Instruction Sheet
408-2585
Crimping Die Assemblies for
SOLISTRAND* Terminals
Die Assemblies
68240-1
68241-1
68242-1
68242-2
1338273-1
20 AUG 08
Rev F
Die Assembly
68243-1
Nest
Mounting
Screw
Retaining
Indenter
Ring
G
POWER UNIT
AMP-O-LECTRIC*
AMP-O-LECTRIC
AMP-O-LECTRIC
AMP-TAPETRONIC*
Model T"
Model G"
Model G"
Model K"
Machine
DIE
Terminating Machine
Terminating Unit
Terminating Machine
Terminating Machine
ASSEMBLY
458000-4
D
354501-[ ]
354500-[ ]
565435-5
69875
68250-1
(409-5853)
(409-5842)
(409-5128)
(409-1993)
(409-2586)
567200-3
567200-3
567200-2
---
---
APPLICATOR
687658-1
68240-1
68241-1
68242-1
68242-2
68243-1
1338273-1
G
D
5
5
5
5
5
5
---
5
5
5
---
5
5
5
5
5
---
5
5
---
5
5
5
5
5
5
5
-------
5
---
5
5
-----
Customer manual shown in parenthesis. Contact Tooling Assistance Center at the number at the bottom of this page for more information.
Model K" Terminating Machine 565435-5 has been superseded by Model G" Terminating Machine 354500-1 for new applications.
For existing applications, the Model K" can still be used.
Figure 1
1. INTRODUCTION
NOTE
Dimensions in this instruction sheet are in
millimeters [with inches in brackets]. Figures and
Crimping Die Assemblies listed in Figure 1 are
designed for use in the terminal applicators contained
in the power units listed. Each die assembly, when
installed in the terminal applicator, crimps
SOLISTRAND terminals onto the appropriate wire
size listed in Figure 2.
These instructions provide specific information
regarding the die assemblies and applicable
terminals. For information regarding operation of the
power unit, refer to the applicable customer manual.
i
illustrations are for reference only and are not
drawn to scale.
Reasons for reissue of this instruction sheet are
provided in Section 6, REVISION SUMMARY.
2. DESCRIPTION
Each die assembly features a nest die and indenter
die with mounting screws and retaining rings for
securing the dies to the applicator.
NOTE
The dies are coated with a preservative to
prevent rust and corrosion. Before use, wipe the
Read these instructions and any referenced
instructions thoroughly before using the dies.
i
preservative from the dies, particularly from the
crimping surfaces.
E2008 Tyco Electronics Corporation, Harrisburg, PA
TOOLING ASSISTANCE CENTER 1-800-722-1111
This controlled document is subject to change.
All International Rights Reserved
PRODUCT INFORMATION 1-800-522-6752
For latest revision and Regional Customer Service,
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
visit our website at www.tycoelectronics.com
1 of 4
LOC B
408-2585
Crimping Die Assemblies for SOLISTRAND Terminals
3. CRIMPING PROCEDURE
DANGER
To avoid personal injury, disconnect machine
from power sources (air and electric) when
Wire Strip Length
Note:
installing dies. Before operating machine, make
certain that all guards and protective covers are
For terminal selection information,
in place.
refer to Catalog 82042.
For die installation, machine setup, and machine
operation, refer to the instructions packaged with the
machine. Use the appropriate wire size and strip
length according to Figure 2.
WIRE
DIE ASSEMBLY
SIZE RANGE
(AWG)
68240-1
STRIP LENGTH
22-16
68241-1
16-14
68242-1
6.35-7.14
12 10
12-10
[.250-.281]
68242-2
68243-1
8
1338273-1 -
22-16
Inspect crimped terminals according to Figure 3. Use
only the terminals that meet the conditions shown in
the “ACCEPT” column. “REJECT” terminals can be
avoided by following the above procedures and by
performing regular die maintenance, as provided in
Section 4, MAINTENANCE AND INSPECTION.
4.37-5.16
[.172-.203]
8.33-9.12
[.328-.359]
4. MAINTENANCE AND INSPECTION
4.37-5.16
It is recommended that a maintenance and inspection
program be performed periodically to ensure
dependable and uniform terminations.
[.172-.203]
Figure 2
Crimp Inspection
ACCEPT
REJECT
4
1
3
5
Single Indent Crimp
1
(Wire Size 8 AWG
Only)
3
Single Indent Crimp
(Wire Size 8 AWG
Only)
2
4
Wire Size Range
2
1
Stamped Here
Wire Size Range
Stamped Here
1
Crimp not centered on wire barrel. Refer to Terminal
In/Out Adjustment" in applicable customer manual.
3
2
Wire size being used does not match wire range
stamped on terminal and die.
1
2
Crimp centered on wire barrel. Crimps may be off center
3
Strip Length Adjustment," Press Timing," or Wire
Wire size being used matches wire size range stamped
Adjustment (In/Out)" in applicable customer manual.
on terminal and die.
3
Wire not fully inserted or wrong strip length. Refer to
BUT NOT OFF END OF WIRE BARREL.
4
Nicked or missing wire conductor strands. Refer to Strip
Depth Adjustment" in applicable customer manual.
Wire fully inserted and insulation does not enter terminal
5
wire barrel.
Excessive flash" on terminal indicates wrong dies, wire,
or terminal combination or damaged dies.
4
Wire is flush with or extends slightly beyond end of
terminal wire barrel.
Note:
If wire insulation enters wire barrel of terminal, the wire
was inserted too far or wrong strip length was used.
Refer to Wire Adjustment (In/Out)" or Strip Length
Adjustment" in applicable customer manual.
Figure 3
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Tyco Electronics Corporation
Rev F
408-2585
Crimping Die Assemblies for SOLISTRAND Terminals
Suggested Plug Gage Design for
Insulation Barrel Section
Frequency of inspection depends on:
1. The care, amount of use, and handling of the
dies.
2. The presence of abnormal amounts of dust and
dirt.
3. The degree of operator skill.
4. Your own established standards.
The dies are inspected before being shipped;
however, it is recommended that the dies be
inspected immediately upon arrival at your facility to
ensure that no damage occurred during shipment.
Due to the precision design, it is important that no
parts of these dies be interchanged except those
replacement parts listed in Section 5.
NO-GO Dim.
GO Dim.
R"
25.4 [1.00] Min Typ
6.35 [.250] (Min) Typ
7.92 [.312] (Min) for Assembly 68243-1
Die Closure Configuration
Assemblies 68240-1, 68241-1,
Assembly 68243-1
68242-1, 68242-2, 1338273-1
(Wire Size 8 AWG Only)
4.1. Daily Maintenance
1. Remove dust, moisture, and other contaminants
with a clean brush, or a soft, lint–free cloth. Do
NOT use objects that could damage the dies.
2. When the dies are not in use, store them in a
clean, dry area.
68241-1
4.2. Periodic Inspection
1. Remove accumulated dirt, grease, and foreign
matter by immersing the dies in a suitable
commercial degreaser.
2. Inspect die crimp area for worn, cracked, or
broken surfaces. If damage is evident, refer to
Section 5, REPLACEMENT AND REPAIR, for
information on obtaining customer repair service.
(Radius)
ASSEMBLY
68240-1
68243-1
1338273-1 -
NO-GO
GO
Max
1.168-1.176
1.318-1.321
1.57
[.0460-.0463]
[.0519-.0520]
[.062]
1.372-1.379
1.521-1.524
1.98
[.0540-.0543]
[.0599-.0600]
[.078]
68242-1
68242-2
R
GAGE ELEMENT DIAMETER
DIE
1.930-1.938
2.080-2.083
2.77
[.0760-.0763]
[.0819-.0820]
[.109]
2.540-2.548
2.690-2.692
3.58
[.1000-.1003]
[.1059-.1060]
[.141]
1.295-1.303
1.445-1.447
1.57
[.0510-.0513]
[.0569-.0570]
[.062]
Inspection of Crimping Chamber
4.3. Gaging the Crimping Chamber
This inspection requires the use of a plug gage
conforming to the dimensions shown in Figure 4. To
gage the crimping chamber, refer to Figure 4, and
proceed as follows:
1. Remove traces of oil or dirt from the crimping
chamber and plug gage.
Dies Bottomed But
2. Align the GO element with the crimping
chamber. Push element straight into the chamber
without using force. The GO element must pass
completely through the crimping chamber.
Not Under Pressure
3. Check the crimping chamber with the NO–GO
element in the same manner as Step 2. The
NO–GO element may start entry, but must not
pass completely through the crimping chamber.
If dies conform to the gage inspection, they are
considered dimensionally correct. If not correct, refer
to Section 5, REPLACEMENT AND REPAIR, for
information on obtaining customer repair service.
GO element must pass
NO-GO element may enter
completely through the
partially, but must not pass
crimping chamber.
completely through the
crimping chamber.
For additional information regarding the use of a plug
gage, refer to instruction sheet 408–7424.
Rev F
Tyco Electronics Corporation
Figure 4
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408-2585
Crimping Die Assemblies for SOLISTRAND Terminals
5. REPLACEMENT AND REPAIR
Customer–replaceable parts are listed in Figure 5. A
complete inventory should be stocked and controlled
to prevent lost time when replacement of parts is
necessary. Parts other than those listed should be
replaced by Tyco Electronics to ensure quality and
reliability. Order replacement parts through your Tyco
Electronics Representative, or call 1–800–526–5142,
or send a facsimile of your purchase order to
717–986–7605, or write to:
Die Assemblies
68240-1
68241-1
68242-1
68242-2
1338273-1
CUSTOMER SERVICE (038–035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105–3608
For customer repair service, please contact a Tyco
Electronics Representative at 1–800–526–5136.
6. REVISION SUMMARY
S Updated document to corporate requirements
S Changed dimension in table in Figure 4
Die Assembly
68243-1
2
2
3
3
1
1
4
4
REPLACEMENT PARTS
ITEM
PART NUMBER FOR DIE ASSEMBLY
68240-1
68241-1
68242-1
68242-2
68243-1
1338273-1
1
1-59781-3
1-59781-3
1-59781-3
1-59781-3
2-59781-9
1-59781-3
2
308209-1
308209-2
308209-3
308209-3
308211-1
308209-7
3
1-21046-3
1-21046-3
1-21046-3
1-21046-3
1-21046-3
1-21046-3
4
308210-1
308210-2
308210-3
308210-7
308212-1
308210-8
DESCRIPTION
QTY PER
ASSEMBLY
SCREW
2
NEST
1
RING, Retaining
2
INDENTER
1
Figure 5
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Tyco Electronics Corporation
Rev
F
