Tyco Electronics 408-10050 User manual

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Instruction Sheet

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

1of 6

LOC B

Crimping Dies for SOLISTRAND*

Terminals and Splices 408-10050

28 DEC 10 Rev C

PROPER USE GUIDELINES

Cumulative Trauma Disorders can result from the prolonged use of manually 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.

Figure 1

1. INTRODUCTION

This instruction sheet provides instruction on

application and maintenance and inspection

procedures for dies that crimp SOLISTRAND ring

tongue terminals, butt splices, and parallel splices.

These dies are used to crimp product on solid or

stranded copper wires. The dies are used in Battery

Operated Hand Tool 1901343-1, -2, -3, and -4

(Customer Manual 409-10070). Read these

instructions, and all applicable references, before

inserting any die assemblies and crimping any

terminals. See Figure 2.

Dimensions on this document are in metric units

with [U.S. customary units in brackets}. Figures and

illustrations are for reference only and are not

drawn to scale.

2. DESCRIPTION (Figure 1)

Each die assembly consists of a nest and an indenter,

ordered separately, which are retained in the crimping

head by set screws. The nest is positioned in the yoke

of the crimping head and the indenter is positioned in

the ram of the tool, in all applications.

3. DIE INSTALLATION AND REMOVAL

Refer to Figure 2 and determine the correct die

assembly and wire size for the terminal splice part

number.

AVOID PERSONAL INJURY. Exercise extreme

caution when using the tool.

3.1. Die Installation

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

the crimp head.

2. Loosen the set screw in the yoke.

3. Insert the shank of the nest into the yoke and

tighten the set screw.

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

5. Loosen the set screw in the ram.

6. Insert the shank of the indenter into the ram and

tighten the set screw.

7. Return the ram to the down position.

8. Pivot the latch arm and yoke toward each other

until the locking flange secures the latch arm to the

yoke.

Nest

Indenter

Yoke

Yoke Screw

Nest

Shank

Push Nest

Into Yoke

Push Indenter

Into am

Adapter

Latch

Arm

Locking

Flange

Nest Indenter

Indenter

Shank

NOTE

DANGER

STOP

408-10050

2of 6

Rev C

Figure 2

Always make sure the yoke and latching arm are

secured by the locking flange before cycling the

tool.

3.2. Die Removal

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

the head.

2. Loosen the set screw in the yoke and remove the

nest.

3. Raise the ram to full up position.

4. Loosen the set screw in the ram and remove the

indenter.

Figure 3.

NOMINAL WIRE SIZE mm2(CIRCULAR MIL AREA

RANGE)

TYPICAL

PRODUCT

DIES

mm2AWG NEST INDENTER

7 - 8 8 6.637-10.539

[13,100-20,800]

33463

RTT•• 1901001-1• 1901002-2•

13 - 15 6 10.539-16.771

[20,800-33,100]

33466

RTT•• 1901000-1• 1901002-1•

21 4 16.771-26.653

[33,100-52,600]

34323

BS••• 1901000-2• 1901002-1•

34 - 35 2 26.653-42.411

[52,600-83,700]

35187

PS•••• 1901000-3• 1901002-1•

• Also used for STRAO-THERM* Heat Resistant Uninsulated Terminals. •• RTT = Ring Tongue Terminals ••• BS = Butt Splice

•••• PS = Parallel Splice.

CAUTION

NOMINAL WIRE

SIZE

mm2 (CIRCULAR

MILL AREA)

STRIP LENGTHS

mm [In.]

mm2AWG

RING TONGUE

TERMINALS BUTT SPLICES PARALLEL SPLICES

MIN. MAX. MIN. MAX. MIN. MAX.

7 - 8 8 6.637-10.539

[13,100-20,800]

8.334

[.328]

9.128

[.359]

10.319

[.406]

11.112

[.437]

10.319

[.406]

11.112

[.437]

13 - 15 6 10.539-16.771

[20,800-33,100]

9.922

[.391]

13.225

[.522]

11.906

[469]

12.700

[.500]

11.112

[.437]

11.905

[.469]

21 4 16.771-26.653

[33,100-52,600]

11.509

[.453]

12.302

[.484]

13.493

[.531]

14.288

[.563]

13.493

[.531]

14.288

[.563]

34 - 35 2 26.653-42.411

[52,600-83,700]

13.06

[.516]

13.890

[.547]

15.081

[.594]

15.875

[.625]

15.081

[.594]

15.875

[.625]

408-10050

3of 6

Rev C

4. WIRE STRIPPING AND CRIMPING PROCEDURE

4.1. Wire Stripping

Strip the wire to the dimensions listed in Figure 3. Do

NOT nick or cut the wire strands.

AVOID PERSONAL INJURY. When operating the

tool, exercise caution while holding the terminals,

splices, or wire near the crimping area.

4.2. Crimping Procedure

1. Ensure the wire range or size stamped on the

terminal or splice corresponds with the size being

used with the wire size or range stamped on the

nest and indenter.

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

the head.

3. Center terminal or splice in nest as shown in

Figure 4. For best results, when brazed seam on

terminal or splice is visible, position seam toward

indenter.

4. Holding the terminal or splice in place, pivot the

latch arm and yoke 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.

5. Activate the tool so that ram advances and holds

terminal or splice in place. Do NOT deform terminal

or splice wire barrel.

6. IInsert stripped wire into terminal or parallel

splice until end of conductor is flush with or

extended slightly beyond end of wire barrel.

7. Insert stripped wire into butt splice until end of

conductor butts against splice wire stop.

8. Activate the tool to complete the crimp.

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 the terminal or

splice.

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

the head.

10. Remove the crimped terminal or splice from the

tool.

11. For butt splice, repeat steps 2 through 10 for

other wire barrel.

12. Refer to Paragraph 5.1, Crimp Inspection, for

standard terminal, butt and parallel splice crimp

inspection procedure.

5. INSPECTION/MAINTENANCE

Remove battery from tool before performing

maintenance, adjustments, inspections, and

repairs.

Figure 4

DANGER

STOP

CAUTION

NOTE

DANGER

STOP

Terminal

Butt

Splice

Parallel

Splice

Inspection Holes of

Terminal or Butt Splice

Must Face Either Die

End of Wire Visible

Through Inspection Hole

Ends of Wires Flush with or

Extended Beyond the End

of the Barrel

Center Terminal or Splice

Wire Barrel in the Nest

408-10050

4of 6

Rev C

These instructions have been approved by Design,

Production, and Quality Control Engineers to provide

documented maintenance and inspection procedures.

Through Tyco Electronics Test Laboratories and the

inspection of production assembly, the procedures

described herein have been established to ensure

quality and reliability of the crimping die assemblies.

Customer-replaceable parts are listed in Figure 2. A

complete inventory should be stocked and controlled

to prevent lost time when replacement of parts is

necessary.

5.1. Crimp Inspection (Figure 5)

The accompanying procedure is included as an aid

to the tool operator ONLY. It is not intended to serve

as a quality control procedure for qualifying finished

crimps on SOLISTRAND Terminals or Splices.

Inspect crimped terminals or splices by checking the

features described in Figure 5. 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

Paragraphs in 5.2 and 5.3.

Figure 5

NOTE

408-10050

5of 6

Rev C

5.2. Daily Maintenance

It is recommended that each operator of the dies be

made aware of, and responsible for, the following

steps of daily maintenance:

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

clean - particularly in the crimping areas - before

placing them in use.

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

surfaces are protected with a THIN coat of any good

SAE‡ No. 20 motor oil, and mate and store them in

a clean, dry area.

5.3. Periodic Inspection

Regular inspections should be performed by quality

control personnel. A record of scheduled inspections

should remain with the dies or be made available to

supervisory 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:

A. Visual Inspection (Figure 6)

1. Remove all lubrication and accumulated film by

immersing the dies in a suitable degreaser that will

not affect paint or plastic.

Figure 6

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.

B. Gaging the Crimping Chamber (Figure 7 and Figure 8)

The inspection requires the use of a plug gage

conforming to the dimensions in Figure 8. Tyco

Electronics does not manufacture or market these

gages.

Proceed as follows:

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

bottomed. Hold the dies in this position.

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.

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. If the crimping chamber

conforms to the gage inspection, the dies are

considered dimensionally correct. If not, they must

be replaced. For additional information regarding

the use of a plug gage, refer to Instruction Sheet

408-7424.

6. REPLACEMENT PARTS

Order replacement dies through your Tyco Electronics

Representative, or call 1-800-526-5142, or send a

facsimile of your purchase order to 717-986-7605, or

write to:

CUSTOMER SERVICE (038-035)

TYCO ELECTRONICS CORPORATION

PO BOX 3608

HARRISBURG PA 17105-3608

7. REVISION SUMMARY

Revisions to this instruction sheet include:

•Logo update

•Updated format to current corporate requirements.

Pitted

Broken

Chipped

‡ Trademark of Society of Automotive Engineers

408-10050

6of 6

Rev C

Figure 7

Figure 8

Dies Bottomed but

Not Under Presssure

“GO” Element Must Pass

Completely Through the

Die Closure

“NO-GO” Element May

Enter Partially, But Must

NOT Pass Completely

Through the Die Closure

DIES DIE CLOSURE DIM. “A” GAGE ELEMENT DIM. “B” DIM.

“C”

RADIUS

“R”

NEST INDENTER GO NO-GO GO NO-GO

1901001-1 1901002-2 2.54

[.1000]

2.692

[.1060]

2.54 - 2.692

[.1000 - .1003]

2.689 - 2.692

[.1059 - .1060]

2.92

[.312]

3.18

[.1225]

1901000-1 1901002-1 3.911

[.1540]

4.1115

[.1620]

3.911 - 3.919

[.1540 - .1543]

4.112 - 4.115

[.1619 - .1620]

11.09

[.437]

4.34

[.171]

1901000-2 1901002-1 4.699

[.1850]

4.902

[.1930]

4.699 - 4.706

[.1850 - .1853]

4.899 - 4.902

[.1929 - .1930]

11.09

[.437] 5.54

1901000-3 1901002-1 5.410

[.2130]

5.613

[.2210]

5.410 - 5.418

[.2130 - .2133]

5.610 -5.613

[.2209 - .2210]

11.09

[.437]

6.35

[.250]

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