408- 9177

Die Assemblies 47378- 1, 48756- 1, and 48757- 1

Rev C

2

of 5

Tyco Electronics Corporation

dies and the terminal wire barrel rests against the

locator. SeeFigure3.

5. Insert the stripped wire into the terminal wire

barrel. The end of the wire must be flush with, or

extend beyond, the edge of the wire barrel.

Wire Strip Length

18.64--20.24

[.734--.797]

AB

AB

“A” Equals Insulation

Barrel

“B” Equals Wire

Barrel

PLASTI-GRIP Terminal

AMPLI-BOND Terminal

Note:

Do Not Scale

from Illustration

WIRE

DIE ASSEMBLY

COLOR

SIZE

(AWG)

INSUL DIA

(Max)

PART

NO.

TYPE

COLOR

CODE

1/0

16.05 [.632] 48756--1 Standard Expansion

Blue

1/0

17.37 [.684] 47378--1

Large Expansion

Blue

2/0

17.37 [.684] 48757--1 Standard Expansion

Yellow

Figure 2

6. Close the crimping head yoke and insert the

latch pin.

To avoid damage to the yoke, latch pin, or die

assembly, make sure that the latch pin is fully

inserted.

7. Hold terminal in position and activate power unit

to complete the crimp. Open the crimping head

yoke and remove the crimped terminal from the

dies.

If the terminal sticks in the dies after crimping,

use a rocking motion on the terminal to release it

from the die.

8. Check the termination to ensure the terminal

retains a grip on the wire. If an adjustment to the

insulation crimp is necessary, refer to Section 4,

INSULATION CRIMP ADJUSTMENT. Refer to

Figure 4 for a properly crimped terminal.

4. INSULATION CRIMP ADJUSTMENT

The insulation barrel crimping dies have three

positions: 1—Tight; 2—Medium; and 3—Loose.

1. Loosen the socket head cap screws on the

stationary die, then push the pin--key all the way in

for the loose position.

2. Hold the stationary insulation crimping die

against the pin--key to prevent the pin--key from

popping back out. Tighten the socket head cap

screws. Similarly, adjust the moving insulation

crimping die.

Always adjust both pin--keys in the same

position.

3. Crimp a terminal to the wire, as described in

Section 3, CRIMPING PROCEDURE.

4. Remove the terminal from the crimping dies and

bend the wire back and forth once. The terminal

should retain its grip or support on the wire. If the

insulation crimp does not grip or support the wire

insulation, position the pin--keys in the next tighter

position and repeat the crimping procedure.

AMPLI--BOND terminals contain a wire insulation

“grip” and PLASTI--GRIP terminals contain a wire

insulation “support.”

5. Repeat Steps 1 through 4 until the desired

insulation grip, or support, is obtained. DO NOT

use a tighter setting than is required.

5. MAINTENANCE AND INSPECTION

Tyco Electronics recommends that a maintenance

and inspection program be performed periodically to

ensure dependable and uniform terminations. The die

assembly should be inspected once a month.

Frequency of inspection should be adjusted to suit

your requirements through experience.

Figure 3

Moving

Die

Bottom of Terminal

Tongue Facing

Stationary Die

Terminal Barrel

Resting Against

Locator

Stationary

Die

CAUTION

!

NOTE

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NOTE

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NOTE

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