Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools. Hand tools are intended for occasional use and low volume
applications. A wide selection of powered application equipment for extended-use, production operations is available.
NOTE
Dimensions in this instruction sheet are in
millimeters [with inches in brackets]. Figures and
Upper Die
i
illustrations are for reference only, and are not
drawn to scale.
2. DESCRIPTION
Machine Screws
(M4 x 14.0)
The 1804039–1 die set has three crimp sections and
the 1976357–1 die set has one crimp section which
are marked to identify the wire sizes used with the
products listed in the table in Figure 1. The AWG wire
sizes are 26–24, 24–22, 22–18, 16–14, and 12–10.
3. DIE INSTALLATION
Lower Die
NOTE: Die set 1976357-1 has only one crimp nest.
Refer to the specific tooling documents provided in
Figure 4 for die installation information for those tools.
Since each application tool is unique, each tool will
have their own specific instructions for die installation.
4. CRIMPING PROCEDURE
Raychem DuraSeal Terminals and Splices
Die Set
Part
Number
Type
Color
Wire Size
mm
2
Insulation
Range
Strip
Length
(AWG)
Strip the wire according to the dimensions listed in
Figure 1. The strip length is determined by the
terminal or splice and by the wire size. Do not nick or
cut the wire strands. Proceed as follows:
1. Close the tool handles until the ratchet releases.
Allow the tool handles to open fully.
Red
0.5-1.0
[22-18]
1.5-2.5
[16-14]
3.0-6.0
[12-10]
0.5-1.0
[22-18]
1.5-2.5
[16-14]
3.0-6.0
[12-10]
0.15-0.25
[26-24]
0.25-0.35
[24-22]
1.40-4.00
[.055-.160]
2.00-4.60
[.080-.181]
2.80-6.50
[.110-.255]
1.40-3.70
[.055-.146]
2.00-4.60
[.080-.181]
2.80-6.50
[.110-.255]
1.40-3.00
[.055-.118]
0.90-3.00
[.035-.118]
6.0-10.0
[.24-.39]
6.0-10.0
[.24-.39]
10.0-13.0
[.39-.51]
6.0-8.0
[.24-.31]
6.5-9.0
[.255-.355]
5.5-6.5
[.215-.255]
Terminal
Blue
Yellow
1804039-1
1804039 1
Red
2. While holding the terminal or splice in place,
squeeze the tool handles together just until the
jaws begin to close on the wire barrel. Make sure
the tool crimp jaws are centered on the crimp
sleeve wire barrel. Refer to Figure 2. Do NOT
deform the wire barrel.
3. Insert the stripped wire into the terminal or
splice making sure that the wire insulation does not
enter the wire barrel.
NOTE
Be sure the wire is stripped to the length
indicated in Figure 1.
Splice
Blue
Yellow
Yellow
1976357 1
1976357-1
Splice
Green
Figure 1
i
NOTE
For proper crimp location, make sure to position
the terminal or splice in the die set correctly. See
1. INTRODUCTION
i
Figure 2.
This instruction sheet provides information for SDE
Die Sets 1804039–1 and 1976357–1 which is
designed to crimp Raychem DuraSeal Crimp
Terminals and Splices. The die assemblies will fit into
the tools shown in Figure 4.
4. While holding the wire in place, squeeze the tool
handles together until the ratchet releases, then
allow the tool handles to open fully. Remove the
terminal or splice.
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
www.tycoelectronics.com
LOC B
E
2009 Tyco Electronics Corporation, Harrisburg, PA
TOOLING ASSISTANCE CENTER 1-800-722-1111
PRODUCT INFORMATION 1-800-522-6752
1
of 4
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
SDE Die Sets 1804039-1 and 1976357-1
Wire Stop
408-10129
Terminal
Terminal
Wire
Upper Crimp
Die
Splice
Metal Wire
Crimp Sleeve
Upper Crimp
Die
Wire
Lower Crimp
Die
Translucent Plastic
Outer Sleeve
Lower Crimp
Die
Figure 2
5. If a splice is being crimped, repeat Steps 2 to 4
for the other crimp side of the splice.
NOTE
If splice cannot be turned for crimping other half,
turn the tool around.
Tyco Electronics does not manufacture or market
these gages. To gage the crimping chamber, proceed
as follows:
1. Remove traces of oil or dirt from the crimping
chamber and plug gage.
2. Close the tool handles, or cycle the crimp
tooling until the dies have bottomed. Do NOT force
dies beyond initial contact.
3. Align the GO element with the crimping
chamber. Push element straight into the crimping
chamber without using force.
The GO element must pass completely through the
crimping chamber. See Figure 3.
4. Align the NO–GO element and try to insert it
straight into the same crimping chamber. The
NO–GO element may start entry, but must not
pass completely through the crimping chamber.
See Figure 3.
If the crimping chamber conforms to the gage
inspection, the dies are considered dimensionally
correct, and should be lubricated with a THIN coat of
any good SAE 20 motor oil. If not, the dies must be
returned to Tyco Electronics for further evaluation.
Refer to Section 7, REPAIR/REPLACEMENT.
For additional information regarding the use of a plug
gage, refer to Tyco Electronics Instruction Sheet
408–7424.
i
CAUTION
Damaged splices should not be used. If a
damaged splice is evident, it should be removed
!
and replaced with a new one. Splices should not
be reterminated.
5. CRIMP INSPECTION
Inspect crimped terminals and splices by checking to
make sure the splice has been crimped in the center
of the wire barrel.
Poor crimps can be avoided by carefully following the
procedures provided in Section 4, and by following
the tool maintenance procedures provided in your
hand tool instruction sheet.
6. DIE INSPECTION
6.1. Visual Inspection
Inspection of the crimping dies should be made on a
regular basis to ensure that they have not become
worn or damaged. Inspect the crimp sections for
flattened, chipped, worn, or broken areas. If damage
or abnormal wear is evident, the dies must be
replaced.
8. REPAIR/REPLACEMENT
If the dies do not meet the GO, NO–GO gage
dimensions provided in Figure 3, the tool and/or dies
are defective and must be replaced.
Order replacements through your Tyco Electronics
Representative, or call 1–800–526–5142, or send a
facsimile of your purchase order to 717–986–7605, or
write to:
CUSTOMER SERVICE (038–035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105–3608
6.2. Measured Die Opening
The dies will perform properly as long as: (1) the
product specified is correct for the application, (2) the
specified die set is used, (3) the die set has been
measured to ensure that the openings are correct,
and (4) the dies bottoms.
7. CRIMP HEIGHT INSPECTION
This inspection requires the use of plug gages
conforming to the dimensions provided in Figure 3.
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