,928)
4/0
85.94
(166,500)
3/0
14.99-17.27
[.590-.680]
33.34
[1 5/16]
25.40
[1]
314948-1
Table 2 (Cont’d)
Flag Ring Tongue
(RT) Terminal
Ring Tongue (RT)
Double Hole Terminal
Ring Tongue (RT)
Single Hole Terminal
408-2281
Rev CS
4 of 12
Transitional
Butt Splice (TS)
Wire
Die
Assy
Crimping
Head
Aluminum
Copper
Insulation
Range
Strip Length
±1.59 [1/16]
mm2
(CMA)†
AWG
mm2
(CMA)†
AWG
A
(Insul)
B
(Wire)
277163-[ ]
55.50
(107,464)
1/0
22.00
(42,615)
4
AI End: 10.80-11.94 [.425-.470]
Cu End: 7.01-7.75 [.276-.305]
32.54
[1 9/32]
25.4
[1]
68010
58422-1
69066
1752787-1
1752877-1
277164-[ ]
21.90
(42,420)
4
8.80
(16,983)
8
AI End: 7.01-7.75 [.276-.305]
Cu End: 5.33-6.48 [.210-.255]
25.40
[1]
17.45
[11/16]
68008-1
277165-[ ]
21.90
(42,420)
4
22.00
(42,615)
4
AI End: 7.01-7.75 [.276-.305]
Cu End: 7.01-7.75 [.276-.305]
25.40
[1]
17.45
[11/16]
68008-1
277168-[ ]
87.20
(168,872)
3/0
53.90
(104,500)
1/0
AI End: 13.21-16.38 [.520-.645]
Cu End: 10.92-12.97 [.430-.495]
34.93
[1 3/8]
25.40
[1]
59877-1
58422-1
1752787-1
Table 2 (Cont’d)
Terminal (RT)
Butt
Splice (BS)
Wire
Die
Assy
Crimping
Head
Single
Hole
Double
Hole
Aluminum
Copper
Insulation
Range
Strip Length
B (Wire)
mm2
(CMA)†
AWG
mm2
(CMA)†
AWG
696866-[ ]
696804-[ ]
696852-[ ]
8.60
(16,564)
8
4.80
(9,354)
10
5.59-6.30
[.220-.248]
11.11
[7/16]
68006
58422-1
69066
1752787-1
1752877-1
696869-[ ]
696887-[ ]
696951-[ ]
696953-[ ]
696999-[ ]
696847-[ ]
14.60
(28,280)
6
8.80
(16,983)
8
6.60-7.39
[.260-.291]
12.70
[1/2]
68007
696872-[ ]
696834-[ ]
696854-[ ]
2333792-[ ]
21.90
(42,420)
4
13.80
(26,818)
6
8.23-9.04
[.324-.356]
15.88
[5/8]
68008-1
696838-[ ]
696890-[ ]
696857-[ ]
35.00
(67,872)
2
22.00
(42,615)
4
9.65-10.59
[.380-.417]
19.10
[3/4]
68009
696875-[ ]
696830-[ ]
696957-[ ]
696959-[ ]
696843-[ ]
55.50
(107,464)
1/0
34.30
(66,500)
2
11.10-13.03
[.437-.513]
20.57
[.810]
68010
1958110-1●
---
---
---
---
11.10-12.37
[.437-.487]
696878-[ ]
696819-[ ]●
696840-[ ]
696861-[ ]
71.30
(138,168)
2/0
53.90
(104,500)
1/0
12.70-14.58
[.500-.574]
25.40
[1]
314964-1▲
69066,
1752877-1
68011-1
58422-1
1752787-1
696881-[ ]
696821-[ ]●
696825-[ ]
696961-[ ]
696963-[ ]
696863-[ ]
87.20
(168,872)
3/0
68.60
(133,000)
2/0
13.21-16.08
[.520-.633]
25.40
[1]
59877-1
696884-[ ]
696823-[ ]●
1958035-[ ]
696893-[ ]
696849-[ ]
110.94
(214,928)
4/0
85.94
(166,500)
3/0
15.62-17.35
[.615-.683]
25.40
[1]
314948-1
Table 2 (Cont’d)
408-2281
Rev CS
5 of 12
Terminal (RT)
Wire
Die
Assy
Crimping
Head
Single
Hole
Double
Hole
Bent
Aluminum
Copper
Insulation
Range
Strip Length
B (Wire)
±1.59 [1/16]
mm2
(CMA)†
AWG
mm2
(CMA)†
AWG
2297683-[ ]
---
---
35.00
(67.872)
2
22.00
(42,615)
4
8.64 – 9.70
[.340 - .382]
19.05
[3/4]
2844065-1
2844065-2
58422-1
1752787-1
2332961-[ ]
---
2297684-[ ] 30°
2844065-2
2331833-[ ]
2331835-[ ]
---
---
55.50
(107,464)
1/0
34.30
(66,500)
2
10.79 – 11.94
(.425 - .470)
20.57
[.810]
2844430-1
2300538-[ ]
2300882-[ ]
2844430-1
2844430-2
1958058-[ ]
1958080-[ ]
---
71.30
(138,168)
2/0
---
---
12.70-14.58
[.500-.574]
25.40
[1]
1976441-1
2217855-1
---
---
1958060-[ ] 15°
2290515-[ ] 30°
---
---
1976441-1
---
---
2221881-[ ] 30°
---
---
1976441-1
2280034-1
1958091-[ ]
---
1958093-[ ] 15°
87.20
(168,872)
3/0
---
---
13.21-16.08
[.520-.633]
1976442-1
---
2300872-[ ]
---
68.60
(133,000)
2/0
1976442-1
2844425-2
2332930-[ ]
2332962-[ ]
---
---
1976442-1
1958054-[ ]
1958078-[ ]
---
110.94
(214,928)
4/0
---
---
14.99-17.35
[.590-.683]
1976443-1
2280035-1
2312838-[ ]
---
1958056-[ ] 15°
2290514-[ ] 30°
---
---
1976443-1
---
---
2221742-[ ] 30°
---
---
1976443-1
2217781-1
---
2300884-[ ]
---
---
---
107.23
(211,678)
4/0
14.99-17.27
[.590-.680]
25.40
[1]
1976443-1
2280035-1
Table 2 (Cont’d)
Flag Terminal
Wire
Die
Assy
Crimping
Head
Straight
90° Bend
Aluminum
Copper
Insulation Range
Strip Length B (Wire)
±1.59 [1/16]
mm2 (CMA)†
AWG
mm2 (CMA)†
AWG
696931-[ ]
696933-[ ]
55.50
(107,464)
1/0
34.30
(66,500)
2
11.18-13.03
[.440-.513]
25.40
[1]
68010-2
58422-1
69066
1752787-1
1752877-1
696925-[ ]
55982-[ ]
696927-[ ]
71.30
(138,168)
2/0
53.90
(104,500)
1/0
12.45-14.58
[.490-.574]
20.57
[.810]
68011-1
58422-1
1752787-1
696910-[ ]
696912-[ ]
110.94
(214,928)
4/0
85.94
(166,500)
3/0
15.21-17.35
[.599-.683]
25.40
[1]
314948-1
†For Reference Only ●Break-Away Terminal Die Assembly with Straighteners ▲Low Pressure Crimp Die Set
Table 2 (End)
The preferred method is:
1. Before each crimp, apply a spray dry lubricant to the crimping area of the dies to reduce sticking of the terminal in the dies.
2. Insert the properly stripped wire fully into the wire barrel of the terminal. Ensure that there are no exposed strands.
CAUTION
DO NOT turn or twist the wire or terminal during wire insertion; otherwise, the internal screen of the terminal could turn and cut
into the wires during crimping.
3. Position the terminal in the stationary die (nest) with the back of the tongue resting against the die, with the crimping head
yoke closed and pin fully inserted.
NOTE
Make sure terminal is positioned so crimper of the moving die (anvil) will crimp the wire barrel of the terminal. See Figure 3.
408-2281
Rev CS
6 of 12
Figure 3
4. Holding the wire in place and fully inserted, activate the power unit to complete the crimp.
5. Remove the crimped terminal from the die assembly. When removing a terminal from the die assembly, grip it as shown in
Figure 4.
NOTE
If terminal sticks in die after crimping, apply a rocking action to free it. Wipe light oil or use spray dry lubricant on dies to
prevent sticking.
Figure 4
An alternate method is:
NOTE
This method is only slightly different than the preferred method. The difference is when the wire is inserted into the wire barrel.
1. Before each crimp, apply a spray dry lubricant to the crimping area of the dies to reduce sticking of the
terminal in the dies.
2. Position the terminal in the stationary die (nest) with back of tongue resting against die, with the
crimping head yoke closed and pin fully inserted.
NOTE
Make sure terminal is positioned so crimper of the moving die (anvil) will crimp the wire barrel of the terminal. See Figure 3.
3. Jog the power unit to advance the ram to hold the terminal in place. Make sure not to deform the wire
barrel; otherwise, it may be difficult to insert the wire into the wire barrel of the terminal.
When Removing, Grip Terminal
Between Die Assembly and
Terminal Cutout
Die Assembly
Terminal Cutout
Terminal Tongue Resting
Against Side of Die
Crimper of Moving Die
(Anvil) Positioned to Crimp
Wire Barrel of Terminal
Pin Fully Inserted
Yoke
408-2281
Rev CS
7 of 12
4. Insert the properly stripped wire fully into the wire barrel of the terminal. Ensure that there are no
exposed strands.
CAUTION
DO NOT turn or twist the wire or terminal during wire insertion; otherwise, the internal screen of the terminal could turn and cut
into the wires during crimping.
5. Holding the wire in place and fully inserted, activate the power unit to complete the crimp.
6. Remove the crimped terminal from the die assembly. When removing a terminal from the die
assembly, grip it as shown in Figure 4.
NOTE
If terminal sticks in die after crimping, apply a rocking action to free it. Wipe light oil or use spray dry lubricant on dies to
prevent sticking.
4.2. Splice
IMPORTANT: To ensure a quality crimp, gage the die assembly at the beginning of a run, after changing a die
assembly — and then periodically during the run. Refer to Paragraph 6.2 for gaging instructions.
The preferred method is:
1. Before each crimp, apply a spray dry lubricant to the crimping area of the dies to reduce sticking of the splice in the dies.
2. Insert the properly stripped wire fully into the wire barrel of the splice. When crimping a splice with a color-coded band, insert
the correct copper wires into the color-coded banded end of the splice. Ensure that there are no exposed strands.
CAUTION
DO NOT turn or twist the wire or splice during wire insertion; otherwise, the internal screen of the splice could turn and cut into
the wires during crimping.
3. Position the splice in the stationary die (nest) so that edge of the die is within the width of the circumferential crimp alignment
mark of the splice. The asterisk alignment mark on the splice must be inside the die, facing up, and in alignment with the
alignment dot of the die. See Figure 5.
NOTE
Make sure that the splice is properly aligned in the stationary die (nest) so that the moving die (anvil) will crimp the wire barrel
of the splice.
4. Holding the wire in place, activate the power unit to complete the first wire barrel crimp.
5. When the first wire barrel crimp is completed, remove the crimping head pin, open the yoke, and remove the splice.
6. To crimp the other wire barrel of the splice, rotate the splice or crimping head 180 degrees, and position the splice in the die
so that the asterisk alignment mark on the splice is inside the die, facing up, and in alignment with alignment dot of the die.
See Figure 5. Follow the same steps used to crimp the first wire barrel (Steps 1 through 5).
An alternate method is:
NOTE
This method is only slightly different than the preferred method. The difference is when the wire is inserted into the wire barrel.
1. Before each crimp, apply a spray dry lubricant to the crimping area of the dies to reduce sticking of the splice in the dies.
2. Position the splice in the stationary die (nest) so that edge of the die is within the width of the circumferential crimp alignment
mark of the splice. The asterisk alignment mark on the splice must be inside the die, facing up, and in alignment with the
alignment dot of the die. See Figure 5.
408-2281
Rev CS
8 of 12
Figure 5
3. Jog the power unit to advance the ram to hold the splice in place. Make sure not to deform the wire barrel; otherwise, it may
be difficult to insert the wire into the wire barrel of the splice.
4. Insert the properly stripped wire fully into wire barrel of the splice. When crimping a splice with a color-coded band, insert the
correct copper wires into the color-coded banded end of the splice. Ensure that there are no exposed strands.
CAUTION
DO NOT turn or twist the wire or splice during wire insertion; otherwise, the internal screen of the splice could turn and cut into
the wires during crimping.
5. Holding the wire in place, activate the power unit to complete the other wire barrel crimp.
6. When the wire barrel crimp is completed, remove the crimping head pin, open yoke, and remove the splice.
7. To crimp the other wire barrel of the splice, rotate the splice or crimping head 180 degrees, and position the splice in the die
so that the asterisk alignment mark on the splice is inside the die, facing up, and in alignment with alignment dot of the die.
See Figure 5. Follow the same steps used to crimp the first wire barrel (Steps 1 through 5).
5. CRIMP INSPECTION
Refer to Application Specification 114-2134 for detailed criteria to check that crimp is applied properly.
The crimp inspection mark (created by the die assembly) on the terminal or splice can be used as a visual
indicator of an acceptable termination, but it does not indicate that the crimp is not acceptable. If the crimp
inspection mark is centered in the crimp area and is evenly and distinctly formed, the crimp is considered
properly applied; however, if it is not:
— refer to Table 2 to verify that the proper terminal or splice and die combination according to the wire
size was used,
— verify that the dies fully bottom during the crimp cycle, and
— ensure that the die assembly is dimensionally correct as specified in paragraph 6.2
Edge of Anvil (Moving Die)
within Width of Circumference
Crimp Alignment Knurl of Splice
Die Alignment Dot
Asterisk Alignment
Mark of Splice
Wire
Pin
Circumferential Crimp
Alignment Knurl of Splice
Anvil (Moving Die)
Die Alignment Dot
408-2281
Rev CS
9 of 12
6. MAINTENANCE AND INSPECTION
Each die assembly is inspected before shipment. It is recommended that the die assembly be inspected
immediately upon arrival at your facility to ensure that it conforms to the gage dimensions provided in Figure 7
and that it has not been damaged during shipment.
Keep the dies together as a complete set (assembly). DO NOT mix dies from different die assemblies or the
same die assemblies. Die part numbers for each die assembly are listed in Figure 6.
DANGER
To avoid personal injury, ALWAYS DISCONNECT electrical and air supply to power unit before performing adjustments,
inspections, or repairs.
Item
Die Assembly
59877-1
68006
68007
68008
68008-1
68009
68010
68010-1
68010-2
68011-1
1
312309-9
312309-1
312309-2
312309-3
1-312309-4
312309-4
1-312309-0
312309-5
1-312309-1
312309-7
2
307465-9
307465-1
307465-2
307465-3
1-307465-3
307465-4
307465-5
1-307465-0
307465-5
307465-7
Item
Die Assembly
314948-1
314964-1▲
1976441-1
1976442-1
1976443-1
2217855-1
2280034-1
2280035-1
2217781-1
1
314951-1
314965-1
1-312309-2
1-312309-3
314951-2
2-312309-7
2-312309-7
314951-4
314951-4
2
307465-9
307465-7
1-307465-1
1-307465-2
1-307465-2
2-307465-8
2-307465-8
2-307465-7
2-307465-7
Item
Die Assembly
2844065-1
2844065-2
2844425-2
2844430-1
2844430-2
Future
1
2-312309-8
2-312309-8
3-312309-0
2-312309-9
2-312309-9
2
2-307465-9
2-307465-9
2-307465-7
3-307465-0
3-307465-0
▲Low Pressure Crimp Die Set
Figure 6
6.1. Daily Maintenance
Each operator must be made aware of - and responsible for - the following steps of daily maintenance:
1. Remove dust, dirt, and other contaminants with a clean brush or a soft, lint-free cloth. DO NOT use
objects that could damage the dies.
2. Make certain the dies are protected with a thin coat of any good SAE 20 motor oil. DO NOT OIL
EXCESSIVELY.
3. When the dies are not in use, mate them and store in a clean dry area.
97.0 [3.80]
Ref
Nest (Stationary Die)
(1 Per Die Assembly)
Anvil (Moving Die)
(1 Per Die Assembly)
Weight: 255 g [9 oz.]
44.50 [1.75] Ref
408-2281
Rev CS
10 of 12
6.2. Gaging the Die Assembly
NOTE
It is highly recommended to gage the die assembly at the beginning of a run, after changing a die assembly - and then
periodically during the run.
Inspect the wire barrel section and insulation sealing section of the crimping chamber using plug gages that
conform to the measurements provided in Figure 7 as follows:
NOTE
Gages can be purchased from Pennoyer-Dodge Company, 6650 San Fernando Road, Glendale, CA 91201
1. Mate the dies until it is evident they have bottomed. Hold the dies in this position.
2. Align the GO element of the plug gage with the crimping chamber. Push the element straight into the
crimping chamber as shown in Figure 8. The GO element must pass completely through the crimping
chamber.
3. Align the NO-GO element with the crimping chamber and try to insert it straight into the crimping
chamber. The NO-GO element may start to enter, but must not pass completely through, as shown in
Figure 8.
If the crimping chamber conforms to the gage inspection, the die assembly is considered dimensionally correct.
If not, the die assembly must be replaced.
6.3. 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 personnel responsible for the dies. Although
recommendations call for at least one inspection per month, the inspection frequency should be based on the
amount of use, ambient working conditions, operator training and skill, and established company standards.
This inspection should be performed as follows:
1. Remove all lubrication and accumulated film by immersing the die assembly in a suitable commercial
degreaser that will not affect the painted alignment dots.
2. Inspect the crimp area for flattened, chipped, cracked, worn, or broken areas. If damage is evident,
the die assembly must be replaced.
7. REPLACEMENT AND REPAIR
Order die assemblies through your TE 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)
TE CONNECTIVITY CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
Die assemblies may be returned for evaluation and repair. For repair service, call 1-800-526-5136.
408-2281
Rev CS
11 of 12
Die
Assy
Gage Element
C
(Exposed
Length)
W
Tip
Width
(max)
Wire Barrel Section
Insulation Sealing Section
GO
NO-GO
R (Radius)
(max)
GO
NO-GO
R (Radius)
(max)
59877-1
7.518-7.526
[.2960-.2963]
7.769-7.772
[.3059-.3060]
7.62 [.300]
16.205-16.213
[.6380-.6383]
16.609-16.612
[.6539-.6540]
8.08 [.318]
9.91
[.390]
16.15
[.636]
68006
2.870-2.877
[.1130-.1133]
3.045-3.048
[.1199-.1200]
3.18 [.125]
6.248-6.256
[.2460-.2463]
6.652-6.655
[.2619-.2620]
3.10 [.122]
6.35
[.250]
6.20
[.244]
68007
3.200-3.208
[.1260-.1263]
3.375-3.378
[.1329-.1330]
3.556
[.140]
7.518-7.526
[.2960-.2963]
7.922-7.925
[.3119-.3120]
3.73 [.147]
6.35
[.250]
7.47
[.294]
68008
68008-1
3.937-3.945
[.1550-.1553]
4.112-4.115
[.1619-.1620]
4.34 [.171]
9.195-9.202
[.3620-.3623]
9.599-9.601
[.3779-.3780]
4.57 [.180]
6.35
[.250]
9.14
[.360]
68009
5.003-5.011
[.1970-.1973]
5.179-5.181
[.2039-.2040]
5.54 [.218]
11.379-11.387
[.4480-.4483]
11.783-11.786
[.4639-.4640]
5.66 [.223]
9.91
[.390]
11.33
[.446]
2844065-1
2844065-2
5.003-5.011
[.1970-.1973]
5.179-5.181
[.2039-.2040]
5.54 [.218]
11.379-11.387
[.4480-.4483]
11.783-11.786
[.4639-.4640]
5.66 [.223]
9.91
[.390]
11.33
[.446]
68010
68010-1
6.197-6.205
[.2440-.2443]
6.372-6.375
[.2509-.2510]
6.73 [.265]
13.818-13.825
[.5440-.5443]
14.221-14.224
[.5599-.5600]
6.88 [.271]
9.91
[.390]
13.77
[.542]
68010-2
6.579-6.586
[.2590-.2593]
6.754-6.756
[.2659-.2660]
6.73 [.265]
13.818-13.825
[.5440-.5443]
14.221-14.224
[.5599-.5600]
6.88 [.271]
9.91
[.390]
13.77
[.542]
68011-1
7.924-7.932
[.3120-.3123]
8.100-8.102
[.3189-.3190]
7.52 [.296]
15.037-15.044
[.5920-.5923]
15.441-15.443
[.6079-.6080]
7.49 [.295]
9.91
[.390]
14.99
[.590]
314948-1
9.550-9.558
[.3760-.3763]
9.802-9.804
[.3859-.3860]
8.13 [.320]
16.205-16.213
[.6380-.6383]
16.609-16.612
[.6539-.6540]
8.08 [.318]
9.91
[.390]
16.15
[.636]
314964-1▲
10.922-10.930
[.4300-.4303]
11.097-11.100
[.4369-.4370]
7.52 [.296]
15.037-15.044
[.5920-.5923]
15.441-15.443
[.6079-.6080]
7.49 [.295]
9.91
[.390]
14.99
[.590]
1976441-1
7.924-7.932
[.3120-.3123]
8.100-8.102
[.3189-.3190]
7.52 [.296]
15.037-15.044
[.5920-.5923]
15.441-15.443
[.6079-.6080]
7.49 [.295]
9.91
[.390]
14.99
[.590]
1976442-1
7.518-7.526
[.2960-.2963]
7.769-7.772
[.3059-.3060]
7.62 [.300]
16.205-16.213
[.6380-.6383]
16.609-16.612
[.6539-.6540]
8.08 [.318]
9.91
[.390]
16.15
[.636]
1976443-1
9.550-9.558
[.3760-.3763]
9.802-9.804
[.3859-.3860]
8.13 [.320]
16.205-16.213
[.6380-.6383]
16.609-16.612
[.6539-.6540]
8.08 [.318]
9.91
[.390]
16.15
[.636]
2217855-1
7.924-7.932
[.3120-.3123]
8.100-8.102
[.3189-.3190]
7.52 [.296]
15.037-15.044
[.5920-.5923]
15.441-15.443
[.6079-.6080]
7.49 [.295]
9.91
[.390]
14.99
[.590]
2217781-1
9.550-9.558
[.3760-.3763]
9.802-9.804
[.3859-.3860]
8.13 [.320]
16.205-16.213
[.6380-.6383]
16.609-16.612
[.6539-.6540]
8.08 [.318]
9.91
[.390]
16.15
[.636]
2280034-1
7.924-7.932
[.3120-.3123]
8.100-8.102
[.3189-.3190]
7.52 [.296]
15.037-15.044
[.5920-.5923]
15.441-15.443
[.6079-.6080]
7.49 [.295]
9.91
[.390]
14.99
[.590]
Figure 7 (Cont’d)
408-2281
Rev CS
12 of 12
Die
Assy
Gage Element
C
(Exposed Length)
W
Tip Width
(max)
Wire Barrel Section
Insulation Sealing Section
GO
NO-GO
R (Radius)
(max)
GO
NO-GO
R (Radius)
(max)
2280035-1
9.550-9.558
[.3760-.3763]
9.802-9.804
[.3859-.3860]
8.13
[.320]
16.205-16.213
[.6380-.6383]
16.609-16.612
[.6539-.6540]
8.08
[.318]
9.91
[.390]
16.15
[.636]
2844425-2
7.518-7.526
[.2960-.2963]
7.769-7.772
[.3059-.3060]
7.62
[.300]
16.205-16.213
[.6380-.6383]
16.609-16.612
[.6539-.6540]
8.08
[.318]
9.91
[.390]
16.15
[.636]
2844430-[ ]
6.197-6.205
[.2440-.2443]
6.372-6.375
[.2509-.2510]
6.73
[.265]
13.818-13.825
[.5440-.5443]
14.221-14.224
[.5599-.5600]
6.88
[.271]
9.91
[.390]
13.77
[.542]
▲Low Pressure Crimp Die Set
Figure 7 (End)
Figure 8
8. REVISION SUMMARY
Revisions to this instruction sheet include:
Table 2 (277 Series), added 90º Bent Terminal PN 1958119-[ ] to the 68008-1 Die Assembly.
Table 2 (277 Series), added 45º Bent Terminal PN 1958195-[ ] to the 68010 Die Assembly.
Table 2 (Transitional Butt Splices), added Terminal PN 277165-[ ] to the 68008-1 Die Assembly.
Table 2 (Nickel Plated), added Single Hole Terminal PN 2331835-[ ] to the 2844430-1 Die Assembly.
