?2012 tyco electronics corporation, a te connectivity ltd. company all rights reserved *trademark te connectivity, te connectivit y (logo), and te (logo) are trademarks. other logos, product and/or company names may be tradem arks of their respective owners. 1 of 7 instruction sheet 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.te.com 408-1412 crimping heads for solistrand* and strato-therm* terminals 19 apr 12 rev c proper use guidelines cumulative trauma disorders can result from the prolonged use of manually powered hand tools. hand tools are intended for occas ional use and low volume applications. a wide selection of powered applicati on equipment for extended-use, production operations is avail able. 1. introduction this instruction sheet provides information on product application and installation, maintenance, and inspection procedures for: figure 1 these instructions may be used for heads not listed in figure 1 but accompanied by this instruction sheet. for unlisted heads, us the wire strip dimensions given in figure 3 for an identical size head. for information regarding general operation of the pneumatic tool, refer to instruction sheet 408-1410 (packaged with the tools). read these instructions thoroughly before using the crimping head. dimensions on this sheet are in millimeters [with inches in brackets]. figures and illustrations are for reference only and are not drawn to scale. reasons for reissue are provided in section 8, revision summary. 2. description the interchangeable crimping heads have integral jaws that close in an arc-like motion. after an operator locates the terminal between the jaws and inserts the wire, the trigger is depressed and the jaws close, crimping the terminal to the wire. the jaws remain closed until the trigger is released. crimping heads are coated with preservative to prevent rust and corrosion. wipe the preservative from heads, particularly fr om crimping surfaces. avoid personal injury. keep fingers clear of crimping jaws when activating tool. 3. installation and removal of crimping head 3.1. installation 1. disconnect tool from air supply. figure 2 do not operate tool without having head installed and lockscrew tightened. 2. remove assembly pins from mounting lugs as shown in figure 2a. 3. pull toggle arm forward and loosen lockscrew in toggle arm. do not remove lockscrew. see figure 2a. crimping heads used in... tool 69005 tool 69010 300454 38394 38923 note i danger stop open crimping jaws link a b mounting lug toggle arm toggle lever assembly pin trigger lockscrew assembly pins align links between mounting lugs of tool mounting lug ! caution original instructions
408-1412 2 of 7 rev c ?also used for high temperature and heat resi stant strato-therm terminals and splices. figure 3 4. open jaws and insert toggle lever of crimping head all the way into hole in toggle arm. 5. tighten lockscrew just enough to hold toggle lever in toggle arm. 6. move head so that links align between mounting lugs of tool. see figure 2b. 7. after head is aligned, lower it to provide access to lockscrew on toggle arm. tighten lockscrew. 8. move head back between mounting lugs and insert assembly pins. 9. connect tool to air supply (550-690kpa [85-100psi]). tool is now ready to be used. 3.2. removal 1. disconnect tool from air supply. 2. remove assembly pins and lower head until lockscrew in toggle arm is visible. 3. loosen lockscrew and pull head out of toggle arm. 4. wire stripping and crimping procedures avoid personal injury. when operating air tool, exercise caution while holdi ng terminals, splices or wire near crimping area. 1. strip wire to dimension lis ted in figure 3. do not nick or cut conductor strands. 2. insert stripped wire into wire barrel of terminal or splice, as shown in figure 4, 5, 6, or 7. 3. place terminal or splic e in crimping jaws as shown in figure 4, 5, 6, or 7. for best results, when brazed seam on splice is visible, position seam toward upper jaw. figure 4 figure 5 tool crimping head wire range wire strip length terminal (std) terminal (lg bbl) flag terminal butt splice parallel splice min max min max min max min max min max 69005 300454 22-16 4.37 [.172] 5.16 [.203] 6.35 [.250] 7.14 [.281] --- --- 6.35 [.250] 7.14 [.281] 7.95 [.313] 8.74 [.344] 16-14 --- --- 16-14 hd 12-10 6.35 [.250] 7.14 [.281] --- --- --- --- 6.35 [.250] 7.14 [.281] 7.95 [.313] 8.74 [.344] 69010 38394? 8 8.33 [.328] 8.61 [.339] --- --- --- --- 10.31 [.406] 11.09 [.437] 10.31 [.406] 11.09 [.437] 38923? 6 9.93 [.391] 10.72 [.422] --- --- --- --- 11.88 [.468] 12.7 [.50] 11.09 [.437] 11.88 [.468] danger stop wire barrel terminal do not allow wire insulation to enter terminal wire barrel end of conductor is flush with or extended slightly beyond end of wire barrel center terminal wire barrel in dies ?b? ?b? ?b? equals wire barrel butt splice wire stop do not allow wire insulation to enter wire barrel center splice wire barrel in dies end of conductor butts against splice wire drop when brazed seam on splice is visible, position seam toward upper jaw
408-1412 3 of 7 rev c figure 6 when using heads that have three (3) die closures, make certain terminal or sp lice is placed in correct closure for the wire size being used. when crimping flag terminals, make certain terminal tongue is held against flat of lower jaw until crimp is started. see figure 6. 4. hold terminal or splice in place and activate tool to complete the crimp. 5. to crimp other half of butt splice, remove it and reposition uncrimped half in crimping jaws and follow same procedure used to crimp first half of splice. if splice cannot be turned, turn tool around. 6. refer to section 5 and figure 8 for terminal or splice crimp inspection procedure. 5. crimp inspection inspect crimped terminals and splices by checking the features described in figure 8. use only the terminations that meet conditions shown in the ?accept? column. ?reject? terminations can be avoided through careful use of instructions in section 4, and by performing regular tool maintenance as instructed in section 6. 6. maintenance/inspection procedure te connectivity recommends that a maintenance/ inspection program be performed periodically to ensure dependable and uniform terminations. heads should be inspected at least once a month. figure 7 frequency of inspection may be adjusted to suit your requirements through experience. frequency of inspection depends on: 1. the care, amount of use, and handling of the head. 2. the type and size of the products crimped. 3. the degree of operator skill. 4. the presence of abnormal amounts of dust and dirt. 5. your own established standards. each crimping head is thoroughly inspected before packaging. new crimping heads should be inspected in accordance with section 6 immediately upon its arrival at your facility. flag terminal wire barrel center terminal wire barrel in dies do not allow wire insulation to enter wire barrel terminal tongue rests against flat end of conductor is flush with or extended slightly beyond end of wire barrel note i parallel splices when brazed seam on splice is visible, position seam toward upper jaw center splice in dies do not allow wire insulation to enter splice when brazed seam on splice is visible, position seam toward upper jaw do not allow wire insulation to enter splice ends of conductors are flush with or extended slightly beyond ends of splice center splice in dies
408-1412 4 of 7 rev c figure 8 wire range stamped under tongue wire range stamped here wire range stamped under tongue wire range stamped here wire range stamped here wire range stamped here parallel splice butt splice flat terminal terminal
408-1412 5 of 7 rev c 6.1. cleaning the crimping head should be immersed in degreasing compound to remove accumulated dirt, grease, and foreign matter. remove remaining degreasing compound with a clean, lint-free cloth. when degreasing compounds are not available, head may be wiped clean with a lint-free cloth. relubricate head as instructed in paragraph 6.3 before placing it back in service. 6.2. visual inspection 1. inspect the crimping head for missing pins or retaining rings. if parts are missing or defective, refer to figure 12 for customer-replaceable parts. 2. inspect the die closure surfaces for flattened, broken, or pitted conditions. although dies may gage within permissible limits, worn or damaged die closure surfaces are objectionable and can affect the quality of the crimp. examples of possible damaged die closure su rfaces are shown in figure 9. figure 9 6.3. lubrication lubricate all pins, pivot points, and bearing surfaces with any good sae 20 mo tor oil as follows: ? heads used in daily production - lubricate daily ? heads used daily (occasional) - lubricate weekly ? heads used weekly - lubricate monthly wipe excess oil from head, particularly from die closure area. oil transferred from the die closure onto certain terminations may affect the electrical characteristics of an application. 6.4. gaging the crimping chambers this inspection requires the use of a plug gage conforming to the dimensions provided in figure 10. te does not manufacture or market these gages. to gage the crimping chamber, proceed as follows: 1. disconnect air su pply and remove head from tool. 2. remove traces of oil or dirt from jaw bottoming surfaces, die closure surfaces, and plug gage elements. 3. with crimping jaws bottomed, check the wire barrel crimp die closure using the proper plug gage. hold gage in straight alignment with the die closure and carefully try to insert, without forcing, the go element. see figure 11. the go element must pass completely through the die closure. 4. try to insert the no-go element. the no-go element may enter partially, but must not pass completely through the die closure. if crimping chambers conform to gage inspection, the tool is considered dimensionally correct, and should be lubricated with a thin coal of any good sae 20 motor oil. if not, refer to section 7, replacement and repair for custom er repair service. 7. replacement and repair customer-replaceable parts are listed in figure 12. a complete inventory can be stocked and controlled to prevent lost time when replacement of parts is necessary. order replacement parts through your te representative, or call 1-800-526-5142, or send a facsimile of your pu rchase, or write to: customer service (038-035) tyco electronics corporation po box 3608 harrisburg pa 17105-3608 tools may also be returned to te for evaluation and repair. for tool repair service, contact a te representative at 1-800-526-5136. 8. revision summary revisions to this document include: ? updated document to corporate requirements ? reactivation of document ? deleted obsolete part numbers and related information throughout document flattened pitted broken
408-1412 6 of 7 rev c figure 10 figure 11 die closure configuration go dimension no-go dimension ?b? ?r? ?b? 25.4 [1.00] min typ all heads 6.35 [.250] min typ suggested plug gage design head number wire size gage element dimension ?b? radius ?r? go no-go 38394 8 2.540-2.547 [.1000-.1003] 2.690-2.692 [.1059-.1060] 3.58 [.141] 38923 6 3.149-3.157 [.1240-.1243] 3.299-3.302 [.1299-.1300] 3.96 [.156] 300454 22-16 1.168-1.176 [.0460-.0463] 1.318-1.320 [.0519-.0520] 1.57 [.062] 16-14 1.371-1.379 [.0540-.0543] 1.521-1.524 [.0599-.0600] 1.57 [.062] 16-14 hd 12-10 1.930-1.938 [.0760-.0763] 2.080-2.082 [.0819-.0820] 2.36 [.093] jaws bottomed but not under pressure ?go? element must pass completely through the die closure ?no-go? element may enter partially, but must not pass completely through the die closure
408-1412 7 of 7 rev c figure 12 detail ?a? detail ?b? 38923 38394 300454 item description qty per head head numbers and component part numbers 38923 (detail ?a?) 38394 (detail ?a?) 300454 (detail ?b?) 1 crimping jaw 1 49632 49493 313525-1 2 crimping jaw 1 49633 49492 313526-1 3 link 1 306322-7 306322-1 5-306321-2 4 link 1 306322-4 306322-4 3-306321-3 5 pin, pivot 1 38385 38385 39141 6 pin 2 38384 38384 38782 7 ring, retaining 4 300102 300102 21045-6 8 pin 1 300448 300448 38783 9 pin 2 2-23620-9 2-23620-9 38781 10 ring, retaining 6 21045-6 21045-6 21045-3 11 spacer 2 38716 38716 38779 12 ling, toggle 2 38380 38380 38039 13 lever, toggle 1 38379 38379 38043
|
