1 of 7 ? 2014 te connectivity family of companies all rights reserved *trademark te connectivity, te connectivity (logo), and te (logo) are trademarks. other logos, product, and/or company names may be tra demarks of their respective owners. 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 ser vice, visit our website at www.te.com. instruction sheet 408 - 2423 08 apr 14 rev b figure 1 1. introduction the crimping dies listed on this instruction sheet are recommended for crimping the pidg and plasti - grip tape - mounted terminals and splices indicated in figure 2. the pidg terminals and splices are used on stranded copper wire, and the plasti - grip terminals and splices are used with solid or stranded copper wire. the dies are designed to be used in amp - tapetronic* machine 69875. refer to customer manual 409 - 1993 , pa ckaged with the machine, for information concerning die installation, crimp adjustments, crimping procedures, and general operation of the machine. this instruction sheet covers die selection, crimping instructions, and die maintenance and inspection proce dures. read these instructions thoroughly before crimping any terminals or splices. note measurements are in millimeters [followed by inch equivalents in brackets]. figures and illustrations are for identification only and are not drawn to scale. reasons for reissue are provided in section 7, revision summary. 2. description (f igure 1) each die assembly features two stationary dies (anvils) and two moving dies (crimpers), a saddle, and attaching hardware. one pair of dies (one anvil and one crimper) forms a c rimping chamber for the terminal or splice wire barrel, and the other pair of dies crimps the insulation barrel. each half of the die assembly is secured in the machine by a captive screw. the dies are color coded according to wire size for easy identifica tion. when the terminal or splice is properly crimped in the correct dies, one or two dots (depending on wire size) will appear on the top and bottom of the terminal or splice. application and maintenance for crimping die assemblies for tape - mounted pidg* and plasti - grip* terminals and splices moving die wire barrel crimper color code dot insulation crimper wire barrel anvil stationary die die holding screw saddle screw saddle insulation anvil color code dot die holding screw original instructions
408 - 2423 rev b 2 of 7 product wire size range (awg ) wire strip length, mm [in.] insulation color code dot code (number of dots) die assembly part number terminal splice min max min max pidg and plasti - grip terminals and splices (except 12 - 10 pidg window splice 26 - 22 3.97 [5/32] 4.76 [3/16] 4.37 [11/64] 5.16 [13/64] yellow 1 69877 26 - 24 5.16 [13/64] 5.95 [15/64] 6.35 [1/4] 7.14 [9/32] yellow 1 69872, 68208 - 1 lg exp 24 - 20 4.76 [3/16] 5.56 [7/32] 5.56 [7/32] 6.35 [1/4] white 2 69878 22 - 16 5.16 [13/64] 5.95 [15/64] 6.35 [1/4] 7.14 [9/32] red 1 69872, 68208 - 1 lg exp 16 - 14 20 - 16 hd 5.16 [13/64] 5.95 [15/64] 6.35 [1/4] 9.53 [3/8] blue 2 69873, 68207 - 1 lg exp 12 - 10 7.94 [5/16] 8.73 [11/32] 8.73 [11/32] 9.53 [3/8] yellow 1 69874 16 - 14 hd 7.94 [5/16] 8.73 [11/32] 8.73 [11/32] 9.53 [3/8] yellow with black stripe 1 69874 12 - 10 7.94 [5/16] 8.73 [11/32] 8.73 [11/32] 9.53 [3/8] yellow 1 69897 lg exp 16 - 14 hd 7.94 [5/16] 8.73 [11/32] 8.73 [11/32] 9.53 [3/8] yellow with black stripe 1 69897 lg exp 8 8.33 [21/64] 9.13 [23/64] 9.13 [ 23/64] 9.53 [3/8] red 1 68116 - 1 ? ? long tongue plasti - grip terminals only. figure 2 (part 1 of 2) plasti - grip butt splice pidg butt splice plasti - grip terminal pidg ter minal pidg faston receptacle color stripe on radiation resistant col or stripe on 16 - 14 hd and radiation resistant col or stripe on 16 - 14 hd crimp dot code crimp dot code
408 - 2423 rev b 3 of 7 product wire size range (awg ) wire strip length, mm [in.] insulation color code dot code (number of dots) die assembly part number terminal splice min max min max pdig radiation resistant terminals and splices 24 - 20 4.76 [3/16] 5.56 [7/32] 5.56 [7/32] 6.35 [1/4] natural with white stripe 2 69878 22 - 16 5.16 [13/64] 5.95 [15/64] 6.35 [1/4] 7.14 [9/32] natural with red stripe 1 69872 16 - 14 5.16 [13/64] 5.95 [15/64] 6.35 [1/4] 7.14 [9/32] natural with blue stripe 2 69873 12 - 10 7.94 [5/16] 8.73 [11/32] 6.35 [1/4] 7.14 [9/32] natural with yellow stripe 1 69874 16 - 14 hd 7.94 [5/16] 8.73 [11/32] 6.35 [1/4] 7.14 [9/32] natural with black stripe 1 69874 pidg strato - therm* terminals 26 - 24 3.97 [5/32] 4.76 [3/16] 6.35 [1/4] 7.14 [9/32] black 1 69935 22 - 20 4.76 [3/16] 5.56 [7/32] 6.35 [1/4] 7.14 [9/32] green 2 69936 18 - 16 5.16 [13/64] 5.95 [15/64] 6.35 [1/4] 7.14 [9/32] orange 1 69937 14 5.16 [13/64] 5.95 [15/64 ] 6.35 [1/4] 7.14 [9/32] white 2 69938 pidg faston* receptacles 641321 - 2 (.187 series) and 641324 - 2 (.110 series) 26 - 24 4.76 [3/16] 5.56 [7/32] 6.35 [1/4] 7.14 [9/32] yellow 1 69877 - 2 figure 2 (part 2 of 2) plasti - grip butt splice pidg butt splice plasti - grip terminal pidg terminal pidg faston receptacle color stripe on radiation resistant color stripe on 16 - 14 hd and radiation resistant color stripe on 16 - 14 hd crimp dot code crimp dot code
408 - 2423 rev b 4 of 7 3. die selection and installation refer to figure 2 and select a compatible die assembly for the terminal or splice, based on the wire size being used. refer to the customer manual supplied with the machine for information concerning installation of dies in the machine. when i nstalling die assembly 68116 - 1 in machine 69875, the terminal extractor/finger guard assembly and the clear plastic applicator guard must be moved out from the machine as follows: 1. remove the terminal extractor/finger guard assembly holding screw. 2. reinstall the extractor/finger assembly using the holding screw (part no. 25064 - 1) and six washers (part no. 21055 - 7) provided with the die assembly. 3. remove the clear plastic applicator (side) guard. 4. reinstall the guard using the two (lower) holding screws (part no. 2 - 21002 - 2) and two spacers (part no. 4 - 25272 - 6) provided with the die assembly. 4. crimping procedure 1. load the terminal or splice tape into the machine. refer to the customer manual for tape loading instructions. 2. strip the wire to the dimension specifie d in figure 2. do not cut or nick the wire. note depending on your wire stripping machine adjustment capabilities, the wire strip length may be increased to the nearest 0.79 mm [1/32 in.] if necessary. 3. insert the prepared wire into the terminal or splice until the wire is bottomed. danger keep hands clear of dies during the crimping procedure . 4. hold the wire in position and activate the machine to crimp the terminal or splice. 5. inspect the crimped product for a proper termination. 5. maintenance/inspecti on 5.1. da ily maintenance it is recommended that a maintenance and inspection program be performed periodically to ensure dependable and uniform terminations. frequency of inspection depends on: 1. the care, amount of use, and handling of the dies. 2. the presence of abno rmal 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 dama ge 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 6.
408 - 2423 rev b 5 of 7 5.2. 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. 5.3. periodic inspection regular inspections should be performed by quality control personnel. a record of scheduled inspec tions should remain with the dies and/or be supplied to supervisory personnel responsible for the dies. though recommendations call for at least one inspection a month, the inspection frequency should be based on the amount of use, ambient working conditio ns, operator raining and skill, and established company standards. the inspections should be performed in the following sequence: visual inspection 1. remove accumulated dirt, grease, and foreign matter by immersing the dies in a suitable commercial degreaser that will not affect paint or plastic material. 2. make sure all die holding components are in place. refer to the parts list in figure 4 if replacements are necessary. 3. check all bearing surfaces for wear. remove and replace worn components. 4. inspect the crim p sections for flattened, chipped, cracked, worn, or broken areas. if damage is evident, the dies must be repaired before returning them to service. see section 6, replacement and repair, for information on obtaining customer repair service. gaging the wir e barrel crimping chamber this inspection requires the use of a plug gage conforming to the dimensions shown in figure 3. to gage the crimping chamber, refer to figure 3, and proceed as follows: 1. remove traces of oil or dirt from the crimping chamber and pl ug gage. 2. mate the dies until it is evident that they have bottomed. 3. 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. 4. check the crim ping chamber with the no - go element in the same manner as step 3. the no - go element may start entry, but must not pass completely through the crimping chamber . if the dies conform to the gage inspection, they are considered dimensionally correct. if not correct, refer to section 6, replacement and repair, for information on obtaining customer repair service. for additional information regarding the use of a plug gage, refer to instruction sheet 408 - 7424 . 6. replacement and repa ir the parts listed in figure 4 are customer - replaceable parts. a complete inventory can be stocked and controlled to prevent lost time when replacement of parts is necessary. order replacement parts through your 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) tyco electronics corporation po box 3608 harrisburg pa 17105 - 3608 dies may also be returned for evaluation and repair. for die repair servi ce, contact a te connectivity representative at 1 - 800 - 526 - 5136.
408 - 2423 rev b 6 of 7 die assembly number gage dimension go diameter no - go diameter 68116 - 1 5.105 [.2010] 5.258 [.2070] 68207 - 1 3.023 [.1190] 3.175 [.1250] 68208 - 1 2.769 [.1090] 2.921 [.1150] 69872 2.769 [.1090] 2.921 [.1150] 69873 3.023 [.1190] 3.175 [.1250] 69874 4.293 [.1690] 4.445 [.1750] 69877 1.600 [.0630] 1.753 [.0690] 69877 - 2 1.600 [.0630] 1.753 [.0690] 69878 2.261 [.0890] 2.413 [.0950] 69897 4.293 [.1690] 4.445 [.1750] 69935 2.311 [.0910] 2.388 [.0940] 69936 2.667 [.1050] 2.743 [.1080] 69937 3.327 [.1310] 3.404 [.1340] 69938 3.835 [.1510] 3.912 [.1540] figure 3 7. revision summary ? updated document to corporate requirements ? changed part number in insul indenter column in figure 4 go dia no - go dia crimping chamber insulation barrel crimper no - go element go element wire barrel crimper
408 - 2423 rev b 7 of 7 replacement parts (quantity is one per die assembly, except for item 8, quantity for item 8 is two.) die assy no. special screw saddle screw saddle special screw insul indenter curved washer insul anvil rtng ring indenter anvil 1 2 3 4 5 6 7 8 9 10 68116 - 1? 1 - 59781 - 4 3 - 59577 - 8 1 - 307275 - 7 2 - 59781 - 5 307913 - 1 24088 - 8 308916 - 1 1 - 21046 - 3 307914 - 1 307915 - 1 68207 - 1 2 - 59781 - 4 1 - 59577 - 5 1 - 307275 - 0 2 - 59781 - 6 307276 - 1 24088 - 8 1 - 59619 - 2 1 - 21046 - 3 59779 - 3 59623 - 5 68208 - 1 2 - 59781 - 4 2 - 59577 - 9 307275 - 9 59781 - 6 307285 - 2 24088 - 8 1 - 59619 - 8 1 - 21046 - 3 59779 - 2 59623 - 6 69872 3 - 59781 - 4 2 - 59577 - 9 307275 - 9 59781 - 6 307285 - 1 24088 - 8 1 - 59619 - 7 1 - 21046 - 3 59779 - 2 59623 - 6 69873 2 - 59781 - 4 2 - 59577 - 9 307275 - 9 59781 - 6 307285 - 2 24088 - 8 1 - 59619 - 8 1 - 21046 - 3 59779 - 3 59623 - 5 69874 59781 - 1 2 - 59577 - 8 1 - 307275 - 0 59781 - 5 307276 - 1 24088 - 8 1 - 59619 - 2 1 - 21046 - 3 310454 - 1 59623 - 4 69877 59781 - 4 2 - 59577 - 7 307275 - 9 59781 - 7 307285 - 3 24088 - 8 1 - 59619 - 5 1 - 21046 - 3 59782 - 2 2 - 59615 - 0 69877 - 2 59781 - 4 2 - 59577 - 7 307275 - 9 59781 - 7 307285 - 3 24088 - 8 1 - 59619 - 5 1 - 21046 - 3 59782 - 2 2 - 59615 - 0 69878 59781 - 3 3 - 59577 - 0 1 - 307275 - 1 59781 - 8 307285 - 4 24088 - 8 1 - 59619 - 4 1 - 21046 - 3 59782 - 8 3 - 59615 - 0 69897 59781 - 1 2 - 59577 - 8 1 - 307275 - 0 59781 - 5 307276 - 2 24088 - 8 904765 - 1 1 - 21046 - 3 310454 - 1 59623 - 4 69935 1 - 59781 - 7 2 - 59577 - 7 1 - 307275 - 5 1 - 59781 - 8 310676 - 3 24088 - 8 310667 - 2 1 - 21046 - 3 310674 - 2 310675 - 2 69936 59781 - 2 2 - 59577 - 9 307275 - 9 59781 - 6 310676 - 4 24088 - 8 310667 - 3 1 - 21046 - 3 310674 - 3 310675 - 3 69937 2 - 59781 - 0 2 - 59577 - 9 1 - 307275 - 6 59781 - 6 310676 - 5 24088 - 8 310667 - 4 1 - 21046 - 3 310674 - 4 310675 - 4 69938 2 - 59781 - 0 2 - 59577 - 9 1 - 307275 - 6 59781 - 6 310676 - 1 24088 - 8 310667 - 1 1 - 21046 - 3 310674 - 1 310675 - 1 ? refer to section 3 for hardware to adapt guards. figure 4 57.53 [2.265] (ref) 15.85 [.624] (ref) 25.4 [1.00] (ref) 1 2 3 4 5 6 7 8 9 10
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