408-2585 Datasheet, PDF (2/4 Pages) Tyco Electronics – Reasons for reissue of this instruction sheet are provided in Section 6, REVISION SUMMARY.

Crimping Die Assemblies for SOLISTRAND Terminals
408-2585
Wire Strip Length
Note: For terminal selection information,
refer to Catalog 82042.
DIE ASSEMBLY
68240-1
68241-1
68242-1
68242-2
68243-1
1338273-1 -
WIRE
SIZE RANGE
(AWG)
STRIP LENGTH
22-16
16-14
4.37-5.16
[.172-.203]
12-10
6.35-7.14
[.250-.281]
8
22-16
Figure 2
8.33-9.12
[.328-.359]
4.37-5.16
[.172-.203]
3. CRIMPING PROCEDURE
DANGER
To avoid personal injury, disconnect machine
from power sources (air and electric) when
installing dies. Before operating machine, make
certain that all guards and protective covers are
in place.
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.
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. MAINTENANCE AND INSPECTION
It is recommended that a maintenance and inspection
program be performed periodically to ensure
dependable and uniform terminations.
Crimp Inspection
ACCEPT
3
1
REJECT
Single Indent Crimp
(Wire Size 8 AWG
Only)
4
1
5
Single Indent Crimp
(Wire Size 8 AWG
Only)
1
3
4
2
Wire Size Range
Stamped Here
3
2
Wire Size Range
Stamped Here
1
Crimp not centered on wire barrel. Refer to Terminal
In/Out Adjustment" in applicable customer manual.
2
Wire size being used does not match wire range
stamped on terminal and die.
1
Crimp centered on wire barrel. Crimps may be off center
BUT NOT OFF END OF WIRE BARREL.
2
Wire size being used matches wire size range stamped
on terminal and die.
3
Wire fully inserted and insulation does not enter terminal
wire barrel.
4
Wire is flush with or extends slightly beyond end of
terminal wire barrel.
3
Wire not fully inserted or wrong strip length. Refer to
Strip Length Adjustment," Press Timing," or Wire
Adjustment (In/Out)" in applicable customer manual.
4
Nicked or missing wire conductor strands. Refer to Strip
Depth Adjustment" in applicable customer manual.
5
Excessive flash" on terminal indicates wrong dies, wire,
or terminal combination or damaged dies.
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
2 of 4
Tyco Electronics Corporation
Rev F