1901003--1 [TE]

Cumulative Trauma Disorders can result from the prolonged use ofmanually powered hand tools.;


型号：	1901003--1
厂家：	TE CONNECTIVITY
描述：	Cumulative Trauma Disorders can result from the prolonged use ofmanually powered hand tools.
文件：	总7页 (文件大小：183K)
中文：	中文翻译
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Instruction Sheet

Crimping Dies for

TERMINYL* and PLASTI-GRIP*

Terminals and Splices

408-10051

23 MAR 11 Rev C

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.

Typical

Crimping

Dies

Moving

Die (Nest)

Yoke Set Screw

Moving

Die (Nest)

Locking

Flange

Locator

Latch Arm

Locator

Stationary

Die (Anvil)

Stationary

Die (Anvil)

Yoke

Adapter

Shank

CRIMPING DIE

WIRE SIZE (AWG)

PART NUMBER

1901006--1

COLOR CODE DOT

Red

Blue

1901007--1

Figure 1

1. INTRODUCTION

2. DESCRIPTION

Each crimping die consists of a stationary die (nest)

and a moving die (anvil). The stationary die features a

locator. Each die contains a color code dot that

matches the color code of the terminal and splice.

When mated, the dies form a crimping chamber.

Crimping Dies 1901006--1 and 1901007--1 are used

with Battery Powered Hand Tool 1901343--1, --2, --3,

and --4 (Customer Manual 409--10070) and Battery

Powered Hand Tool 2031404--1, --11, --21, --31, and

--41 (Customer Manual 409--10103). The dies crimp

TERMINYL Terminals and Splices onto wire sizes 8

through 6 AWG, TERMINYL Splices with step--down

adapters onto wire sizes 16--14 through 6 AWG, and

PLASTI--GRIP Terminals and Splices onto wire sizes

8 through 6 AWG. Refer to Figure 1 to ensure

compatibility of crimping die part number, color code

dot, and wire size.

3. DIE INSTALLATION AND REMOVAL

3.1. Die Installation

1. Pivot the latch arm away from the yoke to open

the crimp head. See Figure 1.

2. Loosen the set screw in the yoke.

3. Insert the shank of the stationary die into the

yoke, and tighten the set screw.

Dimensions in this document are in millimeters

[with inches in brackets]. Figures and Illustrations

are for reference only and are not drawn to scale.

NOTE

4. Extend the ram until the ram set screw is visible.

E2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company TOOLING ASSISTANCE CENTER 1--800--722--1111 This controlled document is subject to change.

1 of 7

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

For latest revision and Regional Customer Service,

TE logo is a trademark.

visit our website at www.te.com

LOC B

*Trademark. Other product names, logos, or company names might be trademarks of their respective owners.

408-10051

5. Loosen the set screw in the ram.

2. Select the proper color--coded terminal for the

wire size. The wire size stamped on the terminal

tongue and on the crimping die must match the

wire size selected.

6. Insert the shank of the moving die into the ram

and tighten the set screw.

To avoid damage to the dies, be sure that the

CAUTION

3. Insert stripped wire fully into terminal wire barrel.

The end of the conductor must not protrude more

than 1.60 mm [.063 in.] beyond the edge of the

wire barrel.

moving and stationary dies are properly oriented.

7. Activate the tool to allow the ram to return to the

“down” position.

Do NOT turn or twist the wire or terminal during

8. Pivot the yoke and latch arm toward each other

until the locking flange secures the latch arm to the

yoke.

NOTE

insertion.

4. Pivot the latch arm away from the yoke to open

the head.

Always make sure the yoke and latching arm are

secured by the locking flange before cycling the

tool.

CAUTION

5. Place the terminal in the stationary die with the

edge of the wire barrel resting against the locator

and the bottom of the terminal tongue facing the

stationary die. See Figure 3.

3.2. Die Removal

1. Pivot the latch arm away from the yoke to open

the head.

6. Holding the terminal in place, pivot the yoke and

latch arm toward each other until the locking flange

secures the latch arm to the yoke.

2. Loosen the set screw in the yoke and remove

the stationary die.

Always make sure the yoke and latching arm are

secured by the locking flange before cycling the

tool.

CAUTION

3. Extend the ram until the ram set screw is visible.

4. Loosen the set screw in the ram. Remove the

moving die.

7. Holding the wire in place, activate the tool to

complete the crimp.

8. When the crimp is completed, pivot the latch

arm away from the yoke to open the head and

remove the terminal.

4. CRIMPING PROCEDURE

4.1. Crimping Terminals

If terminal sticks in die after crimping, apply a

Avoid personal injury. When operating the tool,

exercise caution while holding terminals or wire

near the crimping area.

NOTE

DANGER

rocking action to the terminal to remove it from

the die. Wipe light oil on the dies to prevent

sticking, or use spray dry lubricant.

1. Strip wire to the dimensions listed in Figure 2.

Do not nick or cut the wire strands.

9. Inspect the crimp according to Section 5.

Typical Splice

(Without Step -Down Adapter)

Typical Terminal

Wire Stop

Wire Strip

Length

Wire Strip

Length

Window Indent

WIRE STRIP LENGTH

TERMINYL TERMINAL AND SPLICE

WIRE

SIZE

PLASTI-GRIP TERMINAL

AND SPLICE

(AWG)

TERMINAL

SPLICE

7.96--9.53 [.313--.375]

11.18--12.70 [.440--.500]

15.48--17.07 [.609--.672]

19.45--20.24 [.766--.797]

11.51--12.29 [.453--.484]

15.47--16.26 [.609--.640]

Figure 2

2 of 7

Rev C

408-10051

If splice sticks in die after crimping, apply a

rocking action to the splice to remove it from the

die. Wipe light oil on dies to reduce sticking, or

use spray dry lubricant.

Bottom of Terminal Tongue

Facing Stationary Die

NOTE

9. To crimp the other half of splice, reposition

uncrimped end of splice in the stationary die and

follow the same procedure used to crimp the first

half of splice.

Edge of Wire

Barrel Resting

Against Locator

10. Inspect the crimp according to Section 5.

Crimping Splices With or Without Step -Down Adapter

Top of

Yoke

Edge of Window Indent

Resting Against Locator

Rotate End of Splice

to be Crimped into

Stationary Die

Crimping

Terminals

Figure 3

4.2. Crimping Splices Without Step-Down Adapter

Avoid personal injury. When operating the tool,

exercise caution while holding splice or wire near

the crimping area.

DANGER

End of Splice

Pointed Toward

Top of Yoke at

Approximately

30_ Angle

1. Strip wires to the dimensions listed in Figure 2.

Do not nick or cut the wire strands.

2. Select the proper color--coded splice for the wire

size. The wire size stamped on the splice and on

the crimping die must match the wire size selected.

3. Insert the stripped wire into the wire barrel of the

end of the splice to be crimped until the wire

bottoms against the wire stop within the splice.

4. Pivot the latch arm away from the yoke to open

the head.

5. Place the splice in the stationary die. Grasp the

end of the splice to be crimped and point the

opposite end toward the top of the head yoke at

approximately a 30_ angle. Rotate the end of the

splice to be crimped into the die. Position the edge

of the window indent against the locator. Refer to

Figure 4.

Figure 4

4.3. Crimping Splices With Step-Down Adapter

Avoid personal injury. When operating the tool,

exercise caution while holding splice or wire near

the crimping area.

DANGER

6. Holding the splice in place, pivot the yoke and

latch arm toward each other until the locking flange

secures the latch arm to the yoke.

1. Strip wires to the dimensions listed in Figure 2.

Do not nick or cut the wire strands.

Always make sure the yoke and latching arm are

secured by the locking flange before cycling the

tool.

CAUTION

2. Select the proper splice, adapter, and crimping

die for the wire size. See Figure 5. Note that the

end of the splice containing the adapter has a

different color code. Use the crimping die for the

larger wire size to crimp both ends of the splice.

For example, use Crimping Die 1901006--1 (for

wire size 8 AWG) to crimp both ends of the splice

with step--down adapter for stepping down from

wire size 8 to 16--14 AWG.

7. Holding wire in place, activate the tool to

complete first wire barrel crimp.

8. When crimp is completed, pivot the latch arm

away from the yoke to open the head and remove

the splice.

Rev C

3 of 7

408-10051

4.4. Crimping PLASTI-GRIP Butt Splices

Splices with Step -Down Adapter

Avoid personal injury. When operating the tool,

exercise caution while holding butt splices or wire

near the crimping area.

Step-Down

Adapter

DANGER

1. Strip wires to the dimensions listed in Figure 2.

Do not nick or cut the wire strands.

2. Select the proper color--coded butt splice for the

wire size. The wire size stamped on the butt splice

and on the crimping die must match the wire size

selected.

WIRE SIZE

(AWG)

DIE AND

SPLICE

STEP-DOWN

ADAPTER

CRIMPING

DIE

STEP

COLOR CODE COLOR CODE

3. Pivot the latch arm away from the yoke to open

the head. Remove the stationary die from the

yoke, then remove the locator from the stationary

die. Re--assemble the stationary die onto the yoke.

8 to 16--14

8 to 12--10

6 to 8

1901006--1

1901007--1

Red

Blue

Yellow

Red

To avoid damage to the dies, be sure that the

stationary die is properly oriented with the

moving die.

CAUTION

Figure 5

3. Insert stripped wire into the wire barrel of the

end of the splice to be crimped until the wire

bottoms against the wire stop within the splice.

Refer to Figure 2.

4. Insert the stripped wire into the wire barrel of the

end of the butt splice to be crimped until the wire

bottoms against the wire stop within the splice.

5. Place the butt splice in the stationary die with

the wire barrel of the end of the splice to be

crimped centered over the crimping chamber. See

Figure 6.

4. Pivot the latch arm away from the yoke to open

the head.

5. Place the splice in the stationary die. Grasp the

end of the splice to be crimped and point the

opposite end toward the top of the head yoke at

approximately a 30_ angle. Rotate the end of the

splice to be crimped into the die. Position the edge

of the window indent against the locator. Refer to

Figure 4.

6. Holding the butt splice in place, pivot the yoke

and latch arm toward each other until the locking

flange secures the latch arm to the yoke.

Always make sure the yoke and latching arm are

secured by the locking flange before cycling the

tool.

CAUTION

6. Holding the splice in place, pivot the yoke and

latch arm toward each other until the locking flange

secures the latch arm to the yoke.

Crimping Butt Splices

Wire Barrel in

Stationary Die

Centered Over

Crimping Chamber

Always make sure the yoke and latching arm are

CAUTION

secured by the locking flange before cycling the

tool.

7. Holding the wire in place, active the tool to

complete the first wire barrel crimp.

8. When crimp is complete, pivot the latch arm

away from the yoke to open the head and remove

the splice.

If splice sticks in die after crimping, apply a

NOTE

rocking action to the splice to remove it from the

die. Wipe light oil on dies to reduce sticking, or

use spray dry lubricant.

Locator Removed

from Stationary

Die

9. To crimp the other half of splice, reposition

uncrimped end of splice in the stationary die and

follow the same procedure used to crimp the first

half of splice.

Figure 6

10. Inspect the crimp according to Section 5.

4 of 7

Rev C

408-10051

7. Holding the wire in place, activate the tool to

complete the first wire barrel crimp.

8. When crimp is completed, pivot the latch arm

away from the yoke to open the head and remove

the butt splice.

If butt splice sticks in die after crimping, apply a

rocking action to the butt splice to remove it from

the die. Wipe light oil on dies to reduce sticking,

or use spray dry lubricant.

NOTE

REJECT

Wire Size

Stamped

Here

Wire Size

Stamped

Wire Size

Stamped

Here

Wire Size

Stamped

Here

Wire Size

Stamped

Here

End of wire conductor is flush with or extends beyond edge of

terminal wire barrel a maximum of 1.60 [.063].

End of wire conductor not flush with or extending slightly

beyond end of terminal wire barrel.

Wire fully inserted.

Wire not inserted fully or wrong strip length used.

Crimp not centered on terminal wire barrel. Terminal wire

barrel was not butted against locator when crimped.

Crimp centered on wire barrel.

Wire size not the same as wire size stamped on terminal

tongue, splice body, and wire barrel.

Wire size is the same as wire size stamped on terminal

tongue, splice body, and wire barrel.

Proper color code, wire size, and tooling combination used.

Wrong color code, wire size, and tooling combination used.

Wire conductors butted against wire stop, or flush with or

extended slightly beyond edge of splice wire barrel.

End of wire conductor not visible. Conductor did not butt

against wire stop, or was not flush with or extended slightly

beyond splice wire barrel.

Crimp not centered on splice wire barrel. Edge of window

indent did not butt against locator when crimped.

Nicked or missing wire strands.

Splice was reversed in die (locator was not oriented with

window indent) when crimped.

Excessive “flash” or extruded wire insulation (die was either

damaged or incompatible when crimped).

Figure 7

Rev C

5 of 7

408-10051

9. To crimp the other half of butt splice, reposition

uncrimped end of splice in the stationary die and

follow the same procedure used to crimp the first

half of splice.

3. Check components for wear. Remove and

replace worn components.

4. Inspect the crimp area for flattened, chipped,

cracked, worn, or broken areas. If damage is

evident, the dies must be repaired before returning

them to service (see Section 7, REPLACEMENT

AND REPAIR).

Be sure to re -assemble locator onto stationary

NOTE

die after crimping PLASTI -GRIP butt splices.

10. Inspect the crimp according to Section 5.

5. CRIMP INSPECTION

6.3. Gaging the Crimping Chamber

The die closure inspection is accomplished using plug

gages. A suggested gage design and the GO and

NO--GO diameters of the plug gage elements are

shown in Figure 8. The following procedure is

recommended for inspecting the die closures.

Inspect crimped terminals and splices by checking the

features described in Figure 7. Use only the terminals

and splices that meet the conditions shown in the

“ACCEPT” column.

6. MAINTENANCE/INSPECTION

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

bottomed. Hold the dies in this position.

To avoid personal injury, always remove the

battery from the tool before performing

maintenance or inspection procedures.

DANGER

Suggested Plug Gage Design

Each crimping die is thoroughly inspected before

packaging. Since there is a possibility of damage

during shipment, the crimping die should be inspected

immediately upon arrival at your facility.

GO Diameter

NO -GO Diameter

Regular inspections should be performed by quality

control personnel. A record of scheduled inspections

should remain with the dies and/or be supplied to

supervisory personnel responsible for the dies.

Though recommendations call for at least one

inspection a month, the inspection frequency should

be based on the amount of use, ambient working

conditions, operator training and skill, and established

company standards.

Die Closure Configuration

25.4 [1.00]

(Min Typ)

GAGE ELEMENT DIAMETER

CRIMPING DIE

NO-GO

5.105--5.113

[.2010--.2013]

5.255--5.258

[.2069--.2070]

1901006--1

6.1. Daily Maintenance

6.020--6.027

[.2370--.2373]

6.170--6.172

[.2429--.2430]

1901007--1

It is recommended that each operator of the dies be

made aware of—and responsible for—the following

steps of daily maintenance:

Figure 8

1. Remove dust, dirt, and other contaminants with

a clean brush, or a soft, lint--free cloth. Do NOT

use objects that could damage the dies.

2. Align the GO element with the crimping

chamber. Push element straight into the crimping

chamber without using force. The GO element

must pass completely through the crimping

chamber as shown in Figure 9.

2. Make certain the dies are protected with a THIN

coat of any good SAE 20 motor oil. Do not oil

excessively.

3. Align the NO--GO element and try to insert it

straight into the crimping chamber. The NO--GO

element may start entry but must not pass

completely through as shown in Figure 9.

3. When the dies are not in use, mate them and

store in a clean, dry area.

6.2. Visual Inspection

If the crimping chamber conforms to the gage

inspection, the crimping die is considered

dimensionally correct and should be lubricated with a

THIN coat of SAE 20 motor oil. If not, the dies must

be repaired before returning them to service (see

Section 7, REPLACEMENT AND REPAIR).

1. Remove all lubrication and accumulated film by

immersing the dies in a suitable commercial

degreaser that will not affect paint or plastic

material.

2. Make sure all die components are in place. If

replacements are necessary, refer to the

replacement parts listed in Figure 10.

For additional information concerning the use of a

plug gage, refer to Instruction Sheet 408--7424.

6 of 7

Rev C

408-10051

7. REPLACEMENT AND REPAIR

Crimping

Chamber

The parts listed in Figure 10 are customer--

replaceable. A complete inventory can be stocked

and controlled to prevent lost time when replacement

of parts is necessary. Order replacement parts

through your TE Connectivity Representative, or call

1--800--526--5142, or send a facsimile of your

purchase order to 1--717--986--7605, or write to:

Plug Gage

Crimping

Chamber

CUSTOMER SERVICE (38--35)

TYCO ELECTRONICS CORPORATION

P.O. BOX 3608

HARRISBURG, PA 17105--3608

Element

NO-GO

Element

Dies may be returned for evaluation and repair. For

die repair service, contact a TE Representative at

1--800--526--5136.

GO element must pass

completely through the

crimping chamber.

NO -GO element may enter

partially, but must not pass

completely through the

crimping chamber.

8. REVISION SUMMARY

S Added new text to Section 1

S New logo

Figure 9

1901006 -1

1901007 -1

CRIMP DIE PART NUMBER

ITEM

NO.

QTY PER ASSY

(1901006-1)

QTY PER ASSY

(1901007-1)

DESCRIPTION

1901006-1

1901015--2

1901004--2

-- -- --

1901007-1

1901015--1

1901004--1

1901004--3

1901016--1

1901003--1

21018--5

ANVIL

FLARE PLATE

-- -- --

1901016--2

1901003--2

21018--5

INDENTER

LOCATOR

NUT, Hex, Reg 6--32

SCREW, Skt Hd Cap 6--32

8--21000--8

4--306105--5

1--21000--9

4--306105--5

Figure 10

Rev C

7 of 7

1901003--1 [TE]

相关型号：

1901003--2

1901004--1

1901004--2

1901004--3

1901006--1

1901007--1

1901015--1

1901015--2

1901016--1

1901016--2

1901085-4

1901085-8