300454

Instruction Sheet Crimping Heads for SOLISTRAND* and STRATO-THERM* Terminals 408-1412 19 APR 12 Rev C 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. 1. INTRODUCTION This instruction sheet provides information on product application and installation, maintenance, and inspection procedures for: A Open Crimping Jaws CRIMPING HEADS USED IN... TOOL 69005 TOOL 69010 Mounting Lug Link Toggle Arm 38394 300454 38923 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. Toggle Lever Lockscrew Assembly Pin 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. NOTE i 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. Trigger B Align Links Between Mounting Lugs of Tool Assembly Pins Mounting Lug 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 from crimping surfaces. DANGER Avoid personal injury. Keep fingers clear of crimping jaws when activating tool. STOP 3. INSTALLATION AND REMOVAL OF CRIMPING HEAD 3.1. Installation 1. Disconnect tool from air supply. ©2012 Tyco Electronics Corporation, a TE Connectivity Ltd. company All Rights Reserved *Trademark Figure 2 CAUTION 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. 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 7 ORIGINAL INSTRUCTIONS PROPER USE GUIDELINES 408-1412 WIRE STRIP LENGTH TOOL CRIMPING HEAD WIRE RANGE TERMINAL (Lg Bbl) FLAG TERMINAL BUTT SPLICE PARALLEL SPLICE MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX 5.16 [.203] 6.35 [.250] 7.14 [.281] --- --- 16-14 4.37 [.172] --- --- 6.35 [.250] 7.14 [.281] 7.95 [.313] 8.74 [.344] 16-14 HD 12-10 6.35 [.250] 7.14 [.281] --- --- --- --- 6.35 [.250] 7.14 [.281] 7.95 [.313] 8.74 [.344] 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] 22-16 69005 TERMINAL (Std) 300454 69010 ‡Also used for high temperature and heat resistant 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. Terminal Wire Barrel Do Not Allow Wire Insulation to Enter Terminal Wire Barrel Center Terminal Wire Barrel in Dies End of Conductor is Flush With or Extended Slightly Beyond End of Wire Barrel Figure 4 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 DANGER STOP Avoid personal injury. When operating air tool, exercise caution while holding terminals, splices or wire near crimping area. Butt Splice “B” “B” Equals Wire Barrel “B” Wire Stop Do Not Allow Wire Insulation to Enter Wire Barrel 1. Strip wire to dimension listed in Figure 3. Do not nick or cut conductor strands. Center Splice Wire Barrel in Dies 2. Insert stripped wire into wire barrel of terminal or splice, as shown in Figure 4, 5, 6, or 7. End of Conductor Butts Against Splice Wire Drop 3. Place terminal or splice 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. Rev C When Brazed Seam on Splice is Visible, Position Seam Toward Upper Jaw Figure 5 2 of 7 408-1412 Flag Terminal Parallel Splices When Brazed Seam on Splice is Visible, Position Seam Toward Upper Jaw 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 Center Splice in Dies Do Not Allow Wire Insulation to Enter Splice Ends of Conductors are Flush With or Extended Slightly Beyond Ends of Splice Figure 6 NOTE i When using heads that have three (3) die closures, make certain terminal or splice 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 When Brazed Seam on Splice is Visible, Position Seam Toward Upper Jaw Do Not Allow Wire Insulation to Enter Splice Center Splice in Dies Figure 7 Frequency of inspection may be adjusted to suit your requirements through experience. Frequency of inspection depends on: 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. 1. The care, amount of use, and handling of the head. 6. MAINTENANCE/INSPECTION PROCEDURE 5. Your own established standards. 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. Rev C 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. 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. 3 of 7 408-1412 Terminal Wire Range Stamped Under Tongue Wire Range Stamped Under Tongue Flat Terminal Wire Range Stamped Here Wire Range Stamped Here Parallel Splice Butt Splice Wire Range Stamped Here Wire Range Stamped Here Figure 8 Rev C 4 of 7 408-1412 6.1. Cleaning 6.4. Gaging the Crimping Chambers 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. 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: 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 surfaces are shown in Figure 9. Flattened 1. DISCONNECT AIR SUPPLY 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 customer repair service. 7. REPLACEMENT AND REPAIR Pitted Broken Figure 9 6.3. Lubrication Lubricate all pins, pivot points, and bearing surfaces with any good SAE 20 motor 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. Rev C 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 purchase, 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 5 of 7 408-1412 Suggested Plug Gage Design GO Dimension “B” Die Closure Configuration NO-GO Dimension All Heads 6.35 [.250] Min Typ 25.4 [1.00] Min Typ HEAD NUMBER WIRE SIZE 38394 38923 300454 GAGE ELEMENT DIMENSION “B” “R” “B” RADIUS “R” GO NO-GO 8 2.540-2.547 [.1000-.1003] 2.690-2.692 [.1059-.1060] 3.58 [.141] 6 3.149-3.157 [.1240-.1243] 3.299-3.302 [.1299-.1300] 3.96 [.156] 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] Figure 10 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 Figure 11 Rev C 6 of 7 408-1412 Detail “B” Detail “A” 38923 38394 ITEM DESCRIPTION 300454 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 Figure 12 Rev C 7 of 7