308132-1 [MACOM]
Remove assembly pins from mounting lugs as shown in Figure 1;
| 型号： | 308132-1 |
| 厂家： | 
Tyco Electronics |
| 描述： | Remove assembly pins from mounting lugs as shown in Figure 1 |
| 文件： | 总8页 (文件大小：357K) |
| 中文： | 中文翻译 | 下载： | 下载PDF数据表文档文件 |
This instruction sheet provides instructions on product
application and Maintenance and Inspection for
Insulation Piercing COPALUM Terminal and Splice
Crimping Heads (68081 and 68082) used in
Pneumatic Tool 69015. These crimping heads are
used to crimp COPALUM Terminals and Splices on
No. 8 thru 6 film insulated solid aluminum or copper
wire or stranded copper wire.
Basic instructions on the use of these heads, wire
preparation, etc. are provided in Section 2,
INSTRUCTIONS. Section 3 features terminal or
splice Crimp Inspection Procedure. Section 4
contains a Maintenance and Inspection Procedure
which will enable you to establish a tool certification
program.
Figure 1
2. Remove assembly pins from mounting lugs as
shown in Figure 1.
Crimping heads are coated with preservative to
prevent runt and corrosion. Wipe this preservative
from heads, particularly from the crimping areas. For
further instructions relative to the 69015 tool, refer to
the instructions packaged with the tool.
3. Pull toggle arm forward and insert toggle lever
shank of crimping head all the way into hole in
toggle arm until toggle lever snaps in place. See
Figure 1.
4. Align holes in crimping head links with holes in
mounting lugs.
5. Insert assembly pins.
6. Connect air supply to tool 586 to 689 kPa
[85 to 11 psi].
Reasons for reissue are provided in Section 5,
REVISION SUMMARY.
7. Tool is now ready for operation.
1. Remove assembly pins.
2. Lower head away from mounting lugs, twist
head 90° and remove from toggle arm.
3. Reinstall assembly pins.
1. Select the correct crimping head for the wire
size being used. Wire size and the insulation
piercing crimp symbol ( ) appear on one jaw as
shown in Figure 1.
Solid aluminum or copper (or a combination of both)
and stranded copper conductors may be crimped in
the same wire barrel under the following conditions:
See Figure 2, Detail D
Four identical rectangular conductors, where one
conductor thickness is equal to or greater than 1/4 the
width of one conductor, may be crimped without
removing film insulation.
See Figure 2, Detail A
Maximum CMA fill for copper conductor should not
exceed 40% of total CMA. For example, six No. 14
See Figure 2, Detail E
2
solid aluminum 12.14 mm [24,000] Cir Mil plus one
Two identical rectangular conductors, where
thickness of one conductor is equal to or less than 1/4
of the width of one conductor, may be crimped
without removing film insulation.
2
No. 8 stranded copper 8.10 mm [16,000] Cir Mil
equals 40,000 Cir Mil. The one No. 8 stranded copper
conductor is approximately 40% of total CMA
2
20.24 mm [40,000] Cir Mil being crimped.
See Figure 2, Detail F
In some instances, it may not be possible to fit a
particular CMA loading into the normally
recommended terminal or splice. In these cases,
where seven or more equal round, or a combination
of solid aluminum and stranded copper conductors
are used, and the total CMA is at least 50% of
maximum CMA of the next larger size terminal or
splice, the larger size may be used. Example: three
2
No. 14 solid conductors equal about 6.07 mm
[12,000] Cir Mils. This falls within the CMA range of a
12–10 terminal or splice accepting a maximum CMA
2
of 6.63 mm [13,100] circular mils. However, it may
not be possible to insert all three conductors into the
recommended terminal or splice. It is possible to
insert all three conductors into a No. 8 size terminal or
2
splice accepting a CMA range of 6.63–10.52 mm
2
[13,100–20,800] circular mils. The 6.07 mm [12,000]
circular mils amounts to 59% loading of the maximum
CMA for No. 8 size terminal or splices. Therefore, No.
8 size terminals or splices may be used.
When using a variety of solid conductor sizes, none of
the conductors should vary more than one (1) wire
gage. (Ideally not more than 1/2 wire gage.)
Figure 2
1. Select the proper terminal or splice wire size
and crimping head combination for the wire size
being used. See Figure 3.
See Figure 2, Detail B
A maximum of ten equal size round conductors may
be crimped without removing film insulation.
2. Determine correct terminal or splice wire loading
by referring to Paragraph 2.3, and CMA range
listed in Figure 3.
See Figure 2, Detail C
A maximum of six equal size square conductors may
be crimped without removing film insulation.
3. Strip stranded copper wire to dimension
indicated in Figure 3.
Figure 3
Ensure that the wire size stamped on the terminal
corresponds with the wire size stamped on the
crimping head link.
1. Position terminal wire barrel between locators of
lower jaw as shown in Figure 4A. Back of terminal
tongue must face upper jaw.
2. Insert wire into terminal wire barrel until end of
wire is flush with or extended slightly beyond end
of wire barrel. Hold terminal in place, press thumb
control and hold it down until crimping stroke is
completed.
3. Release thumb control and remove crimped
terminal.
4. Refer to Section 3 and Figure 5 for crimp
inspection.
Figure 4
2. Insert wire into place until it butts against splice
wire stop. Hold splice in place, press thumb control
and hold it down until crimping stroke is completed.
Ensure that wire size stamped on the splice
corresponds with the wire size stamped on the
crimping head link.
3. Release thumb control and remove crimped
splice.
4. 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.
1. Position butt splice in lower jaw so that end of
splice butts against locator and window in splice
faces upper jaw. See Figure 4B.
Ensure that wire size stamped on the splice
corresponds with the wire size stamped on the
crimping head link.
5. To crimp other half of butt splice, remove and
rotate splice 180° end over end. Reposition
uncrimped half in lower jaw as described in step
(1). If splice cannot be rotated, rotate tool. Insert
wire and then crimp the splice.
1. Position splice between locators as shown in
Figure 4C.
2. Insert wires into splice until ends of wires are
flush with or extended slightly beyond wire barrel.
Hold splice in place, press thumb control and hold
it down until crimping stroke is completed.
6. Refer to Section 3 and Figure 5 for crimp
inspection.
Figure 5
3. Release thumb control and remove crimped
splice.
cloth. Re–lubricate head as instructed in Paragraph
4.3 before placing it back in service.
4. Refer to Section 3 and Figure 5 for crimp
inspection.
1. Visually inspect the crimping head for missing
pins or retaining rings. If parts are missing or
defective, refer to Figure 10 for customer
replaceable parts.
2. Inspect the die closure surfaces of the head for
broken, pitted, or chipped 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 6.
Inspect crimped terminals and splices by checking the
features described in Figure 5.
Use only terminals and splices meeting the conditions
shown in the “ACCEPT” column. “REJECT” terminals
and splices can be avoided through careful use of
instructions in Section 2, and by performing regular
crimping head maintenance as provided in Section 4.
Lubricate all pins, pivot points, and bearing surfaces
with a good grade S.A.E. No. 20 motor oil as follows:
Heads used in daily production – Lubricate daily
Heads used daily (occasional) – Lubricate weekly
Heads used weekly – Lubricate monthly
Tyco Electronics recommends that a
Wipe excess oil from head, particularly from crimping
area. Oil transferred from the crimping area onto
certain terminations may affect the electrical
characteristics of an application.
maintenance/inspection program be performed
periodically to ensure dependable and uniform
terminations. Crimping heads should be inspected at
least once a month. Frequency of inspection may be
adjusted to suit your requirements through
experience. Frequency of inspection is dependent
upon:
The care, amount of use, and handling of the
head.
The type and size of the products crimped.
The degree of operator skill.
The presence of abnormal amounts of dust and
dirt.
Your own established standards.
All crimping heads are thoroughly inspected before
packaging. Since there is a possibility of damage in
shipment, new heads should be inspected in
accordance with the following instructions when
received in your plant.
The crimping head should be immersed in a reliable
commercial de–greasing compound to remove
accumulated dirt, grease and foreign matter. Remove
remaining de–greasing compound with a lint–free
cloth. When de–greasing compounds are not
Figure 6
available, head may be wiped clean with a lint–free
locator is in notch of gage member. See Figure 9,
Detail A.
Every crimping head is inspected for proper die
closure before packaging. An inspection should be
performed periodically to check the die closure for
excessive wear. The die closure inspection is
accomplished using the GO NO–GO plug gages.
Tyco Electronics neither manufactures nor sells plug
gages. A suggested plug gage design and the GO
NO–GO dimensions of the plug gage members are
listed in Figures 7 and 8. the following procedure is
recommended for inspecting the die closures.
3. Close the crimping jaws until they are bottomed
but not under pressure.
4. To meet the GO gage conditions, the plug gage
must be free to rotate in either direction as shown
in Figure 9, Detail A.
5. Select the proper NO–GO gage. Position gage
member in lower jaw inner crimp closure so that
locator is in notch of gage member. See Figure 9,
Detail B.
1. Clean oil or dirt from die closure areas, and plug
gage members.
2. Select the proper GO gage. Position gage
member in lower jaw inner crimp closure so that
6. Close the crimping jaws so that inner crimp
surfaces are seated on the NO–GO member.
Figure 7
Figure 8
Figure 9
7. To meet the NO–GO gage conditions, jaw
bottoming surfaces will NOT bottom, and NO–GO
gage member will be held stationary (will not
rotate) by the dies. See Figure 9, Detail B.
It may be advantageous to stock certain replaceable
parts to prevent loss of production time. Figure 10
lists the customer replaceable parts that can be
purchased from Tyco Electronics. Order
replacements through your Tyco Electronics
Representative, or call 1–800–526–5142, or send a
facsimile of your purchase order to 717–986–7605, or
write to:
8. Inspect the right and left outer crimp closures in
the same manner as steps (2) thru (7). See Figure
9, Details C and D.
CUSTOMER SERVICE (038–035)
TYCO ELECTRONICS CORPORATION
P.O. BOX 3608
9. If both the inner crimp and the outer crimp
closures meet the GO NO–GO gage conditions,
the die closures may be considered dimensionally
correct. If you find that the die closures do not
conform with the GO NO–GO gage conditions,
contact your local Tyco Electronics Representative.
HARRISBURG, PA 17105–3608
Updated document to corporate requirements
New format
If locators are worn and need replacement, order parts from this area of table.
Figure 10
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