220195-1

Instruction Sheet 408-2833 Application and Maintenance for Crimping Die Assembly 220195-1 28 APR 11 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. Braid Termination Barrel Indenter Insulation Support Barrel Tab Braid Termination Anvil Tab Bent 90 ° CABLE TERMINAL PART NUMBER RG-58 226854-1 RG-59 226855-1 STYLE DIE ASSEMBLY PART NUMBER Strip With Solder Tab 220195-1 Figure 1 1. INTRODUCTION Crimping Die Assembly 220195-1 is designed to be used in THE PRO-CRIMPER* III Hand Tool Frame 354940-1 to crimp the Braid-Pic terminals shown in Figure 1. Read these instructions thoroughly before using the die assembly. For detailed information on the use and maintenance of PRO-CRIMPER III Hand Tool Frame 354940-1, refer to Instruction Sheet 408-9930, which is packaged with the tool frame. NOTE i All dimensions on this sheet are in millimeters [with inch equivalents in brackets]. Figures and illustrations are for identification only and are not drawn to scale. Reasons for reissue are provided in Section 10, REVISION SUMMARY. 2. DESCRIPTION The die assembly consists of an indenter (upper die) and an anvil (lower die). The indenter is installed in the stationary portion of the tool head and the anvil is installed in the moving portion. When closed, the die assembly forms two crimping sections. One section is an F-crimp for the braid termination barrel; the other is an O-crimp for the © 2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company All Rights Reserved *Trademark insulation support barrel. The Braid-Pic terminals designed for braid termination only have a rectangular tab which - after crimping - must be bent to a 90° angle for insertion into a pc board. (Both the center contact of the cable and the tab are then wave soldered, permanently attaching the terminal/cable assembly to the pc board.) 3. INSTALLING DIE ASSEMBLY 1. Open the tool handles and remove the two die retaining screws from the tool jaws. 2. Orient the die assembly with the hand tool as shown in Figure 2. 3. Insert the die retaining screws through the jaws and dies, and tighten the screws just enough to hold the dies in place. Do not tighten the screws completely at this time. 4. Insert a piece of paper between the dies. (The paper will help align the dies when the handles are squeezed.) 5. .Carefully close the tool handles, making sure that the anvils and crimpers align properly. Continue closing the tool handles until the ratchet in the tool frame has engaged sufficiently to hold the anvils 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 TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners. 1 of 4 LOC B 408-2833 and crimpers in place, then tighten both die retaining screws. To remove the dies, close the tool handles until the ratchet releases, then remove the two die retaining screws and slide the dies out of the tool jaws Braid Termination Barrel Figure 4 4. Place the terminal-cable assembly between the dies with the cable extending away from you, as shown in Figure 5. Figure 2 4. CABLE PREPARATION AND CRIMPING PROCEDURE 1. .Strip the cable as shown in Figure 3. 2. Select a terminal and then place the stripped cable into the braid termination section of the terminal, using a straight downward motion. Make sure that the braid seats in the "pic-type" braidtermination barrel and that the outer insulation fits into the support barrel. See Figure 4. NOTE: Not to Scale Braid Termination Section of Dies Figure 5 5. Squeeze the tool handles together until the ratchet releases, completing the crimp. Make sure the terminal-cable assembly remains in place during the process. 6. Bend the tab of the crimped terminal approximately 90° as shown in Figure 6. 7. Using the pc board layout shown in Figure 7, drill holes to accept the bent tab. 7.94 ± .79 [.312 ± .031] 101.6 [4.00] (Max) Figure 3 3. Pick up the hand tool and squeeze the handles together until the ratchet releases, allowing the crimping dies to spread apart. Then orient the tool so that the insulation crimp (O-crimp) faces you and squeeze the handles slightly to partially close the dies. Rev B 5. CRIMP HEIGHT INSPECTION Crimp height inspection is performed using a micrometer with a modified anvil commonly referred to as a crimp height comparator. Refer to Instruction Sheet 408-7424 for detailed information on obtaining and using crimp height comparators. To inspect the crimp height, proceed as follows: 1. Refer to Figure 8 and select the correct terminal for the wire being used. 2 of 4 408-2833 3. Using a crimp height comparator, measure the braid barrel crimp height as shown in Figure 8. If the crimp height conforms to that shown in the chart, the tool is considered dimensionally correct. If not, refer to Section 6, CRIMP HEIGHT ADJUSTMENT, for information on adjusting the crimp height. Crimped Braid Terminatiomn For additional information concerning the use of the crimp height comparator, refer to instruction sheet 408-7424. 6. CRIMP HEIGHT ADJUSTMENT (FIGURE 9) 1. Remove the lockscrew from the ratchet adjustment wheel. Figure 6 2. With a screwdriver, adjust the ratchet wheel from the locator side of the tool. 3. Observe the ratchet adjustment wheel. If a tighter crimp is required, rotate the adjustment wheel COUNTERCLOCKWISE to a higher-numbered setting. If a looser crimp is required, rotate the adjustment wheel CLOCKWISE to a lowernumbered setting. 4. Replace the lockscrew. 97 mm 9.038 In. [Dia] (Use No. 62 Drill] 5. Make a sample crimp and measure the crimp height. If the dimension is acceptable, replace and secure the lockscrew. If the dimension is unacceptable, continue to adjust the ratchet, and again measure a sample crimp. Figure 7 Screwdriver Position Point on Center of Barrel Opposite Seam Modified Anvil PART NUMBER DIE ASSY CRIMP HEIGHT “A” (In. [mm]) TERMINAL BRAID SECTION INSUL SPT SECTION 226854-1 3.99 to 4.11 [.157 to .162] 5.3 ± .3 [.21 (±.01)] 226855-1 4.24 to 4.37 [.167 to .172] 6.6 ± .3 [.26 (±.01)] 220195-1 Ratchet Adjusatment Wheel Lockscrew (Ref) Figure 9 Figure 8 2. Refer to Section 4, CABLE PREPARATION AND CRIMPING PROCEDURE, and crimp the terminal accordingly. Rev B 7. MAINTENANCE Ensure that the dies are clean by wiping them with a clean, soft cloth. Remove any debris with a clean, soft brush. Do not use objects that could damage the dies. When the dies are not in use, mate them and store the 3 of 4 408-2833 dies in a clean, dry area. Store the tool with the handles closed to prevent objects from becoming lodged within the jaws. Available separately, PRO-CRIMPER III Repair Kit 679221-1 includes a replacement nut and a variety of pins, rings, screws, and springs for use on the PROCRIMPER II Hand Tool Frame. 8. VISUAL INSPECTION The crimping dies should be inspected on a regular basis to ensure that they have not become worn or damaged. Inspect the crimp sections for flattened, chipped, worn, or broken areas. If damage or abnormal wear is evident, the dies must be replaced. See Section 9, REPLACEMENT. Order the repair kit and replaceable parts through your TE 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 (038-035) TYCO ELECTRONICS CORPORATION PO BOX 3608 HARRISBURG PA 17105-3608 9. REPLACEMENT Customer-replaceable parts are shown in Figure 10. If the dies are damaged or worn excessively, they must be replaced. 10. REVISION SUMMARY Since the previous release of this instruction sheet, the new company logo has been applied. PART NUMBERS DIE ASSEMBLY INDENTER ANVIL 220195-1 310646-2 310647-2 Figure 10 Rev B 4 of 4