304992 [MACOM]
Read these instructions and referenced documents before crimping any splices;
| 型号： | 304992 |
| 厂家： | 
Tyco Electronics |
| 描述： | Read these instructions and referenced documents before crimping any splices |
| 文件： | 总6页 (文件大小：146K) |
| 中文： | 中文翻译 | 下载： | 下载PDF数据表文档文件 |
Instruction Sheet
Die Assemblies 45218, 45221,
69303-2, and 69820
408-1634
04 JAN 10 Rev C
Insert Anvil
(Moving Die)
Dimensions on this instruction sheet are in
NOTE
millimeters [with inches in brackets]. Figures are
not drawn to scale.
i
Insert Indenter
(Stationary Die)
Reasons for reissue of this instruction sheet are
provided in Section 8, REVISION SUMMARY.
Screw
2. DESCRIPTION
Ejector
The die assembly consist of an insert indenter
(moving die) and an insert anvil (stationary die).
The stationary die is identified by the chamfered
corners. The stationary die is marked with the die
assembly part number, wire size (AWG), and splice
type. When mated, the die assembly forms one
crimping chamber. Each die is secured in the tool by
a single screw.
Locator (Except Die
Assembly 69820)
DIE ASSEMBLY
PART
SPLICE
MINIMUM OPENING
DIAMETER
MARKING
SIZE
NUMBER
3. DIE INSTALLATION
Install the die assembly onto the tool according to the
instructions supplied with the tool. If using the
pneumatic tooling assembly, follow the instructions
supplied with the applicable crimper or adapter.
18--16
45218
22--14
—
—
ECV--ECN
18--10
ECV--ECN
45221
22--10
22--16
69303--2
69820
18--16 EC
6.73 mm [.265 in.]
6.48 mm [.255 in.]
4. CRIMPING PROCEDURE
18--16 ECVG
22--16
Die Assembly 69820 requires an insulation crimp
adjustment. Before crimping any splices, refer to
Section 5 for proper adjustment.
NOTE
Figure 1
i
1. INTRODUCTION
1. Select proper wire combinations as stated in the
applicable wire combination chart specified in
Figure 2. Strip wires to length indicated in Figure 2.
Do not use wires with nicked or missing strands.
Die Assemblies 45218, 45221, 69303--2 (shown in
Figure 1), and 69820 are used with the following tools
to crimp vinyl closed--end splices and nylon
closed--end splices onto solid and stranded wire sizes
22 through 10 AWG. For specific information
concerning the tools, refer to instruction sheet
(408--series) or customer manual (409--series) listed.
If conductors are twisted together to form a tight
bundle before inserting them into the splice, the
strip length must be maintained after twisting.
NOTE
i
REFERENCE
DOCUMENT
2. Insert the splice, wire barrel first, into the ejector
of the stationary die until splice bottoms. For nylon
splices, the shoulder must rest against the ejector;
for vinyl splices, the end of the wire barrel of must
rest against the locator. Die Assembly 69820 does
not have a locator; therefore, the wire barrel must
rest against the wire barrel section of the die. See
Figure 3. Close dies until splice is held in place.
TOOL
Straight Action Hand Tool 69710--1
408--2095
626 Pneumatic Tooling Assembly
189721--1 or 189722--1
Fitted with Straight Action Crimper
217200--1 or 189721--2
409--5862
408--4195
626 Pneumatic Tooling Assembly
189722--2
Fitted with C--Head Pneumatic Adapter
318161--1
3. Insert stripped wires into splice wire barrel until
conductors bottom. See Figure 3.
409--5862
408--4190
Always keep fingers clear of dies during tool
operation.
DANGER
Read these instructions and referenced documents
before crimping any splices.
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, Harrisburg, PA
All International Rights Reserved
1 of 6
TE logo and Tyco Electronics are trademarks.
LOC B
*Trademark. Other products, logos, and company names used are the property of their respective owners.
408-1634
Die Assemblies 45218, 45221, 69303-2, and 69820
Nylon Splices
Shoulder Resting
Against Die Ejector
Wire Strip Length (Ref)
Typical Closed-End
Splice
SPLICE
INSTRUCTION SHEET FOR WIRE STRIP
WIRE COMBINATIONS
LENGTH
SIZE
TYPE
408--1395
(6.73 [.265] Splice
Min Opening Diameter)
7.94--8.73
[.312--.344]
Vinyl Splice
22--16
ECV
408--2228
End of Wire Barrel
Resting Against
Die Locator
10.32--11.90
[.406--.469]
(6.48 [.255] Splice
Min Opening Diameter)
VS
408--1394
408--1271
8.33--9.13
(Transparent Splice)
22--14
22--10
[.328-- . 359]
ECN
408--8806
(Black Splice)
14.29--15.87
[.562--.625]
ECV
ECN
408--1002
10.72--11.51
[.422--.453]
Nylon or Vinyl Splice in Die Assembly 69820
408--1021
Front of Wire Barrel
Resting Against Wire
Barrel Section of Die
Figure 2
4. Hold the wires in place, and actuate the tooling
through a complete cycle.
5. Allow the dies to open FULLY, then remove the
crimped splice (if splice is difficult to remove, twist
splice one--quarter turn). Inspect the crimped splice
according to Figure 4.
For detailed information on inspection
requirements, refer to Application Specification
114 -2147 for nylon splices and 114 -2149 for
vinyl splices.
NOTE
Figure 3
i
5. INSULATION CRIMP ADJUSTMENT
Crimp Centered on Wire Barrel (May Be
Off Center But Not Off End of Wire Barrel)
(For Die Assembly 69820 Only)
The moving die has three insulation adjustment
settings to adjust the wire insulation grip: 1—Tight,
2—Medium, and 3—Loose. To determine the proper
insulation crimp setting, proceed as follows (refer to
Figure 5):
Properly Stripped Wires
Bottomed in Splice
Correct Wire Size
Combination
1. Remove the moving die from the tool.
No Nicked or Missing
Wire Strands
2. Loosen, but do not remove, the die screw. Set
the insulation crimp adjustment to Setting 1 (as
described in Figure 5).
Figure 4
2 of 6
Tyco Electronics Corporation
Rev C
408-1634
Die Assemblies 45218, 45221, 69303-2, and 69820
Setting 1—Tight
Turn both insulation adjustment spacers until the “1” (stamped on
the die) is visible at the beveled corner of the spacers. When
installed into the tool, the L-shaped edge of the spacers will fit
between the die and the tool.
2. Make sure that the proper screws and retaining
rings are in place and are secured. Check die
alignment and tighten screws (twice daily is
recommended for production use).
3. Make certain that the dies are protected with a
thin coat of any good SAE 20 motor oil. DO NOT
oil excessively.
Setting 2—Medium
Turn the insulation adjustment spacer closest to the die until the
“2” (stamped on the die) is visible at the beveled corner of the
spacer. When installed into the tool, the L-shaped edge of the
spacer will fit between the die and the tool.
4. When dies are not in use, mate them and store
them in a clean, dry area.
Setting 3—Loose
6.2. Periodic Inspection
Turn both insulation adjustment spacers until the “3” (stamped on
the die) is visible at the beveled corner of the spacers. The
L-shaped edge of the spacer will fit into the notch in the side of
the die.
Regular inspections should be performed by quality
control personnel with a record of scheduled
inspection remaining with the die assembly or
supplied to personnel responsible for them. Though
recommendations call for at least one inspection per
month, inspection frequency should be based upon
amount of use, working conditions, operator training
and skill, and established company standards. The
inspections should be performed in the following
sequence.
Die Assembly 69820 Shown
Insulation
Adjustment Spacers
1. Remove all lubrication and accumulated film by
immersing the dies in a suitable commercial
degreaser that will not affect paint or plastic
material.
Setting 3
Screw Loosened
Shown
2. Make sure that screws, retaining rings, and die
components are in place.
Figure 5
3. Check all bearing surfaces for wear. Replace
worn components.
3. Tighten the die screw. Install die into tool.
4. Perform a test crimp following the steps in
Section 4, and inspect the splice insulation. If the
crimp cuts into, or otherwise damages, the
insulation, start with Step 1 and set the insulation
crimp adjustment to the next setting (Setting 2, as
described in Figure 5). Perform another test crimp.
If the crimp does not meet requirements, set the
adjustment to Setting 3. If the crimp meets
4. Inspect the crimping chamber for flattened,
chipped, cracked, worn, or broken areas. If
damage is evident, the dies must be repaired
before returning them to service.
6.3. Gaging the Crimping Chamber
requirements, the adjustment is properly set.
This inspection requires the use of plug gages
conforming to the dimensions provided in Figure 6.
To gage the crimping chamber, proceed as follows:
6. MAINTENANCE AND INSPECTION
6.1. Daily Maintenance
1. Remove traces of oil or dirt from the crimping
chamber and plug gage.
It is recommended that each operator of the die
assembly be made aware of, and responsible for, the
following steps of daily maintenance:
2. For pneumatic tools, reduce air supply pressure
on tool to between 103 and 138 kPa [15 and
20 psi]. Actuate tool until dies bottom. For manual
tools, close handles until dies bottom. DO NOT
force beyond initial contact.
1. Remove all foreign particles from the dies with a
clean, soft brush, or a clean, soft, lint--free cloth.
Do not use objects that could damage the dies.
3. Insert GO element into the crimping chamber;
but do not force it. The GO element must pass
completely through the crimping chamber. See
Figure 7.
SAE is a trademark of SAE International Corporation.
Rev C
Tyco Electronics Corporation
3 of 6
408-1634
Die Assemblies 45218, 45221, 69303-2, and 69820
Suggested Plug Gage Design for
Wire Barrel Section
Inspection of Crimping Chamber
GO
Dia
NO-GO
Dia
Crimping
Chamber
25.4 [1.0]
Min Typ
GO Element
NO-GO Element
Die Closure
Wire barrel GO element must
pass completely through the
crimping chamber.
NO -GO element may enter
partially, but must not pass
completely through the
crimping chamber.
Configuration
GAGE ELEMENT DIAMETER
DIE ASSEMBLY
Figure 7
GO
NO-GO
2.3114--2.3190
[.0910--.0913]
2.4613--2.4638
[.0969--.0970]
45218
45221
69303--2
69820
4. In the same manner, try to insert the NO--GO
element into the crimping chamber. The NO--GO
element may enter partially, but must not pass
completely through the length of the crimping
chamber. See Figure 7.
3.1242--3.1318
[.1230--.1233]
3.2741--3.2766
[.1289--.1290]
2.6670--2.6746
[.1050--.1053]
2.8169--2.8194
[.1109--.1110]
If the crimping chamber conforms to the gage
2.6670--2.6746
[.1050--.1053]
2.8169--2.8194
[.1109--.1110]
inspection, the dies may be 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 gage inspection, the die
assembly must be returned for repair. See Section 7.
Suggested Plug Gage Design for
Insulation Barrel Section
For additional information regarding the use of a plug
gage, refer to 408--7424.
GO Dia
NO-GO Dia
7. REPLACEMENT AND REPAIR
W
Customer--replaceable parts are listed in Figure 8.
A complete inventory should be stocked and
controlled to prevent lost time when replacement of
parts is necessary. Order replacement parts or
additional dies through your representative, or call
1--800--526--5142, or send a facsimile of your
purchase order to 717--986--7605 or write to:
6.35 [.250]
Min Typ
Die Closure
Configuration
GAGE ELEMENT DIAMETER
DIMENSION
“W” WIDTH
(Max)
DIE
ASSEMBLY
CUSTOMER SERVICE (038--035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
GO
NO-GO
3.7846--3.7922 4.2901--4.2926
[.1490--.1493] [.1689--.1690]
69820
7.49 [.295]
HARRISBURG PA 17105--3608
For customer repair service, call 1--800--526--5136.
Figure 6
8. REVISION SUMMARY
Revisions to this instruction sheet include:
S Updated instruction sheet to corporate
requirements
4 of 6
Tyco Electronics Corporation
Rev C
408-1634
Die Assemblies 45218, 45221, 69303-2, and 69820
Die Assembly 45218
Die Assembly 45221
5
5
13
10
10
13
6
6
10
10
4
4
17
1
17
1
14
2
14
2
11
11
8
7
8
12
Die Assembly 69303-2
Die Assembly 69820
6
13
4
6
3
3
1
1
15
2
5
8
18
14
14
2
8
9
4
16
Figure 8 (Cont’d)
Rev C
Tyco Electronics Corporation
5 of 6
408-1634
Die Assemblies 45218, 45221, 69303-2, and 69820
PART NUMBER FOR DIE ASSEMBLY
ITEM
QTY PER
DESCRIPTION
ASSEMBLY
45218
304993
304991
—
45221
305037
305036
—
69303-2
69820
1
2
1--305927--8 2--306131--1
2--306131--4 3--306131--7
SCREW
SCREW
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
3
1--21046--3
306113--2
306024--8
306028--7
—
1--21046--3
2--306113--9
—
RING, Retaining
4
304995
304992
45296
—
305042
305035
45315
—
EJECTOR
5
LOCATOR
6
306960
306958
306961
306959
—
ANVIL (Stationary Die)
ANVIL (Stationary Die, Insulation)
INDENTER (Moving Die)
INDENTER (Moving Die, Insulation)
FLARE PLATE, Upper
FLARE PLATE, Lower
FLARE PLATE, Lower
SPACER, Upper
7
8
2--305938--0
—
45314
—
306029--7
—
9
10
11
12
13
14
15
16
17
18
304990
304989
—
305041
305040
305039
303995
304994
—
—
—
—
—
—
303995
304994
—
9--305832--5
—
9--305832--6 2--59676--3
SPACER, Lower
—
—
—
—
306027--6
306027--7
—
SPACER, Insulation Adjustment
SPACER, Insulation Adjustment
PIN, Coiled Spring
—
—
21041--6
—
21041--6
—
23911--7
WASHER, Spring
Figure 8 (End)
6 of 6
Tyco Electronics Corporation
Rev C
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