408-10129

SDE Die Sets 1804039-1 and 1976357-1

Rev D

2 of 4

Tyco Electronics Corporation

Figure 2

Wire Stop

Metal Wire

Crimp Sleeve

Translucent Plastic

Outer Sleeve

Upper Crimp

Die

Wire

Lower Crimp

Die

Wire

Terminal

Upper Crimp

Die

Lower Crimp

Die

Terminal

Splice

5. If a splice is being crimped, repeat Steps 2 to 4

for the other crimp side of the splice.

If splice cannot be turned for crimping other half,

turn the tool around.

Damaged splices should not be used. If a

damaged splice is evident, it should be removed

and replaced with a new one. Splices should not

be reterminated.

5. CRIMP INSPECTION

Inspect crimped terminals and splices by checking to

make sure the splice has been crimped in the center

of the wire barrel.

Poor crimps can be avoided by carefully following the

procedures provided in Section 4, and by following

the tool maintenance procedures provided in your

hand tool instruction sheet.

6. DIE INSPECTION

6.1. Visual Inspection

Inspection of the crimping dies should be made on a

regular basis to ensure that they have not become

worn or damaged. Inspect the crimp sections for

flattened, chipped, worn, or broken areas. If damage

or abnormal wear is evident, the dies must be

replaced.

6.2. Measured Die Opening

The dies will perform properly as long as: (1) the

product specified is correct for the application, (2) the

specified die set is used, (3) the die set has been

measured to ensure that the openings are correct,

and (4) the dies bottoms.

7. CRIMP HEIGHT INSPECTION

This inspection requires the use of plug gages

conforming to the dimensions provided in Figure 3.

Tyco Electronics does not manufacture or market

these gages. To gage the crimping chamber, proceed

as follows:

1. Remove traces of oil or dirt from the crimping

chamber and plug gage.

2. Close the tool handles, or cycle the crimp

tooling until the dies have bottomed. Do NOT force

dies beyond initial contact.

3. Align the GO element with the crimping

chamber. Push element straight into the crimping

chamber without using force.

The GO element must pass completely through the

crimping chamber. See Figure 3.

4. Align the NO–GO element and try to insert it

straight into the same crimping chamber. The

NO–GO element may start entry, but must not

pass completely through the crimping chamber.

See Figure 3.

If the crimping chamber conforms to the gage

inspection, the dies are considered dimensionally

correct, and should be lubricated with a THIN coat of

any good SAE 20 motor oil. If not, the dies must be

returned to Tyco Electronics for further evaluation.

Refer to Section 7, REPAIR/REPLACEMENT.

For additional information regarding the use of a plug

gage, refer to Tyco Electronics Instruction Sheet

408–7424.

8. REPAIR/REPLACEMENT

If the dies do not meet the GO, NO–GO gage

dimensions provided in Figure 3, the tool and/or dies

are defective and must be replaced.

Order replacements 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:

CUSTOMER SERVICE (038–035)

TYCO ELECTRONICS CORPORATION

PO BOX 3608

HARRISBURG PA 17105–3608

NOTE

i

CAUTION

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