Tyco Electronics PIDG Series User manual

Instruction Sheet

Premium RBY Die Set and Locator

Assembly for PIDG* and PLAS I-GRIP* 408-10256

LOC B

of 4

2008 Tyco Electronics Corporation, Harrisburg, PA

All International ights eserved

TE logo and Tyco Electronics are trademarks.

*Trademark. Other products, logos, and company names used are the property of their respective owners.

TOOLING ASSISTANCE CENTE 1-800-722-1111

P ODUCT INFO MATION 1-800-522-6752 This controlled document is subject to change.

For latest revision and egional Customer Service,

visit our website at

www.tycoelectronics.com

27 OCT 08 ev A

Red / Blue / Yellow erminals

PROPER USE GUIDELINES

CumulativeTraumaDisorderscanresult fromtheprolongeduseofmanuallypoweredhand tools.Handtoolsareintendedforoccasional useandlowvolume

applications. A wide selection of powered application equipment for extended-use, production operations is available.

Die Assembly 2063030-1

( eplaceable Item)

Hand Tool Frame Assembly

9-1478240-0 ( ef)

ERMINAL/S RIP LENG H INFORMA ION

PRODUC WIRE SIZE INSULA ION INSULA ION S RIP LENG H

LINE RANGE, AWG DIAME ER (MAX.) COLOR MINIMUM MAXIMUM

PIDG or

22-16 3.56 [.140] ed 5.15 [.203] 5.95 [.234]

PIDG or

PLASTI-G IP

Til

16-14 4.32 [.170] Blue 5.15 [.203] 5.95 [.234]

Terminals 12-10 6.35 [.250] Yellow 7.94 [.312] 8.73 [.344]

PIDG FASTON* 22-18 Flag 3.56 [.140] ed 8.33 [.328] 9.14 [.360]

Terminals 16-14 Flag 4.32 [.170] Blue 8.33 [.328] 9.14 [.360]

Figure 1

1. IN RODUC ION

This instruction sheet provides application and

maintenance procedures for the Premium RBY Die

Set and Locator Assembly 2063030–1 for PIDG and

PLASTI–GRIP Red / Blue / Yellow Terminals. See

Figure 1.

The die set is designed to crimp PIDG and

PLASTI–GRIP terminals onto pre–stripped wire.

Read these instructions thoroughly before crimping

any terminals.

All dimensions are in millimeters [with inches in

brackets]. Figures and illustrations are for

reference only and are not drawn to scale.

NO E

408-10256

Premium RBY Die Set an Locator Assembly

Rev

of 4 Tyco Electronics Corporation

Figure 2

Typical PIDG

Type Terminal

Insulation

Stripped Wire

Enters From

Back of Tool

Front of Tool

Back of Tool

Yellow

Red

Blue

Wire Crimper

Insulation Crimper

Die Set

2063030-1

Locator

Assembly

Ed e of Terminal

Insulation Ali ned

with Locator

Flat Side of

Terminal

2. DESCRIPTION

(Fi ure 1)

The die set is a replaceable die assembly with three

crimping areas which are marked with the letters R,B,

and Y. The letter corresponds to the insulation color of

the terminal (Red, Blue, or Yellow) to be crimped in

the crimping area. This die set can be used in the

tools listed in Figure 4. Refer to the instructions

packaged with the tools for die installation/removal

and tool operation procedures.

3. CRIMPING PROCEDURE

(Fi ure 2)

1. Strip wire to proper length. See Figure 1.

2. Choose desired terminal and match insulation

color to crimping area letter.

3. Place terminal in the appropriate crimping

chamber between the locator assembly and the

upper die. Make sure that the flat side of the

terminal faces up. See Figure 2.

4. Terminal should be positioned in tool so that

wire enters from the BACK of the tool.

5. Close tool handles until terminal is held in dies

without deforming wire barrel.

6. Place stripped wire in terminal wire barrel and

squeeze handles until ratchet releases.

Damaged terminals may not be used. If a

terminal has been damaged during termination,

it must be cut from the wire and replaced with a

new one.

4. MAINTENANCE AND INSPECTION

4.1. Daily Maintenance

It is recommended that operators of the die set be

made aware of, and responsible for, the following

steps of daily maintenance:

1. Remove dust, moisture, and any other

contaminants from the die with a clean, soft brush,

or a clean, soft, lint–free cloth. Do NOT use hard or

abrasive objects that could damage the die.

2. Make certain that the retaining pins are in place

and that they are secured with retaining rings.

3. All pins, pivot points, and bearing surfaces

should be protected with a thin coat of any good

SAE 20 motor oil. Do not oil excessively.

4. When the tool is not in use, keep handles closed

to prevent objects from becoming lodged in the

crimping jaws. Store the tool in a clean, dry area.

CAUTION

408-10256

Premium RBY Die Set and Locator Assem ly

of 4Rev

Tyco Electronics Corporation

4.2. Periodic Inspection

Regular inspections of the die should be performed by

quality control personnel. A record of scheduled

inspections should remain with the die or be supplied

to supervisory personnel responsible for the die.

Inspection frequency should be based upon amount

of use, working conditions, operator training and skill,

and established company standards.

4.3. Visual Inspection

1. Remove all lubrication and accumulated film by

immersing the tool (handles partially closed) in a

suitable commercial degreaser that will not affect

paint or plastic material.

2. Make certain that all retaining pins are in place

and secured with retaining rings.

3. Close tool handles until ratchet releases and

then allow them to open freely. If they do not open

quickly and fully, the spring is defective and must

be replaced. Refer to the instructions packaged

with the tool.

4. Inspect the tool frame for wear or damage,

paying particular attention to the tool jaws and

pivot points. If damage is evident, refer to the

instructions packaged with the tool for replacement

of parts. If tool is acceptable, lubricate and return

to service.

5. Check the crimping dies occasionally to make

sure dies are not broken or chipped. If damage is

evident, refer to Paragraph 6, PARTS

REPLACEMENT.

5. MEASURING DIE OPENING

The die assembly will perform correctly as long as:

The product specified is correct for the

application.

The specific die assembly is used.

The die assembly has been measured to

ensure that the openings are correct.

The tool has been adjusted correctly.

Figure 3 provides information on die opening sizes.

Figure 3

4.37 +0.08

[.172 +.003] 2.84 +0.08

[.112 +.003]

3.10 +0.08

[.122 +.003]

6. PARTS REPLACEMENT

Customer–replaceable parts are shown in Figure 1. If

the dies are damaged or worn excessively, they must

be replaced. Order the replaceable parts through your

Tyco Electronics Representative, or call

1–800–526–5142, or send a facsimile of your

purchase order to 1–717–986–7605, or write to:

CUSTOMER SERVICE (38–35)

TYCO ELECTRONICS CORPORATION

P.O. BOX 3608

HARRISBURG, PA 17105–3608

For tool repair service, please contact a

representative at 1–800–526–5136.

7. REVISION SUMMARY

Initial release of document

408-10256

Premium RBY Die Set and Locator Assembl

Rev

of 4 Tyco Electronics Corporation

Figure 4

Pro-Crimper Hand Tool 354940-1

(Instru tion Sheet 408-9930) SDE PEW-12 Hand Tool 9-1478240-0

(Instru tion Sheet 408-8851)

SDE Ben h Terminator 1490076-2

(Customer Manual 409-10052) 626 Adapter 679304-1

(Instru tion Sheet 408-4070)

Battery Tool (Shouldered Die) 1725837-1, -2

(Customer Manual 409-10053) Battery Tool (Pin Die) 1213890-1, -2

(Customer Manual 409-10065)

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