1901657--2 [TE]

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


型号：	1901657--2
厂家：	TE CONNECTIVITY
描述：	Cumulative Trauma Disorders can result from the prolonged use ofmanually powered hand tools.
文件：	总5页 (文件大小：191K)
中文：	中文翻译
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Instruction Sheet

Crimping Dies for

Heavy-Duty Seamless Straight

Ring Tongue Terminals and Butt Splices

408-10110

16 MAY 11 Rev D

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.

Indenter

(Moving Die)

Nest

(Stationary Die)

CRIMPING DIE

NOMINAL WIRE SIZE

(AWG)

USED IN

INDENTER

1901657--1

1901657--2

1901657--3

NEST

1--1490413--4

1--1490413--5

1--1490413--6

1--1490413--7

1--1490413--8

1--1490413--9

2--1490413--0

2--1490413--1

Figure 1

Hydraulic Crimping Head

1490747-- 1,

1901820--1, or

1901821--1

1/0

2/0

3/0

4/0

Hydraulic Hand Crimping Tool

1490748--1 or

1490749-- 1

Reasons for reissue of this instruction sheet are

provided in Section 7, REVISION SUMMARY.

1. INTRODUCTION

This instruction sheet provides application

instructions, maintenance, and inspection procedures

for the crimping dies listed in Figure 1. These dies are

used to crimp heavy--duty seamless straight ring

tongue terminals and butt splices onto solid or

stranded copper wire also listed in Figure 1.

2. DESCRIPTION

Each die consists of a nest and an indenter (available

separately) which are retained in the crimping head or

crimping tool by retainer pins. The nest is positioned

in the yoke and the indenter is positioned in the ram.

Refer to Catalog 1308674 for information and part

numbers for the terminals and splices.

3. DIE INSTALLATION AND REMOVAL

The dies are designed to be installed in a hydraulic

crimping head or hydraulic hand crimping tool.

Available heads and tools are listed in Figure 1.

Refer to Figure 1 and determine the correct dies, wire

size, crimping head, and hydraulic hand tool to use.

Dimensions on this instruction sheet are in

millimeters [with inches in brackets]. Figures and

illustrations are for identification only and are not

drawn to scale.

Never operate the head or tool with the dies

removed.

NOTE

CAUTION

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 5

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.

408-10110

Hydraulic Crimping Head

Hydraulic Hand Crimping Tool

Yoke

Upper Die

Release Button

Stationary Die

Release Button

“C” Head

Yoke

Nest

Indenter

Nest

“C” Head

Indenter

Moving Die

Release Button

Ram

(Advanced)

Lower Die

Release Button

Ram

(Advanced)

Figure 2

To avoid personal injury, make sure to exercise

extreme caution when using the head or tool.

Avoid depressing the footswitch or trigger control

when installing or removing the dies.

3. Depress the button, and slide the indenter out of

the ram.

DANGER

4. CRIMPING PROCEDURE

1. Ensure that the wire range or size stamped on

the terminal or splice corresponds with the wire

size being used and the wire range or size marked

on the nest and indenter.

3.1. Die Installation

1. Depress the upper die release button (head) or

stationary die release button (tool) located on the

“C”--head. See Figure 2.

2. Strip the wire to the dimension given in Figure 3.

DO NOT nick or cut the wire strands.

2. Slide the nest into place in the “C”--head. See

Figure 2.

3. Release the button, and rock the nest back and

forth until the nest snaps into position.

Note: Not to Scale

4. Activate the head or tool according to the

instructions included with the head or tool until the

lower die release button (head) or moving die

release button (tool) located in the ram is exposed.

Depress the button.

Strip Length

(Refer to Table)

Insulation

Conductors

5. Slide the indenter into position in the ram. See

Figure 2.

NOMINAL WIRE SIZE (AWG)

STRIP LENGTH

11.43 [.450]

12.06 [.475]

13.34 [.525]

14.60 [.575]

15.87 [.625]

6. Release the button, and rock the indenter back

and forth until the indenter snaps into position.

7. Return ram to the down position.

3.2. Die Removal

1. Depress the upper die release button (head) or

stationary die release button (tool) located on the

“C”--head, and slide the nest out. See Figure 2.

1/0

2/0

3/0

4/0

17.46 [.688]

2. Activate the head or tool according to the

instructions included with the head or tool until the

lower die release button (head) or stationary die

release button (tool) located in the ram is exposed.

19.05 [.750]

20.64 [.812]

Figure 3

2 of 5

Rev D

408-10110

8. For splices, insert a stripped wire into the

uncrimped wire barrel until the end of the

conductor is visible in the sight hole.

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

terminal or splice making sure that the end of the

wire is visible through the sight hole.

9. Inspect the crimp according to Figure 5. This is

included as an aid to the tool operator ONLY. It is

not intended to serve as a quality control

4. Center the terminal or splice in the nest as

shown in Figure 4.

inspection for qualifying finished crimps on these

terminals and splices. Use only terminals or splices

that meet the conditions shown in the ACCEPT

column. Terminals and splices displaying the

features shown in the REJECT column can be

avoided by careful use of these instructions and by

performing the maintenance and inspection

procedures described in Section 5.

To avoid personal injury, make sure to exercise

caution when holding terminals, splices, or wire

near the crimping area.

DANGER

Damaged terminals or splices should not be

used. If a damage is evident, the terminal or

splice should be cut from the wire and replaced

with a new one. DO NOT re -terminate terminals

or splices.

CAUTION

Terminal or Splice

Centered in Nest

(See Detail)

5. MAINTENANCE AND INSPECTION

To avoid personal injury, DISCONNECT THE

DANGER

POWER SUPPLY before performing

maintenance, adjustments, inspection, or repair.

5.1. Daily Maintenance

Detail

It is recommended that each operator of the dies be

made aware of, and responsible for, the following

steps of daily maintenance:

Terminal

Splice

Nest

Sight Hole

Facing Nest

Sight Hole

Facing Nest

1. Remove dust, moisture, and other contaminants

from the dies with a clean brush, or a clean, soft,

lint--free cloth. DO NOT use objects that could

damage the dies.

2. If dies are coated with oil or preservative, wipe

them clean—particularly in the crimping

areas—before placing them in use.

Wire Visible

Through

Wire Visible

Through

Indenter

Sight Hole

3. When dies are not in use, make certain all

surfaces are protected with a THIN coat of any

good SAE 20 motor oil, then mate and store them

in a clean, dry area.

Figure 4

5. Activate the head or tool according to the

instructions included with the head or tool so that

ram advances and holds the terminal or splice in

place. DO NOT deform the wire barrel.

5.2. Periodic Inspection

Periodic inspections should be performed by quality

control personnel. A record of scheduled inspections

should remain with the dies or be made available to

personnel responsible for the dies. Though

recommendations call for at least a monthly

inspection, the inspection frequency should be based

upon the amount of use, working conditions, operator

training and skill, and established company

standards. These inspections should be performed in

the following sequence.

6. For terminals, insert the stripped wire into the

wire barrel until the end of the conductor is visible

in the sight hole. For butt splices, insert a stripped

wire into the wire barrel until the end of the

conductor is visible in the sight hole.

7. Activate the head or tool to crimp the wire

barrel.

A. Visual Inspection

If the terminal or splice sticks in the die after

crimping, grasp the wire close to the crimp and

apply a rocking motion to remove it from the die.

NOTE

1. Remove all lubrication and accumulated film by

immersing the dies in a suitable degreaser that will

not affect paint or plastic.

Rev D

3 of 5

408-10110

REJECT

Terminal

Splice

Crimp is centered on wire barrel. Crimp may be off

center but not off end of wire barrel.

Wire size being used matches the wire range or size

stamped on terminal or splice and dies.

Crimp is off end of wire barrel.

Wire size being used does not match the wire range

or size stamped on terminal or splice and dies.

Wire insulation does not enter wire barrel.

Wire insulation enters wire barrel. Check that the

strip length is correct.

End of wire is visible through sight hole of terminal or

splice.

End of wire is not visible through sight hole of terminal

or splice. Wire was not inserted far enough.

Excessive “flash” on terminal or splice. This indicates

damaged dies or wrong wire size, splice, or tooling com-

bination was used.

Nicked or missing strands.

Figure 5

2. Check all surfaces for wear. Inspect the crimp

area for flattened, chipped, cracked, worn, or

broken areas. If damage is evident, the die must

be replaced. Refer to Figure 6.

B. Gaging the Crimping Chamber

This inspection requires the use of a plug gage

conforming to the dimensions in Figure 7. Refer to

Figure 7, and gage the crimping chamber as follows:

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

bottomed. Hold the dies in this position.

Flattened

Chipped

Pitted

2. Align the GO element with the wire barrel

crimping chamber. Push the element straight into

the the crimping chamber without using force. The

GO element must pass completely through the

crimping chamber.

Broken

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

straight into the same crimping chamber. The

NO--GO element may start entry but must not pass

completely through.

Figure 6

4 of 5

Rev D

408-10110

If the crimping chamber conforms to the gage

inspection, the dies are considered dimensionally

correct. If not, the dies must be replaced. For

additional information regarding the use of a plug

gage, refer to Instruction Sheet 408--7424.

CUSTOMER SERVICE (038--035)

TYCO ELECTRONICS CORPORATION

PO BOX 3608

HARRISBURG PA 17105--3608

7. REVISION SUMMARY

6. REPLACEMENT

Revisions to this instruction sheet include:

Order replacement 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:

S Updated document to corporate requirements

S Corrected dimensions in table in Figure 7

Suggested Plug Gage Design

GO Gage Element

Diameter

NO -GO Gage Element

Diameter

Die Closure

Configuration

Diameter

Radius

50.8 [2.00] Typ

DIE

DIE CLOSURE DIAMETER GAGE ELEMENT DIAMETER

DIMENSION

NEST

INDENTER

1901657--1

1901657--2

1901657--3

NO-GO

(Typ)

2.54

[.1000]

2.692

[.1060]

2.54--2.548

[.1000--.1003] [.1059--.1060]

2.689--2.692

7.92

[.312]

3.18

[.125]

1--1490413--4

1--1490413--5

1--1490413--6

1--1490413--7

1--1490413--8

1--1490413--9

2--1490413--0

2--1490413--1

3.911

[.1540]

4.115

[.1620]

3.911--3.919

[.1540--.1543] [.1619--.1620]

4.112--4.115

11.09

[.437]

4.34

[.171]

4.699

[.1850]

4.902

[.1930]

4.699--4.706 4.899--4.902

[.1850--.1853] [.1929--.1930]

5.410--5.418 5.610--5.613

[.2130--.2133] [.2209--.2210]

6.172--6.179 6.372--6.375

[.2430--.2433] [.2509--.2510]

6.959--6.967 7.160--7.163

[.2740--.2743] [.2819--.2820]

7.832--7.830 8.023--8.026

[.3080--.3083] [.3159--.3160]

8.788--8.796 8.989--8.991

[.3460--.3463] [.3539--.3540]

11.09

[.437]

5.54

[.218]

5.410

[.2130]

5.613

[.2210]

11.09

[.437]

6.35

[.250]

6.172

[.2430]

6.375

[.2510]

11.09

[.437]

7.52

[.296]

6.959

[.2740]

7.832

[.3080]

7.163

[.2820]

8.026

[.3160]

14.27

[.562]

14.27

[.562]

8.33

[.328]

3.525

[.375]

8.788

[.3460]

8.991

[.3540]

14.27

[.562]

10.693

[.421]

Inspection of Crimping Chamber

Dies Bottomed But

Not Under Pressure

Crimping Chamber

Plug Gage

Element

NO-GO

Element

GO element must pass

completely through the

crimping chamber.

NO -GO element may enter

partially, but must not pass

completely through the

crimping chamber.

Crimping

Chamber

Figure 7

Rev D

5 of 5

1901657--2 [TE]

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