Instruction Sheet
Crimping Dies for SOLISTRAND*
Terminals and Splices
408-9786
19 OCT 11 Rev D
PROPER USE GUIDELINES
Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools. Hand tools are intended for occasional use
and low volume applications. A wide selection of powered application equipment for extended-use, production operations is available.
Crimping Dies for Head
Numbers 69065, 69067,
and Hand Tool 59973-1
Push Nest Into Yoke
Yoke
Push Indenter Into Ram
Place Screwdriver Here
to Remove Dies
Nest
Indenter
Ram Advanced
Latch Pin Removed
Hydraulic Hand Tool 59973-1
Figure 1
1. INTRODUCTION
This instruction sheet provides instruction on
application and maintenance and inspection
procedures for dies that crimp SOLISTRAND ring
tongue terminals, butt splices, and parallel splices.
These dies are used to crimp product on solid or
stranded copper wires 6.637-117.049 mm²
[13.1-231 MCM]. The dies are used in Hydraulic
Heads 69065, 69067 and Hydraulic Hand Tool
59973-1.
Read these instructions, and all applicable references,
before inserting any die assemblies and crimping any
terminals. See Figure 2.
NOTE
i
Dimensions on this document are in metric units
with [U.S. customary units in brackets}. Figures and
illustrations are for reference only and are not
drawn to scale.
Reason for revision is give in Section 7, REVISION
SUMMARY.
3. DIE INSTALLATION AND REMOVAL
Refer to Figure 2 and determine the correct die
assembly, wire size, proper product number, and
which tool head is correct to use.
DANGER AVOID PERSONAL INJURY. Exercise extreme
caution when using power unit. Avoid depressing
STOP
foot switch or trigger control when installing or
removing die assemblies.
3.1. Die Installation
1. Remove latch pin on head of crimping head and
open yoke.
2. Push nest into yoke until nest snaps into position.
3. Activate power unit to advance ram to
approximate position shown in Figure 1.
4. Push indenter in ram until indenter snaps into
position.
2. DESCRIPTION (Figure 1)
Each die assembly consists of a nest and an indenter,
ordered separately, which are retained in the crimping
head by ball plungers. The nest is positioned in the
© 2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
*Trademark
yoke of the crimping head and the indenter is
positioned in the ram of the tool, in all applications.
5. Return ram to the down position.
6. Close yoke and insert latch pin.
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
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners.
1 of 6
LOC B
408-9786
NOMINAL WIRE SIZE
mm² [CIRCULAR
MILL AREA RANGE)
TYPICAL
PRODUCT
DIES
mm²
AWG
7-8
8
6.637-10.539
[13,100-20,800]
33463
RTT♦
13-15
6
10.539-16.771
[20,800-33,100]
33466
RTT♦
21
4
16.771-26.653
[33,100-52,600]
34323
BS†
34-35
2
26.653-42.411
[52,600-83,700]
35187
PS▲
59-60
1/0
42.411-60.551
[83,700-119,500]
36946
PS▲
67-70
2/0
72.259-96.274
[150,500-190,000]
36948
PS▲
48133
80-95
3/0
96.274-117.049
[190,000-231,000]
36927
RTT♦
48134
100-125
4/0
96.274-117.049
[190,000-231,000]
36932
RTT♦
300430
RTT♦ = Ring Tongue Terminals
BS† + Butt Splice
TOOL OR
HEAD NUMBER
NEST
INDENTER
48126■
48355■
48128-1•
48127-1•
48128■
48127■
48129-1•
48127-1•
48129■
48127■
48130-1•
48127-1•
48130■
48127■
48132-1•
48131-1•
69067 (408-2454)
48132■
48131■
48133-1•
48131-1•
Hand Tool 59973-1 (4086803)
Head Number 69065
(408-2452)
48131
PS▲ = Parallel Splice
■ = also Dies for STRATO-THERM* Heat Resistant Terminals
• = Dies for Heavy Duty Terminals
Figure 2
CAUTION Ensure the latch pin is fully inserted or damage
may occur to the yoke, dies, or latch pin.
!
3.2. Die Removal
1. Remove latch pin and open yoke.
2. Insert blade of screwdriver under nest and pry
nest out of yoke.
3. Raise ram to full up position.
4. Insert blade of screwdriver under nest and pry
indenter out of ram.
used with the wire size or range stamped on the
nest and indenter.
2. Center terminal or splice in nest as shown in
Figure 4. For best results, when brazed seam on
terminal or splice is visible, position seam toward
indenter.
3. Activate power unit so that ram advances and
holds terminal or splice in place. Do NOT deform
terminal or splice wire barrel.
4. Insert stripped wire into terminal or parallel splice
until end of conductor is flush with or extended
slightly beyond end of wire barrel.
4. WIRE STRIPPING AND CRIMPING PROCEDURE
5. Insert stripped wire into butt splice until end of
conductor butts against splice wire stop.
4.1. Wire Stripping
6. Activate power unit to complete the crimp.
Strip wire to dimensions listed in Figure 3. Do NOT
nick or cut wire strands.
NOTE
DANGER AVOID PERSONAL INJURY. When operating
power unit, exercise caution while holding
STOP
terminals, splices, or wire near crimping area.
i
If the terminal sticks in the die after crimping, grasp
the wire close to the crimp and apply a rocking
motion to remove the die.
7. For butt splice, repeat steps 5 and 6 for other wire
barrel.
4.2. Crimping Procedure
1. Ensure the wire range or size stamped on the
terminal or splice corresponds with the size being
Rev D
8. Refer to Paragraph 5.1, Crimp Inspection, for
standard terminal, butt and parallel splice crimp
inspection procedure.
2 of 6
408-9786
NOMINAL WIRE
SIZE
mm²
AWG
mm²
[CIRCULAR MILL
AREA)
7-8
8
13-15
STRIP LENGTHS mm [in.]
RING TONGUE TERMINALS
BUTT SPLICES
PARALLEL SPLICES
MIN.
MAX.
MIN.
MAX.
MIN
MAX.
6.637-10.539
[13,100-20,800]
8.334 [.328]
9.128 [.359]
10.319 [.406]
11.112 [.437]
10.319 [.406]
11.112 [.437]
6
10.539-16.771
[20,800-33,100]
9.922 [.391]
13.255 [.522]
11.906 [.469]
12.700 [.500]
11.112 [.437]
11.906 [.469]
21
4
16.771-26.653
[33,100-52,600]
11.509 [.453]
12.302 [.484]
13.493 [.531]
14.288 [.563]
13.493 [.531]
14.288 [.563]
34-35
2
26.653-42.411
[52,600-83,700]
13.096 [.516]
13.890 [.547]
15.081 [.594]
15.875 [.625]
15.081 [.594]
15.875 [.625]
59-60
1/0
42.411-60.551
[83,700-119,500]
18.653 [.734]
20.240 [.797]
15.875 [.625]
17.462 [.687]
17.462 [.687]
19.050 [.750]
67-70
2/0
60.551-72.259
[119,500-150,500]
18.653 [.734]
20.240 [.797]
15.875 [.625]
17.462 [.687]
17.462 [.687]
19.050 [.750]
80-95
3/0
72.259-96.274
[150,500-190,000]
19.050 [.750]
20.637 [.812]
17.463 [.688]
19.050 [.750]
17.463 [.688]
19.050 [.750]
100-125
4/0
96.274-117.049
[190,000-231,000]
19.446 [.766]
20.637 [.812]
17.463 [.688]
10.050 [.750]
10.050 [.750]
20.637 [.812]
Figure 3
Inspection Holes of
Terminal or Butt
Splice Must Face
Either Die
Center Terminal or
Splice Wire Barrel
in Next
End of Wire Visible
Through Inspection
Hole
Ends of Wires Flush
with or
Extended Beyond
End of Barrel
Brazed Seam (Typ)
Figure 4
Rev D
3 of 6
408-9786
5. INSPECTION/MAINTENANCE
quality and reliability of the crimping die assemblies.
Customer-replaceable parts are listed in Figure 2. A
complete inventory should be stocked and controlled
to prevent lost time when replacement of parts is
necessary.
DANGER Disconnect power supply before performing
maintenance, adjustments, inspections, and
STOP
repairs.
These instructions have been approved by Design,
Production, and Quality Control Engineers to provide
documented maintenance and inspection procedures.
Through Tyco Electronics Test Laboratories and the
inspection of production assembly, the procedures
described herein have been established to ensure
5.1. Crimp Inspection (Figure 5)
NOTE
i
The accompanying procedure is included as an aid
to the tool operator ONLY. It is not intended to serve
as a quality control procedure for qualifying finished
crimps on SOLISTRAND Terminals or Splices.
Figure 5
Rev D
4 of 6
408-9786
Inspect crimped terminals or splices by checking the
features described in Figure 5. Use only terminals or
splices that meet the conditions shown in the ACCEPT
column. Terminals and splices displaying the features
shown in the REJECT column can be avoided by
careful use of these instructions and by performing the
maintenance and inspection procedures described in
Paragraphs in 5.2 and 5.3.
Pitted
Broken
5.2. Daily Maintenance
It is recommended that each operator of the dies be
made aware of, and responsible for, the following
steps of daily maintenance:
Chipped
1. Remove dust, moisture, and other contaminants
from the dies with a clean brush, or a clean, soft,
lint-free cloth. Do NOT use objects that could
damage the dies.
2. If dies are coated with oil or preservative, wipe
clean - particularly in the crimping areas - before
placing them in use.
3. When dies are not in use, make certain all
surfaces are protected with a THIN coat of any good
SAE No. 20 motor oil, and mate and 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 or be made available to
supervisory personnel responsible for the dies.
Though recommendations call for at least a monthly
inspection, the inspection frequency should be based
upon the amount of use, working conditions, operator
training and skill, and established company standards.
These inspections should be performed in the
following sequence:
A. Visual Inspection (Figure 6)
1. Remove all lubrication and accumulated film by
immersing the dies in a suitable degreaser that will
not affect paint or plastic.
1. Check all surfaces for wear. Inspect the crimp
area for flattened, chipped, cracked, worn, or
broken areas. If damage is evident, the die must be
replaced.
B. Gaging the Crimping Chamber (Figures 7 and 8)
The inspection requires the use of a plug gage
conforming to the dimensions in Figure 8. Tyco
Electronics does not manufacture or market these
gages.
Proceed as follows:
Figure 6
2. Align the GO element with the wire barrel
crimping chamber. Push the element straight into
the the crimping chamber without using force. The
GO element must pass completely through the
crimping chamber.
3. Align the NO-GO element and try to insert it
straight into the same crimping chamber. The NOGO element may start entry but must not pass
completely through. If the crimping chamber
conforms to the gage inspection, the dies are
considered dimensionally correct. If not, they must
be replaced. For additional information regarding
the use of a plug gage, refer to Instruction Sheet
408-7424.
6. REPLACEMENT PARTS
Order replacement dies 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
7. REVISION SUMMARY
Revisions to this instruction sheet include:
• Changed company name and logo
1. Mate the dies until it is evident that they have
bottomed. Hold the dies in this position.
Rev D
5 of 6
408-9786
Dies for Head Numbers 69065, 69067, and Hand Tool 59973-1
“NO-GO" Element May Enter
Partially, but Must Not Pass
Completely Through the Die
Closure
“GO" Element Must Pass
Completely Through the
Die Closure
Dies Bottomed but Not Under Pressure
Figure 7
DIES
DIE CLOSURE DIM. “A”
GAGE ELEMENT DIM. “B"
NEST
INDENTER
GO
NO-GO
GO
NO-GO
DIM.
“C"
RADIUS
“R"
48126
48355
2.54
[.1000]
2.692
[.1060]
2.54-2.548
[.1000-.1003]
2.689-2.692
[.1059-.1060]
7.92
[.312]
3.18
[.125]
48128-1
48127-1
3.911
[.1540]
4.115
[.1620]
3.911-3.919
[.1540-.1543]
4.112-4.115
[.1619-.1620]
11.09
[.437]
4.34
[.171]
48128
48127
3.911
[.1540]
4.115
[.1620]
3.911-3.919
[.1540-.1543]
4.112-4.115
[.1619-.1620]
11.09
[.437]
4.34
[.171]
48129-1
48127-1
4.699
[.1850]
4.902
[.1930]
4.699-4.706
[.1850-.1853]
4.899-4.902
[.1929-.1930]
11.09
[.437]
5.54
[.218]
48129
48127
4.699
[.1850]
4.902
[.1930]
4.699-4.706
[.1850-.1853]
4.899-4.902
[.1929-.1930]
11.09
[.437]
5.54
[.218]
48130-1
48127-1
5.410
[.2130]
5.613
[.2210]
5.410-5.418
[.2130-.2133]
5.610-5.613
[.2209-.2210]
11.09
[.437]
6.35
[.250]
48130
48127
5.410
[.2130]
5.613
[.2210]
5.410-5.418
[.2130-.2133]
5.610-5.613
[.2209-.2210]
11.09
[.437]
6.35
[.250]
48132-1
48127-1
6.172
[.2430]
6.375
[.2510]
6.172-6.179
[.2430-.2433]
6.372-6.375
[.2509-.2510]
11.09
[.437]
7.52
[.296]
48132
48131
6.172
[.2430]
6.375
[.2510]
6.172-6.179
[.2430-.2433]
6.372-6.375
[.2509-.2510]
11.09
[.437]
7.52
[.296]
48133-1
48131-1
6.959
[.2740]
7.163
[.2820]
6.959-6.967
[.2740-.2743]
7.160-7.163
[.2819-.2820]
14.27
[.562]
8.33
[.328]
48133
48131
6.959
[.274]
7.163
[.2820]
6.959-6.967
[.2740-.2743]
7.160-7.163
[.2819-.2820]
14.27
[.562]
8.33
[.328]
48134
48131
7.823
[.3080]
8.026
[.3160]
7.823-7.830
[.3080-.3083]
8.023-8.026
[.3159-.3160]
14.28
[.562]
3.525
[.375]
300430
48131
8.788
[.3460]
8.991
[.3540]
8.788-8.796
[.3460-.3463]
8.989-8.991
[.3539-.3540]
14.28
[.562]
10.693
[.421]
Figure 8
Rev D
6 of 6