Instruction Sheet
408-- 8915
17 MAR 10
Rev B
PROPER USE GUIDELINES
Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools. Hand tools are intended for occasional use and low volume
applications. A wide selection of powered application equipment for extended-- use, production operations is available.
Yoke
NOTE
i
Removable
Latch Pin
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 of this instruction sheet are
provided in Section 8, REVISION SUMMARY.
2. DESCRIPTION
Pivot Pin
Piston
(Ram)
Main components of the crimping head are: a yoke
which houses the stationary die and retains the
terminal assembly for crimping, a removable latch pin
which allows pivoting of the yoke on the pivot pin
(typically required for splice terminations), a cylinder
which contains the head’s hydraulic chamber, a piston
(ram) which holds and controls the moving die, and a
quick connect/disconnect coupler which mates with
the coupler on the hose to release or supply pressure.
DANGER
Cylinder
Male Quick--Disconnect
Coupler
Dust Cap
Figure 1
1. INTRODUCTION
This instruction sheet covers application and
maintenance procedures for Crimping Head
1752788--1 shown in Figure 1. The crimping head
accepts interchangeable die sets for a variety of
heavy--duty terminals and splices for large wire sizes
— within the range of 250 MCM through 600 MCM
(thousand circular mils). Refer to instructions
packaged with specific die sets for compatible
products, wire ranges, strip dimensions, and
application procedures.
The crimping head is designed and recommended
only for use with Foot Hydraulic Pump 1583659--1,
Hand Hydraulic Pump 1583661--1, Electric Hydraulic
Pump 1583660-- 1 (115 Vac), or 1583660--2 (230 Vac).
Read these instructions, and all applicable
references, before using the crimping head.
To avoid injury when using hydraulic crimping
equipment, observe the following precautions:
-- Do NOT modify the crimping equipment in any
way.
-- Use only dies, terminals, and wire specified for
the head.
-- Do NOT perform repairs other than those
specified in the instructional material supplied
with the equipment.
3. INSTALLATION
Each crimping head is shipped with a coating of
lubricating oil to prevent rust and corrosion. Wipe the
oil off before installing the crimping head on the power
unit. Note that the crimping head is shipped without
oil inside the cylinder. To install crimping head,
proceed as follows:
DANGER
Make sure that hydraulic pressure to the hose is
released and that power supply is disconnected
to electric power unit, if applicable.
1. Remove protective dust caps from both quick
connect/disconnect couplers.
2. Hold hose vertically to prevent oil spillage.
Attach hose to coupling section on head. Thread
properly and tighten securely.
CAUTION
!
TOOLING ASSISTANCE CENTER 1-- 800-- 722-- 1111
E2010 Tyco Electronics Corporation, Berwyn, PA
PRODUCT INFORMATION 1-- 800-- 522-- 6752
All Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products names, logos, or company names might be trademarks of their respective owners.
Oil flow must be unobstructed between power
unit and crimping head. Make sure that all
couplers are fully mated and tightened.
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com
1 of 4
LOC B
ORIGINAL INSTRUCTIONS
Hydraulic Crimping Head
1752788- 1
408-- 8915
Hydraulic Crimping Head 1752788-- 1
NOTE
i
If crimping head must be removed after being in
production, pressure must be released in the
hydraulic system before head is removed.
-- If using Electric Hydraulic Pump 1583660--[ ],
DISCONNECT POWER UNIT FROM POWER
SUPPLY.
-- If using Foot Hydraulic Pump 1583659--1,
depress pressure release pedal, or if using Hand
Hydraulic Pump 1583661--1, activate the
pressure release knob.
Moving/Lower
Die
Latch Pin
Removed
Yoke
Setscrew
Ram Setscrew
4. DIE INSERTION AND REMOVAL (Figure 2)
DANGER
Stationary/Upper
Die
Avoid personal injury. When using power unit,
exercise caution to avoid accidently depressing
foot pedal or hand control when installing or
changing dies.
Ram
Advanced
Make sure that matched die set, terminal, and wire
size are compatible. With crimping head properly
installed, refer to die set instructions, and
insert/change die set as follows:
1. Remove latch pin and open yoke on crimping
head.
2. Loosen setscrew in yoke. Refer to die set
instructions and insert stationary (upper) die which
includes the nest area into well of yoke. Tighten
setscrew.
3. Activate power unit to advance ram until
setscrew is visible (about 12.7 mm [.50 in.]).
Loosen setscrew.
4. Insert moving (lower) die, which serves as the
indenter, into ram well, making sure that moving
die is properly oriented to mate with stationary die.
Tighten setscrew.
5. Close yoke and secure with latch pin.
6. Slowly close dies to ensure proper alignment.
7. Complete the cycle and return the ram to the
DOWN position.
CAUTION
!
Always ensure that latch pin is fully inserted or
damage may occur to yoke, dies, or latch pin.
Figure 2
The following crimping procedure provides general
information. Refer to instructions packaged with
individual die sets for specific products, wire sizes,
strip dimensions, positioning of terminals and splices
in the dies, and crimping procedures.
CAUTION
!
1. Insert terminal or splice in the stationary (upper)
die according to instructions packaged with the
dies. Make sure the latch pin is secure before
activating the power unit.
2. Slowly advance moving (lower) die with short,
quick strokes until terminal or splice is secure.
3. Insert the stripped wire.
4. Cycle tool to complete crimp. Remove crimped
terminal or splice.
NOTE
i
5. CRIMPING PROCEDURE
DANGER
2 of 4
Never operate the power unit without having a
crimping head attached to the hose.
If the splice or terminal sticks in the die after
crimping, apply a rocking action to remove it from
the die.
6. MAINTENANCE AND INSPECTION
Avoid personal injury. When operating power unit,
exercise caution while holding terminals, splices,
or wire near crimping area.
DANGER
Tyco Electronics Corporation
Make sure hydraulic pressure is released and
power supply is disconnected before following
inspection and maintenance procedures, unless
otherwise specified in the procedure.
Rev B
408-- 8915
Hydraulic Crimping Head 1752788-- 1
Each crimping head is assembled and inspected
before shipment. It is recommended that the crimping
head be inspected immediately upon its arrival at your
facility, and at regularly scheduled intervals, to ensure
that the crimping head has not been damaged during
handling. Frequency of inspection depends upon the
following: care, amount of use, and handling of the
head; type and size of products crimped; degree of
operator skill; and environmental conditions.
4. If head shows evidence of galling, cracks, oil
leakage, or rough cycling, return the crimping head
for repair (refer to Section 7, REPLACEMENT
AND REPAIR).
NOTE
i
6.1. Cleaning
Remove accumulations of dirt and grease on the
crimping head, especially in areas where dies are
installed and terminals are crimped. Clean the entire
head frequently with a clean, lint--free cloth.
Once a year, or every 7,500 cycles (whichever
comes first), the hydraulic head should be
returned to Tyco Electronics for magnetic particle
inspection. Additionally, inspect and service the
head (as described in Figure 3) every month or
1,000 cycles. Refer to Instruction Sheet
408--8909.
6.3. Crimping Head Check-- Out Procedure
6.2. Visual Inspection
If the ram fails to return to the DOWN position after
completion of a crimping cycle, the cause may be in
the crimping head. To determine whether or not the
trouble is in the crimping head, proceed as follows:
Refer to Figure 3 and proceed as follows:
A. Electric Hydraulic Pumps 1583660-- [ ]
1. With hydraulic pressure released, inspect the
assembled head for nicks, scratches, and cracks.
Inspect for cracks especially at the corners of the
yoke and around the top of the cylinder.
Check These Areas for Cracks
Check Die Areas
for Damage
Press the retract/release button on the hand remote
pendant or foot remote, and hold for several seconds.
This will release any pressure in the hydraulic system.
If the ram returns to DOWN position, the trouble is
NOT in the crimping head. If ram does not return,
ensure that the coupler is fully engaged. If coupler is
engaged and ran still does not go DOWN, return the
crimping head to Tyco Electronics for repairs.
B. Foot Hydraulic Pump 1583659-- 1
Depress the pressure release pedal.
C. Hand Hydraulic Pump 1583661-- 1
Activate the pressure release knob.
7. REPLACEMENT AND REPAIR
Customer--replaceable parts are listed in Figure 4.
A complete inventory can be stocked and controlled
to prevent lost time when replacement of parts is
necessary. Order replacement parts through your
Representative, or call 1--800--526--5142, or send a
facsimile of your purchase order to 1--717--986--7605,
or write to:
Check for Excessive Wear
at Pivot Pin and Latch Pin
Figure 3
2. Inspect pivot pin holes and latch pin holes for
wear. Replace parts, as needed.
3. Activate power unit. Raise ram to UP position.
Inspect flat and round surfaces of ram for galling
(fretting or wear by friction), cracks, or oil leakage.
Release pressure and make sure that ram retracts
smoothly.
Rev B
CUSTOMER SERVICE (38--35)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105--3608
For customer repair service, call 1--800--526--5136.
8. REVISION SUMMARY
Revisions to this instruction sheet include:
S Added “Original Instructions” to page 1
Tyco Electronics Corporation
3 of 4
408-- 8915
Hydraulic Crimping Head 1752788-- 1
123.19
[4.850]
63.5
[2.50]
2
8
5
4
3
325
[12.79]
6
7
1
9
REPLACEMENT PARTS
ITEM
PART NUMBER
DESCRIPTION
QTY PER HEAD
1
311470--1
COUPLER, Quick Connect//Disconnect
1
2
306209--8
PIN, Removable Latch
1
3
8--59558--5
PIN, Pivot
1
4
1--21045--1
RING, Retaining
1
5
21061--9
SETSCREW
2
6
4--23147--7
SPRING, Compression
1
7
1--21919--6
PIN, Dowel
1
8
4--21012--0
SETSCREW
1
9
23150--3
NIPPLE, Hex
1
Figure 4
4 of 4
Tyco Electronics Corporation
Rev B
