Tyco Electronics 1901820-1 User manual

Instruction Sheet

408-10111

LOC B

of 4

2007 Tyco Electronics Corporation, Harrisburg, PA

All International Rights Reserved

TE logo and Tyco Electronics are trademarks.

*Trademark. Other products, logos, and company names used are the property of their respective owners.

TOOLING ASSISTANCE CENTER 1-800-722-1111

PROD CT INFORMATION 1-800-522-6752 This controlled document is subject to change.

For latest revision and Regional Customer Service,

visit our website at

www.tycoelectro ics.com

30 OCT 07 Rev B

Hydraulic Crimpi g Head 1901820-1

MPORTANT SAFETY INFORMATION

408-10111

Hydr ulic Crimping He d 1901820-1

Rev

of 4 yco Electronics Corporation

Figure 1

Upper Die

Release

Button

Die Retaining

Pins

Ram

(Advanced)

Quick-Disconnect

Coupling Dust Cap

Cylinder

Lower Die Release

Button

C"-Head

1. INTRODUCTION

This instruction sheet provides operation and

maintenance instructions for the 12 Ton Hydraulic

Crimping Head 1901820–1. See Figure 1.

The crimping head is designed to use dies that crimp

the terminals in Figure 2. Figure 2 also lists the wire

sizes onto which the terminals and splices are

crimped, as well as the instruction sheet for the

crimping dies.

TERMINALS WIRE SIZE

(AWG) INSTRUCTION

SHEET

AMPOWER*

erminals and Splices 6 hrough 3/0 408-8703

SOLIS RAND*

erminals and Splices 8 hrough 4/0 408-8691

ERMINYL*

erminals and Splices 8 hrough 4 408-8704

Figure 2

Dimensions on this document are in metric units

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

otherwise specified.

2. DESCRIPTION

(Figure 1)

Main components of Hydraulic Crimping Head

1901820–1 include a “C”–head, which houses the

stationary die, the upper and lower die release

buttons which release the dies, a cylinder which

contains the head’s hydraulic chamber, a piston (ram)

which holds and controls the moving die, and a

quick–disconnect coupling (cylinder half) which mates

with the coupling on the hose to release or supply

pressure. A dust cap covers the quick–disconnect

coupling.

3. INSTALLATION

3.1. He d Inst ll tion

Prior to installing the head, ensure that the pump

and hose being used are working properly, and

are adjusted to and rated at 10,000 psi. An

incorrectly adjusted or rated pump/hose could

result in severe tooling damage, as well as

personal injury.

1. Release the hydraulic pressure to the hose.

Disconnect electric power unit from power supply.

2. Remove protective dust caps.

3. Thoroughly clean the coupling on the

pump/hose and the coupling on the crimping head.

4. Mate both quick–disconnect couplings and

tighten the collar of the coupler assembly on the

hose.

Oil flow must be unobstructed between the power

unit and the crimping head. Ensure that all

couplings are fully mated and tightened.

If a crimping head must be removed after the

power unit was in operation, be sure to release

the pressure in the hydraulic system. When

using Hydraulic Power Unit 1804700-[ ],

DISCONNECT THE POWER UNIT FROM THE

POWER SUPPL . When using Hydraulic Foot

Pump 1583659-1 or Hydraulic Hand Tool

1583661-1, depress the pressure release pedal

to release pressure.

3.2. Die Inst ll tion

To avoid personal injury, do NOT accidentally

depress the footswitch or handle control when

installing or removing dies.

NOTE

CAUTION

NOTE

DANGER

408-10111

Hydraulic Crimping Head 1901820-1

of 4Rev

Tyco Electronics Corporation

Operating the head WITHOUT the crimping dies

installed will damage the C"-Head or ram.

Install the dies as described in the appropriate die

instruction sheet. Refer to Figure 2.

4. CRIMPING PROCEDURE

The following procedure provides only general

information concerning crimping. Refer to the

instructions packaged with the dies (see

Figure 2) and power unit for detailed information,

including wire stripping dimensions and instructions

for positioning terminals and splices in the dies.

1. Insert terminal or splice in the stationary die

according to the instructions packaged with the

dies.

2. Activate the power unit to advance the dies and

hold the terminal or splice in place.

3. Insert stripped wire into the terminal or splice.

4. Activate the power unit to complete the crimp.

5. INSPECTION/MAINTENANCE

Make s re hydra lic press re is released and

power s pply is disconnected before following

inspection and maintenance proced res, nless

otherwise specified in the proced re.

Each crimping head is assembled and inspected

before shipment. It is recommended 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.

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,

whichever comes first. Refer to Figure 1.

5.1. 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.

5.2. Visual Inspection

In addition to the inspections listed in Figure 3,

inspect the head for nicks, scratches, and cracks.

Inspect for cracks especially at the corners of the

“C”–head and around the top of the cylinder. Refer to

Figure 4.

Inspect the metal surfaces for nicks, cracks,

scratches, and excessive wear, especially where

sliding contact occurs.

5.3. Crimping Head Check-Out Procedure

If the ram fails to retract 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, release pressure in the power unit.

If the ram retracts, the trouble is not in the crimping

head. If ram does NOT retract, refer to Section 6,

RETURN/REPAIR.

6. RETURN/REPAIR

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

P.O. BOX 3608

HARRISBURG, PA 17105–3608

Crimping heads may also be returned for evaluation

and repair. For tool repair service, contact a Tyco

Electronics representative at 1–800–526–5136.

7. REVISION SUMMAR

Since the previous release of this document, the

corporate logo was updated.

CAUTION

DANGER

408-10111

Hydraulic Cri ping Head 1901820-1

Rev

of 4 Tyco Electronics Corpor tion

ITEM TO BE

INSPECTED INSPECTION/PROBLEM POSSIBLE SOLUTION

Inspect for cr cks, gouges, nicks, or g lling on the

C"-He d or where the C"-He d cont cts dies. Return tool for rep ir (see Section 6,

RETURN/REPAIR).

C"-He d Check to see if the upper die ret ining pin does not

hold the st tion ry die in pl ce. Return tool for rep ir (see Section 6,

RETURN/REPAIR).

Check to see if the upper die rele se button sticks

(it should norm lly move in nd out e sily when

moder te pressure is pplied).

Return tool for rep ir (see Section 6,

RETURN/REPAIR).

Ins

ect for evidence of cr cks,

es, nicks, or

If there re cr cks, return the tool for rep ir (see

Section 6, RETURN/REPAIR).

p,gg,,

g lling. For tr ces of gouges, nicks, or g lling: Remove ny

sh rp edges using fine emery cloth.

Cylinder Inspect for oil le ks between the cylinder nd

coupling.

For oil le ks nd sticky coupling tighten or repl ce

Check to see if the coupling sticks to the cylinder (it

should norm lly turn on nd off freely when moder te

pressure is pplied with pplied with wrench).

or o

il l

s n

y coup

ng,

en or rep

the coupling

Quick-Disconnect

Coupling The coupling m tes h rd or won't m te or rele se, or

it le ks oil, or it sticks t the hose connection. Repl ce coupling.

Inspect the r m in the Power ON" (r m dv nced)

position for evidence of g lling, cr cks, or oil le ks

bt th dth lid

If there re cr cks or le ks, return the tool for rep ir

(see Section 6, RETURN/REPAIR).

between the r m nd the cylinder. If there is g lling, remove ny sh rp edges using

fine emery cloth.

R m

Check to see if the lower die ret ining pin does not

hold the moving die in pl ce. Return tool for rep ir (see Section 6,

RETURN/REPAIR).

R m

Check to see if the lower die rele se button sticks

(it should norm lly move in nd out e sily when

moder te pressure is pplied).

Return tool for rep ir (see Section 6,

RETURN/REPAIRS).

Inspect the r m in the Power OFF" (r m retr cted)

position to ensure th t the r m returns freely to its

origin l position.

Return tool for rep ir (see Section 6,

RETURN/REPAIRS).

Figure 3

Figure 4

Check These

Areas for Cracks

Quick-Disconnect

Coupling 311470-1

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