Instruction Sheet

Crimping Die Assemblies

408--9177

LOC B

1

of 5

E

2009 Tyco Electronics Corporation, Harrisburg, PA

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.

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 Service,

visit our website at www.tycoelectronics.com

21 DEC 09 Rev C

47378- 1, 48756- 1, and 48757- 1

Figure 1

Color Code

Stationary

Dies

Pin--Key(s)

Socket Head

Cap Screw(s)

Wire Barrel

Crimping

Chamber

Insulation

Barrel

Crimping

Chamber

Moving

Dies

Locator

Block

Locator

1. INTRODUCTION

Tyco Electronics Crimping Die Assemblies 47378--1,

48756--1, and 48757--1 are designed to be used with

Tyco Electronics Crimping Heads. The heads are

used in Tyco Electronics electric hydraulic pumps,

foot or hand pumps, or battery--powered pumps. The

die assemblies crimp AMPLI--BOND* Terminals and

PLASTI--GRIP* Terminals onto wire sizes 1/0 or 2/0

AWG with an insulation diameter of 17.37--18.72 mm

[.684--.737 in.].

This instruction sheet describes crimping procedures,

insulation crimp adjustments, and maintenance and

inspection. For information on tool setup and

operation, refer to the instructions packaged with the

crimping head, power unit, or hydraulic pump:

8,200 PSI Tooling

408--2453

Crimping Head 69066

408--9535

Crimping Head 58422--1

409--1950

Hydraulic Power Unit 69120--1, --2

409--5860

Hydraulic Hand Pump 314979--1

10,000 PSI Tooling

408--8914

Crimping Head 1752787--1

408--8956

Crimping Head 1752877--1

409--10060

Battery--Operated Hydraulic Pump 1804111--1

409--10081

Hydraulic Power Unit 1804700--1, --2

Measurements are in millimeters [with inches in

brackets].

Reasons for reissue are provided in Section 7,

REVISION SUMMARY.

2. DESCRIPTION

The die assembly consists of two stationary dies and

twomovingdies. Themovingdies featurea

spring--loaded locator mounted on a block which aids

in positioning the terminal in the dies. Each die

contains a pin--key which is used for insulation crimp

adjustment. When mated, the dies form crimping

chambers which crimp the terminal wire barrel and

insulation barrel simultaneously. Each die is held in

the crimping head by a single setscrew. See Figure 1.

The dies are color coded to match the terminal

insulation color. Observe the embossed wire size that

appears on both sides of the wire barrel of finished

crimps to ensure that it agrees with the wire size

stamped on the terminal tongue.

3. CRIMPING PROCEDURE

To avoid personal injury, ALWAYS keep fingers

clear of crimping dies when operating the

power unit.

1. Refer to Figure 2 and select the appropriate die

assembly for the wire size and terminal being

used.

When a tight insulation support is required for

PLASTI--GRIP terminals, use the standard

expansion type die assembly.

2. Install the die assembly according to the

instructions packaged with the crimping head.

3. Strip the wire according to the dimensions

provided in Figure 2. DO NOT nick the wire

strands or use wires with nicked or missing

conductor strands.

4. With the yoke on the crimping head open, place

the terminal in the moving dies. Make sure the

bottom of the terminal tongue faces the stationary

NOTE

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DANGER

NOTE

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