Instruction Sheet CrimpingDieAssemblies 408--2822 59826-1,59827-1,and59828-1 21 Mar 11 Rev B For complete instructions concerning the related applicators or machines, refer to the customer documents supplied with the respective tooling. These documents will explain further instructions relative to tooling adjustments, die installation, tape loading, maintenance, etc. Moving Read this sheet thoroughly before installing or using Dies the die assemblies. Reason for revision is provided in Section 8, REVISION SUMMARY. Color Code Dimensions in this document are in millimeters NOTE and inches . Figures and illustrations are for reference only and are not drawn to scale. i 2. DESCRIPTION These die assemblies consists of two stationary dies and two movable dies. These features allow one set of dies to crimp the wire barrel while crimping the insulation simultaneously. See Figure 1. Refer to Catalogs 82004 and 82042 for complete Stationary product information and features. Dies Avoid personal injury. Always disconnect machine DANGER from power supply when performing adjustments, die installation or removal, and machine APPLICATOR MACHINED maintenance. Always keep guards and covers in DIES (DOCUMENT) (DOCUMENT) place during normal machine operation. 567200--2 1901700-- (409--10078) 3. WIREPREPARATIONANDCRIMPINSTRUCTIONS 354500-- (409--5842) 1490501-- (409--10029) Figure 2 lists the preferred wire strip lengths for 59826--1 1725900-- (409--10047) products discussed in this publication. However, 567200--3 59827--1 1725910-- (409--10027) depending on your wire stripping machine adjustment 59828--1 1725950-- (409--10047) (strip length) capabilities, wire strip length may be 1901700-- (409--10078) increased to the nearest 0.8 mm .031 in. if necessary. 122500-- (409--5852) 687658--1 356500-- (409--5878) Do not use wires with nicked or missing CAUTION conductor strands. D Other Tyco Electronic machines may be available. Contact the Tooling Assistance Center number at the bottom of this page for more information. Figure 1 Refer to the respective machine manual for crimp instructions. 1. INTRODUCTION This Instruction Sheet (IS) covers the use and care of 4. COLORANDDOTCODE Crimping Die Assemblies 59826--1, 59827--1, and 59828--1. See Figure 1. These dies are used to crimp Dies, terminals, and splices are color--coded for a the PIDG* and PLASTI--GRIP* FASTON* terminals given wire range as shown in Figure 2. Color coding and splices listed in Figure 2 which are designed to is used as a method of verifying that the correct be used in the various applicators and machines combination of die set and terminal or splice was listedinFigure1. used. E2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company TOOLING ASSISTANCE CENTER 1--800--722--1111 This controlled document is subject to change. 1 of 7 All Rights Reserved PRODUCT INFORMATION 1--800--522--6752 For latest revision and Regional Customer Service, visit our website at www.te.com TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. LOCB *Trademark. Other logos, product and/or Company names may be trademarks of their respective owners.408-2822 Typical PIDG Type Typical PLASTI-GRIP Type Terminalsand Splices Terminalsand Splices C B C B Window Indent C B C B Wire Stop Wire Stop FASTON Receptacle FASTON Receptacle B Equals Wire Barrel B Equals Wire Barrel C Equals Insulation Barrel C Equals Insulation Barrel DIE SET PRODUCT WIRE STRIP LENGTH NUMBERNUMBER IINNSSULAULATITIOONN WWIRIREE SSIIZZEE TERMINALS SPLICES PRODUCT 22 AANNDD CCOOLLOORR CCOOLLOORR mmmm AAWWGG MIN MAX MIN MAX CODE DOT CODE 5.16 5.95 6.35 7.14 0.3--1.3 PIDG and PLASTI--GRIP Terminals and Splices .203 .234 .250 .281 22--16 5982659826----11 RReedd (Red) 7.54 8.33 0.3--0.8 PIDG and PLASTI--GRIP FASTON ReceptaclesU ------ ------ .297 .328 22--18 1.3--2.0 16--14 5.16 5.95 6.35 7.14 PIDG and PLASTI--GRIP Terminals and Splices 0.5--1.3 .203 .234 .250 .281 59827--1 Blue 20--16 HD ((BBllueue)) 7.54 8.33 1.3--2.0 PIDG and PLASTI--GRIP FASTON ReceptaclesU ------ ------ .297 .328 16--14 3.0--5.0 12--10 PIDG Terminals and PLASTI--GRIP 7.94 8.73 8.73 9.53 1.3--2.0 Terminals and Splices .313 .344 .344 .375 59828--1 Yellow 16--14 HDG ((YYeellolloww)) 7.94 9.53 3.0--5.0 PIDG and PLASTI--GRIP FASTON ReceptaclesU ------ ------ .313 .375 12--10 UCrimp using foot petal control only. GYellow with black stripe product insulation color code. Figure 2 2 of 7 RevB