408-2674

2 of 4

Rev A

3. With tape release lever “up”, remove holding

screws and dies.

2.3. Wire Preparation and Crimp Instructions

1. Select the correct wire strip length from Figure 1.

Do NOT use wires with nicked or missing conductor

strands.

2. Place main power switch in the ON position and

be sure tape release lever is lowered.

3. Insert stripped wire conductor into terminal wire

barrel until it butts against the stop, see Figure 3.

4. Depress and release foot switch. The machine

will cycle and crimp the terminal.

5. Remove crimped terminal.

6. Repeat steps (3) thru (5) for each terminal to be

crimped.

7. Refer to Section 3 and Figure 4 for “Crimp

Inspection” procedure.

Figure 3

3. CRIMP INSPECTION

Inspect crimped terminals by checking the features

described in Figure 4.

Use only the terminals that meet the conditions shown

in the “ACCEPT” column. “REJECT” terminals can be

avoided through careful use of instructions provided in

the machine manual and by performing regular die

maintenance as instructed in Section 4.

Figure 4

4. MAINTENANCE / INSPECTION PROCEDURE

TE Connectivity recommends that a maintenance and

inspection program be performed periodically to

ensure dependable and uniform terminations. Dies

should be inspected at least once a month. Frequency

of inspection may be adjusted to suit your

requirements through experience. Frequency of

inspection is dependent upon:

Terminal Wire Barrel

Wire Conductor Butts

Against Stop

Stationary Die

1 Crimp centered on wire barrel. Crimp may be slightly

off center BUT NOT OFF END OF WIRE BARREL.

AWG wire size being used matches wire size stamped

under terminal tongue and on dies.

Wire insulation does not enter wire barrel.

Wire conductor is flush with or extends beyond end of

terminal wire barrel.

2

3

4

Crimped off end of terminal wire barrel. Refer to

409-2586 for crimp location adjustment.

AWG wire size being used does not match wire size

stamped under terminal tongue or on dies.

Wire conductor not inserted far enough in terminal. End

of conductor must be flush with or extend beyond end

of terminal wire barrel.

Wire insulation entered wire barrel of terminal. CHECK

FOR INCORRECT STRIP LENGTH.

Excessive “flash” on crimped wire barrel indicates

wrong wire, terminal, or die combination was used or

damaged dies.

Nicked or missing conductor strands.

1

2

3

4

5

6