1490352-5 [TE]

Crimping Die Assemblies;


型号：	1490352-5
厂家：	TE CONNECTIVITY
描述：	Crimping Die Assemblies
文件：	总6页 (文件大小：226K)
中文：	中文翻译
下载：	下载PDF数据表文档文件

Instruction Sheet

408-8703

Crimping Die Assemblies

1583092-1 through 1583098-1

18 APR 11 Rev B

PROPER USE GUIDELINES

Cumulative Trauma Disorders can resultfrom the prolonged use ofmanually 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.

Crimping Die Assemblies for AMPOWER* Terminals and Splices

Nest

Indenter

CRIMPING DIES

INDENTER

1490351--1

1490351--2

1490351--3

1490351--4

1490351--5

1490351--6

1490351--7

WIRE SIZE

CMA RANGE

HYDRAULIC CRIMP TOOLING

ASSEMBLY

1583092--1

1583093--1

1583094--1

1583095--1

1583096--1

1583097--1

1583098--1

NEST

AWG

mm²

HEADS

HAND TOOLS

1490352--1

1490352--2

1490352--3

1490352--4

1490352--5

1490352--6

1490352--7

20,800--33,100

33,100--52,600

52,600--83,700

83,700--119,500

119,500--150,500

150,500--190,000

190,000--231,000

10.5--16.8

16.8--26.7

26.7--42.4

42.4--60.6

60.6--76.3

76.3--96.3

96.3--117

1490745--1

1490746--1

1490747-- 1

1976230--1

1490748--1

1490749-- 1

1/0

2/0

3/0

4/0

1490746--1

1976230--1

1490749--1

Figure 1

Read these instructions carefully prior to installing,

removing, or using the dies.

1. INTRODUCTION

This instruction sheet covers application and

maintenance procedures for the AMPOWER

Crimping Die Assemblies listed in Figure 1. The die

assemblies are used in Hydraulic Heads 1490745--1,

1490746--1, 1490747--1, 1976230--1 (not to be used

with splices), and Hydraulic Hand Tools 1490748--1

and 1490749--1. See Figures 1 and 3.

2. DESCRIPTION

The AMPOWER die assemblies listed in the table in

Figure 1 are used to crimp AMPOWER terminals and

splices. Wire strip length is provided in Figure 2.

Basic instructions for the installation and removal of

dies are covered in Section 3; wire preparation and

crimping procedures are covered in Section 4; and

Maintenance and Certification are covered in

Section 6.

The die assemblies are single position sets, each

consisting of an anvil subassembly and an indenter

subassembly.

All dimensions on this document are in metric

units [with U.S. customary units in brackets].

Figures and illustrations are for identification only

and are not drawn to scale.

Refer to Figure 1 to ensure compatibility of crimping

dies and wire size. For instructions relative to the

crimping head and the hydraulic power units, refer to

the instructions packaged with them.

NOTE

E2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company

*Trademark

TOOLING ASSISTANCE CENTER 1--800--722--1111 This controlled document is subject to change.

1 of 6

PRODUCT INFORMATION 1--800--522--6752

For latest revision and Regional Customer Service,

visit our website at www.te.com

LOC B

TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners.

408-8703

AVOID PERSONAL INJURY. When changing

dies, exercise caution and avoid accidentally

depressing foot switch or trigger controls of

power units.

Wire Strip Lengths

DANGER

Length of Barrel “B” Plus 1.6 [.062] 1/16

(Except Terminals and Butt Splices)

B +1.6 [.062] 1/16

3.1. Die Insertion

Refer to Figures 1 and 3 for a listing of tooling that

these dies will fit into. Ensure that the possibility of

accidental activation of the hydraulic power unit has

been eliminated, and proceed as follows:

B +1.6 [.062] 1/16

1. Depress the upper release button located in the

C--head and slide the nest into place.

2. Release the button and rock the die

back--and--forth until the nest snaps in place.

3. Activate the power unit until the lower die

release button located in the ram is exposed.

4. Depress the release button and slide the

indenter into place.

Figure 2

3. DIE INSERTION AND REMOVAL

5. Release the button and rock the indenter

back--and--forth until the die snaps in place.

Do not operate the tool without the dies.

CAUTION

6. Return the ram to the down position.

Hydraulic Hand

Tool 1490749-1

Hydraulic Hand

Tool 1490748-1

Tools Using Crimping Dies for AMPOWER

Terminals and Splices (Refer to Figure 1)

CAUTION

electrical lines.

WARNING

Hydraulic Head

1490745-1

Hydraulic Head

1490746-1

Hydraulic Head

1490747-1

Figure 3

2 of 6

Rev B

408-8703

3.2. Die Removal

4.2. Crimping Procedure

1. Ensure that the wire size stamped on the

terminal or splice corresponds to the wire size

stamped on the stationary die.

Ensure that the possibility of accidental activation of

the hydraulic power unit has been eliminated, and

proceed as follows:

2. Center the terminal or splice in the stationary die

as shown in Figure 4.

1. Depress the upper release button located in the

C--head and slide the nest out of the head.

3. Activate the power unit so that the moving die

advances and holds the terminal or splice in place

without deforming the wire barrel.

2. Activate the power unit until the lower die

release button in the ram is exposed.

4. Insert the stripped wire until it bottoms in the

terminal or butt splice. The end of the wire must be

visible through the sight hole.

3. Depress the release button and slide the

indenter out of the ream.

Sight holes of butt splices must always face

either the upper or lower die.

NOTE

4. WIRE PREPARATION AND CRIMPING PROCEDURES

4.1. Wire Preparation

5. When inserting the stripped wires into a parallel

splice, the ends of the wires must be at least flush

with, or extend slightly beyond the end of the wire

barrel.

1. Select proper size terminal or splice for wire size

being used.

6. Activate the power unit to complete the crimp.

2. Determine correct terminal or splice wire loading

by referring to CMA (Circular Mill Area) range listed

in the table in Figure 1. The total CMA of wires

being used must be within the CMA range of the

terminal or splice.

7. To crimp the other half of the butt splice, remove

and reposition the uncrimped half in the stationary

die. Insert the wire until it bottoms against the

splice sire stop (visible through the sight holes),

and then crimp the splice.

3. Strip the wire to the dimensions indicated in the

table in Figure 2, taking care not to nick or cut the

wire strands.

8. Inspect the crimp by referring to Section 5,

CRIMP INSPECTION, and to Figure 5.

Terminal

Butt Splice

End of Inserted Wire

Ends of Inserted Wires

Must Be Visible

Must be Visible

Through Sight Hole

Through Sight Holes

Center Half of Butt Splice in

Stationary Die (Sight Holes

Must Face Upper or Lower Die)

Center Terminal Wire

Barrel in Stationary Die

Parallel Splice

Center Parallel Splice

in Stationary Die

Figure 4

Rev B

3 of 6

408-8703

terminals and splices, as depicted in the “REJECT”

5. CRIMP INSPECTION

column of Figure 5 can be avoided through careful

use of the instructions in Section 4 and by performing

regularly scheduled die maintenance as described in

Section 6.

Inspect crimped terminals and splices by checking the

features described in Figure 5. Use only terminals

and splices that meet the conditions shown in the

“ACCEPT” column of Figure 5. Unacceptable

REJECT

Terminal

Parallel

Splice

Butt

Splice

Crimped off end of splice or terminal wire barrel.

Crimps centered. Crimps may be off center BUT NOT OFF

END OF WIRE BARREL.

Embossed wire size does not match CMA of wire being

used, or wire size stamped on terminal or splice.

Embossed wire size matches CMA of wire being used

and wire size stamped on terminal or splice.

Wire not inserted far enough in terminal or splice. End of

wire must be visible through sight holes of terminals or

butt splices.

Insulation does not enter wire barrel.

Wire insulation entered barrel of terminal or splice. CHECK

FOR INCORRECT STRIP LENGTH.

Wire is visible through sight hole of terminal or butt splice.

Excessive “flash” indicates wrong wire, splice, or tooling

combination was used.

On parallel splices, bare wire ends must be flush with

or extended slightly beyond end of barrel.

Nicked or missing strands.

Figure 5

4 of 6

Rev B

408-8703

possible damage to die closure surfaces are shown in

Figure 6.

6. MAINTENANCE

TE Connectivity recommends that a

maintenance/inspection program be performed

periodically to ensure dependable and uniform

terminations. Frequency of inspection is dependent

upon operator skill and care of dies, amount of use,

presence of abnormal amounts of dust and dirt, type

and size of products being crimped, and your

company’s established standards.

6.3. Die Closure Inspection

Every die set is inspected for proper die closure

before shipment. However, inspection of die closure

for excessive wear is required on a periodic basis

depending upon usage and conditions.

The die closure inspection is accomplished using

GO/NO--GO plug gages. A suggested plug gage

design and the GO/NO--GO dimensions for plug gage

members are provided in Figure 7. TE does not

manufacture or market these gages. The following

procedure is recommended for inspecting the die

closure.

Pitted

Chipped

1. Clean oil or dirt from die closure surfaces and

from plug gage members.

Broken

Suggested Plug Gage Design

Die Closure

Configuration

Dim.

NO-GO

Dim.

“B”

Figure 6

50.8 [2.000]

2 In. Min.

“A” Dim.

6.1. Die Maintenance and Certification

All dies are thoroughly inspected prior to shipment.

Because of the possibility of damage in transit, new

dies should be inspected in accordance with the

information provided in this section and be inspected

at regularly scheduled intervals to ensure their

conformance to standards.

DIE CLOSURE

DIM. “A”

GAGE MEMBER

DIM. “B”

DIE

NO.

NO-GO

3.734--3.741

NO-GO

3.734

3.988

3.985--3.988

1583092--1

1583093--1

1583094--1

1583095--1

1583096--1

1583097--1

1583098--1

[.1470] [.1570] [.1470--.1473] [.1569--.1570]

Dies are coated with a preservative to prevent rust

and corrosion. Wipe preservative from dies,

4.496

[.1770]

4.75

[.187]

4.496--4.503

4.747--4.750

[.1770--.1773] [.1869--.1870]

particularly from crimping areas, prior to use. Do not

allow deposits of dirt, grease, or other contaminants

to accumulate on the die closure surfaces. These

deposits may cause excessive wear in the die closure

surfaces, thereby affecting the quality of the crimp.

Wipe dies frequently with a clean dry cloth and store

them in a clean, dry area when not in use.

5.38

[.212]

5.639

5.380--5.392 5.636--5.639

[.2220] [.2120--.2123] [.2219--.2220]

6.655

6.909

6.655--6.662

6.906--6.909

[.2620] [.2720] [.2620--.2623] [.2719--.2720]

7.544

7.798

7.544--7.551

7.795--7.798

[.2970] [.3070] [.2970--.2973] [.3069--.3070]

8.509 8.763 8.509--8.517 8.760--8.763

[.3350] [.3450] [.3350--.3353] [.3449--.3450]

6.2. Visual Inspection

Visually inspect die closure surfaces for broken,

pitted, or chipped areas. Although dies may gage

within permissible limits, worn or damaged die closure

surfaces can affect crimp quality. Examples of

9.576

[.3770]

9.83

[.387]

9.576--9.583

9.827--9.830

[.3770--.3773] [.3869--.3870]

Figure 7

Rev B

5 of 6

408-8703

Inspection of Die Closure with Plug Gage

Detail A

Detail B

“GO” Gage Must Pass Completely

Through the Die Closure

“NO -GO” Gage May Enter Partially,

But Must Not Pass Completely

Through the Die Closure

Dies Bottomed But Not Under Pressure

Figure 8

2. Mate the dies until it is evident that they have

bottomed. Hold the dies in this position.

7. REPLACEMENT PARTS

Worn or damaged dies may not be repaired. It is

recommended that spare sets be stocked and

controlled to prevent lost time. See Figure 9. Order

replacement dies 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:

3. Hold gage in straight alignment with die closure

and carefully try to insert, without forcing, the GO

member. See Figure 8, Detail B. The GO member

must pass completely through the die closure.

CUSTOMER SERVICE (38--35)

TYCO ELECTRONICS CORPORATION

P.O. BOX 3608

4. Try to insert the NO--GO member. The NO--GO

member may enter partially, but must not pass

completely through die closure.

HARRISBURG, PA 17105--3608

For tool repair service, please contact a TE

Representative at 1--800--526--5136.

5. If die closure meets GO/NO--GO gage

conditions, dies may be considered dimensionally

correct. If die closure does not conform with

GO/NO--GO gage conditions, the dies must be

replaced.

8. REVISION SUMMARY

S Updated document to corporate requirements

S Corrected table in Figure 1

Single Position Dies

SINGLE POSITION DIES

ITEM DESCRIPTION

1583092-1

1490351--1

1490352--1

1583093-1

1490351--2

1490352--2

1583094-1

1490351--3

1490352--3

1583095-1

1490351--4

1490352--4

1583096-1

1490351--5

1490352--5

1583097-1

1490351--6

1490352--6

1583098-1

1490351--7

1490352--7

Moving Die

Stationary Die

Figure 9

6 of 6

Rev B

1490352-5 [TE]

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