408-1724
Crimping Dies 48858-1 through 48861-1
3 of 6
Rev N
Tyco Electronics Corporation
2. To adjust the insulation crimp, loosen socket
head cap screws and push pin–key all the way in
so that insulation crimp section of the die is in the
loose position.
Figure 5
Stationary
Die
Wire Barrel
Crimping Section
Moving
Die
Insulation Barrel
Crimping Section
Color Code
Pin-Key
Color Code
Socket Head
Cap Screws
Socket Head
Cap Screws
Insulation Barrel
Crimping Section
Pin-Key
3. Press and hold insulation die down against the
pin–key. This will prevent the spring–loaded
pin–key from popping back.
4. Tighten socket head cap screws.
Make certain insulation crimping sections of
moving and stationary dies are both adjusted to
the same position.
5. Perform a test crimp (refer to Paragraph 3.1).
AMPLI-BOND terminals provide a grip" on wire
insulation. PLASTI-GRIP terminals provide only
a support" for the wire.
6. Remove crimped terminal from dies and visually
inspect the insulation crimp portion of terminal. The
insulation crimp should “
grip” wire insulation (when
using AMPLI–BOND terminals) or provide
“
support” for wire insulation (when using
PLASTI–GRIP terminals).
7. If the insulation crimp does not grip or support
wire insulation as described in step 6, loosen
socket head cap screws and set the pin–keys in
the medium position. Then follow Steps 3 and 4.
8. Make another test crimp over previously
crimped terminal.
Figure 6
Wire fully inserted.
1
Crimp centered on wire barrel.
2
Correct color code and die combination. (Terminal insulation
color matches color dots on dies.)
3
Wire size being used is same as wire size embossed on
terminal insulation and stamped on terminal tongue.
4
End of conductor is flush with or extends beyond end of
wire barrel of terminal.
5
Insulation barrel is in contact with wire insulation.
(AMPLI-BOND terminals have insulation grip" and
PLASTI-GRIP terminals have insulation support".)
6
Wire not fully inserted.
1
Crimp not centered on wire barrel. (Terminal was not butted
against stop plate. See Figure 4.)
2
Wrong die and terminal color code combination. See Figure 1.
3
Excessive flash or extruded insulation. (Wrong size or damaged
dies.)
4
End of conductor is not flush with or extending beyond end of
wire barrel of terminal.
5
Wire insulation pinched. (Insulation crimp too tight on
AMPLI-BOND terminals.)
6
Nicked or missing conductor strands.
7
Crimp Inspection of
AMPLI-BOND and
PLASTI-GRIP Terminals
Accept
Reject
3
1
2
4
5
4
4
6
4
7
5
1
6
3
2
NOTE
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NOTE
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