408-7563 Datasheet, PDF (2/4 Pages) TE Connectivity Ltd – Reasons for reissue of this instruction sheet are provided in Section 7, REVISION SUMMARY.

408- 7563
4. PREPARATION AND CRIMPING
Install a reel of terminals on the machine and align a
terminal with the dies. Refer to customer manual
409--1993.
CAUTION
Crimp only terminals specified for the dies you
are using.
Refer to Figure 1 to verify the correct wire size and
insulation diameter for the product you intend to
crimp.
Wire Insulation Must
be Inside the
Insulation Barrel
Bellmouth
Must be
Present at
Wire Barrel
4.1. Insulation Crimp Adjustment
1. With the machine power supply disconnected
and the front guard removed, raise the tape
release lever and turn the insulation crimp
adjustment knob to position No. 4 (loose). Then
lower the tape release lever.
2. Insert an unstripped wire into the terminal, and
hand cycle the machine one full crimp cycle.
3. Remove the crimped terminal from the machine.
Bend the wire 90_ to both sides. If the wire pulls
out of the terminal, raise the release lever, turn the
adjustment to next lower number, and lower the
release lever. Then repeat steps 2 and 3 until the
crimp is properly adjusted.
NOTE
The insulation crimp should hold the wire
insulation firmly without cutting into it.
4.2. Crimping Procedures
Strip the wires to the dimension shown in Figure 1,
being careful not to cut or nick the conductor strands.
Then, proceed as follows:
1. Insert the stripped end of a wire into the aligned
terminal until the wire insulation begins to wedge
against the terminal insulation barrel, or until it is
against the end of the terminal wire barrel.
2. Hold the wire in place and actuate the machine
through a complete cycle.
NOTE
Be sure to allow the crimping dies to open fully
before removing the crimped terminal.
4.3. Crimp Inspection (Figure 2)
Visually inspect completed crimps, noting the
following:
— Ends of wire strands must be flush to, or extend
beyond, the front of the wire barrel. However, ends
may not extend far enough to interfere with
insertion of the mating tab.
— Wire insulation must be inside the insulation
barrel with no conductor showing.
Terminal May Not be
Bent or Twisted
Wire Ends Must
be Flush to or
Beyond End of
Wire Barrel
Figure 2
— A slight bellmouth must be present in the
terminal plastic insulation at the front of the wire
barrel.
— Terminal may not be bent or twisted in a way
that damages the termination or makes mating
difficult.
NOTE
For more information on product crimp
specifications, refer to application specification
114- 1002.
5. MAINTENANCE AND INSPECTION
5.1. Daily Maintenance
1. Remove dust, moisture, and other contaminants
with a clean, soft brush, or a clean, soft, lint--free
cloth. Do NOT use any objects that could damage
the dies or tool.
2. Make sure all die hardware and parts are
properly secured.
3. Coat all surfaces with a thin coat of any good
SAE 20 motor oil. Do not oil excessively.
4. When the dies are not in use, store them in a
clean, dry area.
5.2. Periodic Inspection
Regularly scheduled inspections should be conducted
and recorded by quality control personnel. It is
recommended that the inspection procedures that
follow be performed once a month; more often if your
work environment, company standards, or amount of
tool use indicates the need.
2 of 4
Rev B