1901004--3 [TE]
Cumulative Trauma Disorders can result from the prolonged use ofmanually powered hand tools.;型号: | 1901004--3 |
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 | 下载: | 下载PDF数据表文档文件 |
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
8
6
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
All Rights Reserved
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
8
6
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
1901006--1
1901007--1
Red
Red
Blue
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
ACCEPT
REJECT
Wire Size
8
4
Stamped
4
5
4
2
Here
3
5
10
1
1
3
4
2
Wire Size
Stamped
9
Wire Size
Stamped
Here
Wire Size
Stamped
4
9
Here
4
4
Here
4
4
4
10
8
Wire Size
Stamped
2
5
Here
3
4
3
5
6
2
4
2
10
6
7
1
1
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.
2
3
Wire fully inserted.
Wire not inserted fully or wrong strip length used.
2
3
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.
4
4
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.
5
6
5
6
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.
7
Crimp not centered on splice wire barrel. Edge of window
indent did not butt against locator when crimped.
8
9
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).
10
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
GO
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
GO
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
4
2
4
5
7
7
5
2
3
6
6
1
1
8
8
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
1
2
3
4
5
6
7
8
ANVIL
1
2
1
1
1
1
1
2
2
2
FLARE PLATE
FLARE PLATE
-- -- --
1
1901016--2
1901003--2
21018--5
INDENTER
LOCATOR
1
NUT, Hex, Reg 6--32
SCREW, Skt Hd Cap 6--32
SCREW, Skt Hd Cap 6--32
2
8--21000--8
4--306105--5
1--21000--9
4--306105--5
2
2
Figure 10
Rev C
7 of 7
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