Tyco Electronics 1752787-1 User manual

Instruction Sheet

Hydraulic Crimping 408--8914

LOC B

1of 4

E2010 Tyco Electronics Corporation, Berwyn, PA

TE logo and Tyco Electronics are trademarks.

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

TOOLING ASSISTANCE CENTER 1--800--722--1111

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

This controlled document is subject to change.

For latest revision and Regional Customer Service,

visit our website at www.tycoelectronics.com

18 MAR 10 Rev BHead 1752787- 1

Male

Quick--Disconnect

Coupler

Figure 1

Latch Pin

Dust Cap

Yoke

Pivot

Cylinder

Piston

(Ram)

This tool is used to crimp: AMPLI--BOND* Terminals,

PLASTI--GRIP* Terminals, TERMINYL* Terminals and Splices,

Pre--Insulated nylon Heavy Duty Terminals, Pre--Insulated

AMPOWER* Terminals, and Sealed COPALUM* Terminals and

Splices.

1. INTRODUCTION

This instruction sheet provides application,

maintenance, and inspection procedures for Crimping

Head 1752787--1 shown in Figure 1. The crimping

head accepts interchangeable die sets for a variety of

heavy--duty terminals and splices for large wire sizes

-- within Size 8 through 4/0 AWG range. Refer to

instructions packaged with specific die sets for

compatible products, wire ranges, strip dimensions,

and application procedures.

The crimping head is designed and recommended

only for use with Foot Hydraulic Pump 1583659--1;

Hand Hydraulic Pump 1583661--1, or Electric

Hydraulic Pump 1583660--1 (115 Vac), or 1583660--2

(230 Vac).

Read these instructions, and all applicable

references, before inserting any die assemblies and

crimping any terminals or splices.

Dimensions on this sheet are in millimeters [with

inches in brackets]. Figures are for reference only

and are not drawn to scale.

2. DESCRIPTION

Main components of the crimping head are: a yoke

which houses the stationary die and retains the

terminal assembly for crimping, a removable latch pin

which allows pivoting of the yoke on the pivot pin

(typically required for splice terminations), a cylinder

which contains the head’s hydraulic chamber, a piston

(ram) which holds and controls the moving die, and a

quick connect/disconnect coupler which mates with

the coupler on the hose to release or supply pressure.

To avoid injury when using hydraulic crimping

equipment, observe the following precautions:

-- Do NOT modify the crimping equipment in any

way.

-- Use only dies, terminals, and wire specified for

the head.

-- Do NOT perform repairs other than those

specified in the instructional material supplied

with the equipment.

3. CRIMPING HEAD INSTALLATION

Each crimping head is shipped with a coating of

lubricating oil to prevent rust and corrosion. Wipe the

oil off before installing the crimping head on the power

unit. Note that the crimping head is shipped without

oil inside the cylinder. To install crimping head,

proceed as follows.

Make sure that hydraulic pressure to the hose is

released and that power supply is disconnected

to electric power unit, if applicable.

1. Remove protective dust caps from both quick

connect/disconnect couplers.

2. Hold hose vertically to prevent oil spillage.

Attach hose to coupling section on head. Thread

properly and tighten securely.

ORIGINAL INSTRUCTIONS

NOTE

DANGER

408- 8914

Hydraulic Crimping Head 1752787- 1

Rev B2 of 4 Tyco Electronics Corporation

Oil flow must be unobstructed between power

unit and crimping head. Make sure that all

couplers are fully mated and tightened.

If crimping head must be removed after being in

production, pressure must be released in the

hydraulic system before head is removed.

-- If using Electric Hydraulic Pump 1583660--[ ],

DISCONNECT POWER UNIT FROM POWER

SUPPLY.

-- If using Foot Hydraulic Pump 1583659--1,

depress pressure release pedal, or if using Hand

Hydraulic Pump 1583661--1, activate the

pressure release knob.

Figure 2

Stationary/Upper Die

Moving/Lower Die

Latch Pin

Removed

Ram

Advanced

Ram

Setscrew

Yoke

Setscrew

4. DIE INSERTION AND REMOVAL (Figure 2)

Avoid personal injury. When using power unit,

exercise caution to avoid accidently depressing

foot pedal or hand control when installing or

changing dies.

Make sure that matched die set, terminal, and wire

size are compatible. With crimping head properly

installed, refer to die set instructions, and

insert/change die set as follows:

1. Remove latch pin and open yoke on crimping

head.

2. Loosen setscrew in yoke. Refer to die set

instructions and insert stationary (upper) die which

includes the nest area into well of yoke. Tighten

setscrew.

3. Activate power unit to advance ram until

setscrew is visible (about 12.7 mm [.50 in.]).

Loosen setscrew.

4. Insert moving (lower) die, which serves as the

indenter, into ram well, making sure that moving

die is properly oriented to mate with stationary die.

Tighten setscrew.

5. Close yoke and secure with latch pin.

6. Slowly close dies to ensure proper alignment.

7. Complete the cycle and return the ram to the

DOWN position.

Always ensure that latch pin is fully inserted or

damage may occur to yoke, dies, or latch pin.

5. CRIMPING PROCEDURE

Avoid personal injury. When operating power unit,

exercise caution while holding terminals, splices,

or wire near crimping area.

The following crimping procedure provides general

information. Refer to instructions packaged with

individual die sets for specific products, wire sizes,

strip dimensions, positioning of terminals and splices

in the dies, and crimping procedures.

Never operate the power unit without having a

crimping head attached to the hose.

1. Insert terminal or splice in the stationary (upper)

die according to instructions packaged with the

dies. Make sure the latch pin is secure before

activating the power unit.

2. Slowly advance moving (lower) die with short,

quick strokes until terminal or splice is secure.

3. Insert the stripped wire.

4. Cycle tool to complete crimp. Remove crimped

terminal or splice.

If the splice or terminal sticks in the die after

crimping, apply a rocking action to remove it from

the die.

6. INSPECTION/MAINTENANCE

Make sure hydraulic pressure is released and

power supply is disconnected before following

inspection and maintenance procedures, unless

otherwise specified in the procedure.

CAUTION

NOTE

DANGER

CAUTION

DANGER

NOTE

DANGER

408- 8914

Hydraulic Crimping Head 1752787- 1

3of 4Rev BTyco Electronics Corporation

Each crimping head is assembled and inspected

before shipment. Tyco Electronics recommends that

the crimping head be inspected immediately upon its

arrival at your facility, and at regularly scheduled

intervals, to ensure that the crimping head has not

been damaged during handling. Frequency of

inspection depends upon the following: care, amount

of use, and handling of the head; type and size of

products crimped; degree of operator skill; and

environmental conditions.

6.1. Cleaning

Remove accumulations of dirt and grease on the

crimping head, especially in areas where dies are

installed and terminals are crimped. Clean the entire

head frequently with a clean, lint--free cloth.

6.2. Visual Inspection

Refer to Figure 3 and proceed as follows:

1. With hydraulic pressure released, inspect the

assembled head for nicks, scratches, and cracks.

Inspect for cracks especially at the corners of the

yoke and around the top of the cylinder.

2. Inspect pivot pin holes and latch pin holes for

wear. Replace parts, as needed.

Figure 3

Check These Areas

for Cracks

Check Die Areas

for Damage

Check for Excessive Wear

at Pivot Pin and Latch Pin

3. Activate power unit. Raise ram to UP position.

Inspect flat and round surfaces of ram for galling

(fretting or wear by friction), cracks, or oil leakage.

Release pressure and make sure that ram retracts

smoothly.

4. If head shows evidence of galling, cracks, oil

leakage, or rough cycling, return the crimping head

to Tyco Electronics for repairs. (Refer to Section 7,

REPLACEMENT AND REPAIR).

Once a year, or every 7,500 cycles (whichever

comes first), the hydraulic head should be

returned to Tyco Electronics for magnetic particle

inspection. Additionally, inspect and service the

head (as described in Figure 3) every month or

1,000 cycles. Refer to Instruction Sheet

408--8909.

6.3. Crimping Head Check- Out Procedure

If the ram fails to return to the DOWN position after

completion of a crimping cycle, the cause may be in

the crimping head. To determine whether or not the

trouble is in the crimping head, proceed as follows:

A. Electric Hydraulic Pump 1583660- [ ]

Press the retract/release button on the hand remote

pendant or foot remote, and hold for several seconds.

This will release any pressure in the hydraulic system.

If the ram returns to DOWN position, the trouble is

NOT in the crimping head. If ram does not return,

ensure that the coupler is fully engaged. If coupler is

engaged and ran still does not go DOWN, return the

crimping head to Tyco Electronics for repairs.

B. Foot Hydraulic Pump 1583659- 1

Depress the pressure release pedal.

C. Hand Hydraulic Pump 1583661- 1

Activate the pressure release knob.

7. REPLACEMENT AND REPAIR

Customer--replaceable parts are listed in Figure 4. A

complete inventory can be stocked and controlled to

prevent lost time when replacement of parts is

necessary. Order replacement parts through your

Tyco Electronics Representative, or call

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

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

CUSTOMER SERVICE (38--35)

TYCO ELECTRONICS CORPORATION

PO BOX 3608

HARRISBURG PA 17105--3608

Tools may also be returned to Tyco Electronics for

evaluation and repair. For tool repair service, contact

a Tyco Electronics Representative at

1--800--526--5136.

NOTE

408- 8914

Hydraulic Crimping Head 1752787- 1

Rev B4 of 4 Tyco Electronics Corporation

8. REVISION SUMMARY

SAddition of “ORIGINAL INSTRUCTIONS”

76.84 [3.025]

123.19 [4.850]

337

[13.27]

Section A- A

WEIGHT:

13.6 kg [30 lb] (Approx.)

REPLACEMENT PARTS FOR CRIMPING HEAD 1752787--1

ITEM PART NUMBER DESCRIPTION QTY PER HEAD

1311470--1 COUPLER, Quick Connect/Disconnect 1

2306209--8 PIN, Removable Latch 1

38--59558--5 PIN, Pivot 1

41--21045--1 RING, Retaining 1

521061--9 SETSCREW 2

64--23147--7 SPRING, Compression 1

71--21919--6 PIN, Dowel 1

84--21012--0 SETSCREW 1

923150--3 NIPPLE, Hex 1

Figure 4

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