3--304052--6 [MACOM]
Reasons for reissue are provided in Section 8, REVISION SUMMARY.;
| 型号： | 3--304052--6 |
| 厂家： | 
Tyco Electronics |
| 描述： | Reasons for reissue are provided in Section 8, REVISION SUMMARY. |
| 文件： | 总9页 (文件大小：237K) |
| 中文： | 中文翻译 | 下载： | 下载PDF数据表文档文件 |
Instruction Sheet
PIDG* and PLASTI-GRIP* Terminal
and Splice Crimping Heads
408-10029
08 DEC 10 Rev B
Battery
Lock
Battery Powered
Crimp Tool
Retract Button
Crimp Head
Mounting Holes
DAHT Adapter
Assembly
Battery
Cartridge
1725839-1
Typical DAHT
Crimp Head (Ref)
Quick-Release
Pins
Figure 1
inspection. For information concerning tool setup and
operation, refer to Customer Manual 409--10056
packaged with the battery tool kit.
1. INTRODUCTION
Crimping Heads 1--46121--0, 1--47386--0, 1--47386--4,
1--47387--0, 1--47387--7, 1--525690--0, and
1--525691--0 are designed to crimp PIDG Terminals
and Splices, and PLASTI--GRIP Terminals and
Splices onto solid or stranded copper wire size 26--14
AWG. Refer to Figure 2. The crimping heads are
used with Double Action Battery Powered Hand Tool
Kits 1213804--[ ].
Dimensions are in metric units with [inches in
brackets]. Figures and illustrations are for
reference only and are not drawn to scale.
NOTE
i
Reasons for reissue are provided in Section 8,
REVISION SUMMARY.
The crimping heads can also be used with the
626 Double Action Pneumatic Tool Adapter
1213563 -1.
NOTE
2. DESCRIPTION
i
The crimping head consists of integral jaws which
close in an arc--like motion. After an operator locates
the terminal or splice between the crimping jaws and
inserts the stripped wire, the tool is activated to crimp
the terminal or splice to the wire.
This instruction sheet provides recommended
procedures for wire preparation, crimping head
installation, crimping, and maintenance and
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.tycoelectronics.com
E2010 Tyco Electronics Corporation, Berwyn, PA
1 of 9
All Rights Reserved
TE logo and Tyco Electronics are trademarks.
LOC B
*Trademark. Other product names, logos, or company names might be trademarks of their respective owners.
408-10029
PIDG Butt Splice
PIDG and PLASTI-GRIP Terminal and Splice Crimping Heads
PLASTI -GRIP
Terminal
PIDG Type
Terminal
3 Equally Spaced Stripes on
Nylon Insulation Restricting
WIRE STRIP LENGTH
TERMINALS SPLICES
WIRE SIZE
RANGE
(AWG)
TERMINAL/SPLICE
CRIMPING
HEAD
DOT
CODE
PRODUCT
INSULATION
COLOR CODE
Min.
Max.
Min.
Max.
PIDG
3.97
4.78
4.37
5.16
1--46121--0
1 Dot
1 Dot
26--22
Yellow
Red
Terminals and Splices
[.156]
[.188]
[.172]
[.203]
1--47386--0
1--47386--4
1--525690--0
22--16
(Commercial)
5.16
[.203]
5.94
[.234]
6.35
[.250]
7.14
[.281]
PIDG
Terminals and Splices
and
1--47387--0
1--47387--7
1--525691--0
PLASTI--GRIP
Terminals
5.16
[.203]
5.94
[.234]
6.35
[.250]
7.14
[.281]
2 Dots
16--14
Blue
WIRE STRIP
LENGTH
WIRE SIZE
RANGE
(AWG)
TERMINAL/SPLICE
INSULATION
COLOR CODE
CRIMPING
HEAD
DOT
CODE
INSULATION
DIAMETER RANGE
PRODUCT
Min.
Max.
0.66--1.40
Yellow with Black
Stripe
Yellow with Blue
Stripe
4.75
5.56
26
24
24
22
20
18
16
14
[.026--.055]
[.187]
[.219]
1--46121--0
1 Dot
1 Dot
0.79--1.40
[.031--.055]
0.79--1.40
[.031--.055]
Yellow with Blue
Stripe
0.97--2.79
[.038--.110]
Red with Green
Stripe
PIDG Nylon
Insulation
Restricting Terminals
1--47386--0
1--47386--4
1--525690--0
1.17--2.79
[.046--.110]
Red with Red
Stripe
6.35
[.250]
7.14
[.281]
1.42--2.79
[.056--.110]
Red with White
Stripe
1.60--3.30
[.063--.130]
Blue with Blue
Stripe
1--47387--0
1--47387--7
1--525691--0
2 Dots
1.98--3.30
[.078--.130]
Blue with Green
Stripe
NOTE: Refer to Tyco Electronics Catalog 82042 for product part numbers.
Figure 2
3. HEAD INSTALLATION AND REMOVAL
3.1. Head Selection
3.2. Installation
To avoid personal injury, be sure to exercise
extreme caution when handling the crimp tool.
Avoid accidentally depressing the trigger control
when installing or removing crimp heads.
DANGER
DANGER
The crimping heads are coded to match the terminal
and splice insulation color. Observe the embossed
dots on the insulation of finished crimps to ensure that
the correct combination of terminal or splice and head
was used. See Figure 2.
DO NOT operate the battery tool without the
proper crimping head installed. After crimping
head is installed, make sure that the quick pins
are properly inserted to avoid personal injury and
damage to the tool.
Crimping heads are coated with a preservative to
prevent rust and corrosion. Wipe this preservative
from the head, particularly from the crimping
surfaces.
NOTE
i
2 of 9
Tyco Electronics Corporation
Rev B
408-10029
PIDG and PLASTI-GRIP Terminal and Splice Crimping Heads
1. Remove quick pins from the adapter assembly.
Refer to Figure 1.
PIDG and PLASTI -GRIP Terminals
“C” “B”
“C” “B”
“C” “B”
PIDG
2. Insert crimping head into the adapter assembly.
PIDG
Nylon Insulation
Terminal
Restricting
Terminal
3. After the crimping head is properly aligned,
insert the quick pins through the two holes in the
adapter and through the holes in the crimp head.
“B” Equals Wire Barrel
“C” Equals Insulation Barrel
PLASTI -GRIP
Terminal
The quick pins will “snap” into position when they
are properly inserted.
NOTE
i
Locator
3.3. Removal
Terminal Tongue
Positioned Under
Locator
To avoid personal injury, ALWAYS disconnect the
battery from the tool before removing crimping
head.
DANGER
Remove the quick pins from the crimping head; then
remove the crimping head from the tool holder.
4. CRIMPING PROCEDURES
Wire Barrel Against Locator
To avoid personal injury, ALWAYS keep fingers
clear of crimping jaws when operating the tool.
Never place anything within the crimping jaws
except Tyco Electronics terminals or splices.
DANGER
Locator
Figure 3
4.1. Terminal Crimping Procedure
4.2. Butt Splice Crimping Procedure
1. Strip wire to dimensions shown in Figure 2. DO
NOT nick wire strand or use wires with nicked or
missing conductor strands.
1. Strip wire to dimensions shown in Figure 2. DO
NOT nick wire strand or use wires with nicked or
missing conductor strands.
2. Position splice between crimping jaws so that
the window indent slides under the locator of crimp
head. See Figure 4A.
2. Center the terminal or splice wire barrel in the
appropriate crimp chamber. See Figure 3.
3. Depress the trigger to advance the moving ram.
This closes the crimp jaws in order to hold the
terminal in place. DO NOT deform the wire barrel.
3. Depress the trigger to advance the moving ram.
This closes the crimp jaws to hold the terminal in
place. DO NOT deform the wire barrel.
4. Insert stripped wire into terminal until the end of
the conductor butts against the locator as shown in
Figure 3.
4. Insert stripped wire into wire barrel of splice until
the end of the conductor is against the splice wire
stop. See Figure 4A.
5. Activate the tool to complete the crimp. The
crimp tool automatically returns to the first position
of the cycle when the crimp is complete.
5. Activate tool to complete the crimp.
6. To crimp the other half of the butt splice,
reposition it in the crimping jaws and repeat Steps
1 through 5. If the splice cannot be turned, rotate
crimping head. See Figure 4B.
6. Refer to Section 5 and Figure 6 for crimp
inspection.
Rev B
Tyco Electronics Corporation
3 of 9
408-10029
PIDG and PLASTI-GRIP Terminal and Splice Crimping Heads
7. Refer to Section 5 and Figure 6 for crimp
inspection.
The insulation crimping section of the crimping head
has three positions: 1—Tight; 2—Medium; and
3—Loose.
4A
PIDG Butt Splice
“C” “B”
1. Insert insulation adjustment pins in Position 3.
See Figure 5.
Window
Indent
Always place both adjustment pins in the same
“B” Equals Wire Barrel
“C” Equals Insulation Barrel
NOTE
position. See Figure 5.
i
Splice Wire Stop
2. Place terminal or splice in crimping jaws, as
shown in Figures 3 and 4.
3. Insert unstripped wire only into the
insulation barrel of the terminal or splice. See
Figures 3 and 4.
Window Indent Faces
Indenter and Slides
Under Locator
(A) First Crimp
Locator
4. Crimp terminal or splice as described in
Paragraph 4.1 or 4.2.
5. Remove terminal or splice. Bend wire forward
and then backward. The terminal or splice should
retain its grip on the wire. If the wire pulls out,
reposition the insulation adjustment pins in the next
tighter position and repeat crimping procedure.
6. Repeat adjustment as necessary until desired
insulation grip is obtained. DO NOT use a tighter
setting than required.
End of Conductor
Butts Against Splice
Wire Stop
Positions
4B
(B) Second Crimp
Locator
Window Indent on
Splice Slides Under
Locator
2
2
3
1
1
3
End of Conductor
Butts Against Splice
Wire Stop
Insulation
Adjustment
Pin(s)
(Ref)
Figure 4
Figure 5
4.3. Insulation Crimp Adjustment
A. PIDG Terminals and Splices
B. PLASTI-GRIP Terminals
PIDG terminals and splices contain a wire
insulation “grip.”
PLASTI -GRIP terminals contain only a wire
insulation “support”.
NOTE
NOTE
i
i
4 of 9
Tyco Electronics Corporation
Rev B
408-10029
PIDG and PLASTI-GRIP Terminal and Splice Crimping Heads
The insulation crimping section of the crimping head
has three positions: 1—Tight; 2—Medium; and
3—Loose.
4. The presence of abnormal amounts of dust and
dirt.
5. Your own established standards.
Position 3 is for wire having a large insulation
diameter; Position 2 is for wire having a medium
insulation diameter; and Position 1 is for wire having a
small insulation diameter.
Each crimping head is thoroughly inspected before
packaging. Since there is the possibility of crimping
head damage during shipment, new crimping heads
should be inspected immediately upon arrival at your
facility.
1. Perform insulation crimp adjustment by placing
adjustment pins in Position 3 (loose), as shown in
Figure 5.
6.1. Daily Maintenance
Tyco Electronics recommends that each operator be
responsible for the following steps of daily
maintenance:
2. Crimp the terminal as described in Paragraph
4.1, Terminal Crimping Procedure.
3. Remove crimped terminal from crimping jaws
and visually inspect the insulation barrel crimp of
the terminal. The insulation barrel crimp should be
in contact with and should support the wire
insulation. If the insulation barrel crimp does not
provide “support” for wire insulation, place
adjustment pins in Position 2 (medium) and repeat
the crimp procedure.
1. Remove dust, moisture, and other contaminants
with a clean, soft brush, or a lint--free cloth. Do
NOT use objects that could damage the head.
2. Make sure that all pins, rings, and other
components are in place and secure.
To avoid personal injury and damage to the tool,
make sure quick pins are properly inserted.
DANGER
4. Repeat adjustment as necessary until desired
insulation support is obtained. DO NOT use a
tighter setting than required.
3. Make certain all surfaces are protected with a
thin coat of any good SAE 20 motor oil. Do NOT oil
excessively.
5. CRIMP INSPECTION
Inspect crimped terminals and splices by checking the
features described in Figure 6. Use only terminals or
splices that meet the conditions shown in the
“ACCEPT” column. “REJECT” terminations can be
avoided through careful use of instructions in
Section 4, and by performing regular head
4. When the head assembly is not in use, store it
in a clean dry, area.
6.2. Periodic Inspection
Regular inspections should be performed by quality
control personnel. A record of scheduled inspections
should remain with the crimping heads or be supplied
to supervisory personnel responsible for the crimping
heads. Though recommendations call for at least one
inspection a month, the frequency should be based
on amount of use, working conditions, operator
training and skill, and your established company
policies. These inspections should include a visual
inspection (Paragraph 6.3) and a crimping chamber
inspection (Paragraph 6.5).
maintenance, as described in Section 6.
6. MAINTENANCE AND INSPECTION
To avoid personal injury, ALWAYS disconnect the
battery from the tool before performing
maintenance or inspection.
DANGER
Tyco Electronics recommends that a maintenance
and inspection program be performed periodically to
ensure dependable and uniform terminations. The
crimping head should be inspected once a month.
Frequency of inspection should be adjusted to suit
your requirements through experience. Frequency of
inspection depends on:
6.3. Visual Inspection
1. Remove all lubrication and accumulated film by
immersing the crimping head in a suitable
commercial degreaser that will not affect paint or
plastic.
2. Make certain all components are in place. If
replacements are necessary, refer to Figure 9.
1. The care, amount of use, and handling of the
crimping head.
3. Check all bearing surfaces for wear.
2. The type and size of the product crimped.
3. The degree of operator skill.
4. Inspect crimp area for flattened, chipped, or
broken areas. Replace worn or damaged parts.
Rev B
Tyco Electronics Corporation
5 of 9
408-10029
PIDG and PLASTI-GRIP Terminal and Splice Crimping Heads
Crimp Inspection
8
ACCEPT
REJECT
4
4
7
5
3
8
4
5
5
3
PIDG
1
Insulation
1
Restricting
Terminals
2
6
Wire
6
2
1
2
2
Range
Stamped
Under
1
5
PIDG and
PLASTI -GRIP
Terminals
Tongue
4
7
1
3
Wire Range
Stamped
Under
5
6
Tongue
8
9
2
5
4
2
1
4
1
7
PIDG
Butt Splice
1
2
Wire
Stop
6
2
2
8
9
2
5
1
2
6
2
6
1
3
Wire Range
6
Stamped Here
3
Wire Range
7
6
Stamped Here
1
1
2
Insulation barrel is in firm contact with wire insulation.
Correct color code, dot code, and tool combination.
Wire insulation extruded. (Insulation crimp too tight on PIDG
terminals.) See Paragraph 4.3.
Wrong dot code and color code combination. See chart,
Figure 2.
Wire size is not within wire range stamped on terminal tongue
or splice.
Crimp not centered on wire barrel. (Terminal was not butted
against locator. See Figure 3.)
End of conductor is not flush with or extending beyond end of
wire barrel. (Check for correct strip length.)
Excessive flash or extruded insulation. (Wrong tool, terminal, or
splice combination used, or damaged dies.) See Figure 2.
2
3
Wire size is within wire range stamped on terminal tongue or
splice.
3
4
5
4
5
Crimp centered on wire barrel.
End of conductor is flush with, or extends beyond end of
terminal wire barrel.
End of conductor against wire stop of splice.
NOTE: If conductor is not against wire stop, conductor must
at least be flush with, or extend slightly beyond wire barrel
of splice.
6
6
7
8
9
Nicked or missing conductor strands.
7
Wire insulation does not enter wire barrel.
Wire not fully inserted or wrong strip length.
Wire insulation entered wire barrel. Check for correct wire size
or strip length.
Figure 6
6 of 9
Tyco Electronics Corporation
Rev B
408-10029
PIDG and PLASTI-GRIP Terminal and Splice Crimping Heads
6.4. Lubrication
Suggested Plug Gage Design Insulation Crimp
GO Dim. NO-GO Dim.
Lubricate all pins, pivot points, and bearing surfaces
with a high quality grease. Tyco Electronics
recommends the use of MolykoteS grease, which is a
commercially available lubricant. Lubricate according
to the following schedule:
NO
GO
GO
Jaw Closure
Configuration
6.35
3.18
[.125]
[.250]
Typ.
Head used in daily production -- lubricate daily
Head used daily (occasional) -- lubricate weekly
Head used weekly -- lubricate monthly
GAGE ELEMENT
DIAMETERS
JAW
CRIMPING
HEAD
CLOSURE
DIMENSIONS
GO
NO-GO
0.889--1.397
[.0350--.0550]
0.889--0.897
[.0350--.0353]
1.394--1.397
[.0549--.0550]
Wipe excess grease from crimping head, particularly
from jaw closure areas. Grease transferred from jaw
closure area onto certain terminations may affect the
electrical characteristics of an application.
1--525690--0
1--47386--0
0.762--1.270
1--47386--4 [.0300--.0500]
0.762--0.770
[.0300--.0303]
1.267--1.270
[.0499--.0500]
1--47387--0
1.016--1.524
1.016--1.024
[.0400--.0403]
1.521--1.524
[.0599--.0600]
1--47387--7 [.0400--.0600]
0.762--1.270
1--46121--0
0.762--0.770]
[.0300--.0303]
1.267--1.270
[.0499--.0500]
6.5. Gaging the Crimping Chamber
[.0300--.0500]
1.143--1.651
1--525691--0
1.143--1.151
[.0450--.0453]
1.648--1.651
[.0649--.0650]
This inspection requires the use of plug gages
conforming to the dimensions shown in Figure 7. Tyco
Electronics does not manufacture or market these
gages.
[.0450--.0650]
Figure 7 (end)
Disconnect the battery and remove crimping
head from tool before inspecting crimping
chambers.
DANGER
Suggested Plug Gage Design Wire Barrel Crimp
1. Remove oil and dirt from the jaw bottoming
surfaces and plug gage element surfaces.
GO Dia
NO-GO Dia
2. Close wire barrel crimping jaws until they are
bottomed, but not under pressure.
Jaw Closure
50.8 [2.0]
Min. Typ.
Configuration
3. Align GO element with wire barrel crimping
section. Push element straight into crimping
chamber without using force. The GO element
must pass completely through the chamber as
shown in Figure 8A.
GAGE ELEMENT
DIAMETERS
JAW
CRIMPING
HEAD
4. Align the NO--GO element and try to insert it
into the chamber. The element may start entry, but
it must not pass completely through the crimping
chamber.
CLOSURE
DIMENSIONS
GO
NO-GO
1--47386--0
1--47386--4
1--525690--0
2.769--2.921
[.1090--.1150]
2.769--2.776
[.1090--.1093]
2.918--2.921
[.1149--.1150]
5. Repeat this procedure for the insulation crimping
section using a plug gage as shown in Figure 8B.
1--47387--0
1--47387--7
1--525691--0
3.023--3.175
[.1190--.1250]
3.023--3.030
[.1190--.1193]
3.172--3.175
[.1249--.1250]
If the crimping chamber passes the gage inspection,
the crimping head is considered dimensionally correct
and should be lubricated with a THIN coat of any
good SAE 20 motor oil. If the crimping chamber does
not conform to the plug gage conditions, contact your
local Tyco Electronics Field Representative or refer to
Section 7, REPLACEMENT AND REPAIR.
1.600--1.752
[.0630--.0690]
1.600--1.608
[.0630--.0633]
1.750--1.752
[.0689--.0690]
1--46121--0
Figure 7 (cont’d)
For additional information about the use of a plug
gage, see Instruction Sheet 408--7424.
SMolykote is a trademark.
Rev B
Tyco Electronics Corporation
7 of 9
408-10029
PIDG and PLASTI-GRIP Terminal and Splice Crimping Heads
7. REPLACEMENT AND REPAIR
CUSTOMER SERVICE (38--35)
TYCO ELECTRONICS CORPORATION
P.O. BOX 3608
Replacement parts and recommended spares are
listed in Figure 9. The recommended spares should
be stocked for immediate replacement.
HARRISBURG, PA 17105--3608
For further repair and replacement information,
call the Tyco Electronics Tooling Assistance Center at
the number at the bottom of page 1.
Order replacement parts through your Tyco
Electronics Representative, or call 1--800--526--5142,
or send a facsimile of your purchase order to
1--717--986--7605, or write to:
8. REVISION SUMMARY
S Updated document to corporate requirements
Detail A
Inspection of Wire Barrel
Crimping Section
Detail B
Inspection of Insulation
Crimping Section
Wire Barrel Jaws
Adjustment
Pins
Pos
(Ref
Bottomed But Not
Under Pressure
Insulation Jaws Bottomed
But Not Under Pressure
GO Element Must Pass
Completely Through the
Crimping Chamber
NO -GO Element May Enter
Partially, But Must Not Pass
Through the Crimping Chamber
Figure 8
8 of 9
Tyco Electronics Corporation
Rev B
408-10029
PIDG and PLASTI-GRIP Terminal and Splice Crimping Heads
2
3
1
4
5
CUSTOMER REPLACEMENT PARTS
PART NUMBER FOR CRIMPING HEAD
QTY
PER
HEAD
1-47386-4
1-47387-7
1-525690-0
1-525691-0
ITEM
NO.
DESCRIPTION
1-47387-0
1-47386-0
1-46121-0
1
2
3
4
5
45965--6
9--305927--1
302994
302993
9--305927--1
302994
3--304052--6
3--306105--9
302994
525355--8
LOCATOR
1
1
1
1
2
9--305927--1 SCREW, 8--32 x 8.38 [.330]
302994--1
301201
39207
HOUSING, Stop
301201
301201
301201
SPRING, Compression
PIN, Adjustment
39207
39207
39207
Figure 9
Rev B
Tyco Electronics Corporation
9 of 9
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