Tyco Electronics 69067 User manual

Instruction Sheet

408-2454

LOC B

of 4

2008 Tyco Electronics Corporation, Harrisburg, PA

All International ights eserved

TE logo and Tyco Electronics are trademarks.

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

TOOLING ASSISTANCE CENTE 1-800-722-1111

P ODUCT INFO MATION 1-800-522-6752 This controlled document is subject to change.

For latest revision and egional Customer Service,

visit our website at

www.tycoelectronics.com

25 AUG 08 ev B

Hy raulic Crimping Hea 69067

Figure 1

Pivot Pin

Yoke

Latch Pin

DYNA-C IMP*

Hydraulic Crimping

Head 69067

Quick-Disconnect Coupler,

Cylinder Half (Mates With

Coupler on Hose or Handle

Control)

Dust

Cap

1. INTRODUCTION

This instruction sheet provides application and

maintenance and Inspection Procedures for

DYNA–CRIMP Crimping Head 69067. The tool is

used to crimp SOLISTRAND* Terminals, Flag

Terminals, and Splices onto 8–4/0 AWG wire. See

Instruction Sheet 408–9785.

The crimping head is designed for DYNA–CRIMP

tools:

Hydraulic Power Unit 69120–[ ] (409–1950)

Hydraulic Hand Pump 314979–1 (409–5860)

Read these instructions, and all applicable

references, before inserting any die assemblies and

crimping any terminals or splices.

All dimensions on this document are in metric

units [with inches in brackets]. Figures and

illustrations are for reference only and are not

drawn to scale.

Reasons for reissue are provided in Section 8,

REVISION SUMMARY.

2. DESCRIPTION

(Figures 1 and 4)

The main components of the crimping head include: 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 (cylinder half),

which mates with the coupler on the hose or handle

control to release or supply pressure.

To avoid personal injury when using

D NA-CRIMP equipment, observe the following

precautions:

Do NOT modify the crimping equipment in any

way.

Use only dies, terminals, and wire specified for

the head.

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 hose or

handle control is released and that power supply

is disconnected from electric unit, if applicable.

1. Remove protective dust caps from both

quick–connect/disconnect couplers.

2. Hold hose or handle control in vertical position

to prevent oil spillage. Attach hose or handle

control to coupling section on head. THREAD

PROPERLY AND TIGHTEN SECURELY.

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 moved.

If using Hydraulic Power Unit 69120-[ ],

DISCONNECT POWER UNIT FROM POWER

SUPPL .

If using Hydraulic Hand Pump 314979-1,

depress pressure release lever.

NOTE

DANGER

CAUTION

NOTE

408-2454

Hydrauli Crimping Head 69067

Rev

of 4 Tyco Elec ronics Corpora ion

Figure 2

Push Nes in o

Yoke Well

Push Inden er

in o Ram Well

La ch Pin

Removed

Ram Advanced

Yoke

Place Screwdriver

Here o Remove Dies

4. DIE INSERTION AND REMOVAL

To avoid p rsonal injury, x rcis caution wh n

using pow r unit to avoid accid ntly d pr ssing

th foot p dal or th handl control wh n

installing or changing di s.

4.1. Die Insertion

1. Remove latch pin and open yoke on crimping

head.

2. Insert stationary die (upper) into yoke by

pushing die until the “ball seat” snaps into position.

See Figure 2.

3. Advance ram slightly before inserting the

indenter (moving die, lower), making sure that

moving die is properly oriented to mate with

stationary die. See Figure 2.

4. Close yoke and secure with latch pin.

5. Complete the cycle and return the ram to the

“DOWN” position.

Ensur that th latch pin is fully ins rt d or

damag may occur to th yok , di s, or latch pin.

4.2. Die Removal

1. Remove latch pin and open yoke.

2. Insert screwdriver under stationary die and pry

die out of yoke. See Figure 2.

3. Raise ram to full “UP” position.

4. Insert screwdriver under moving die and pry out

of ram.

A latch pin kit (part numb r 69709-4) is availabl

as an acc ssory it m. Th latch pin is attach d to

th pivot pin by a chain to avoid misplacing th

latch pin.

5. CRIMPING PROCEDURE

To avoid p rsonal injury wh n op rating th

pow r unit, b sur to x rcis caution whil

holding th t rminals, splic s, or wir n ar th

crimping ar a.

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.

K p th pow r unit in th upright position. N v r

op rat th unit without having a crimping h ad

attach d to th handl control or crimping h ad

coupling.

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

die according to instructions with the dies. MAKE

SURE THE LATCH PIN IS SECURE before

activating the power unit.

2. To advance ram when using handle control,

depress RESET switch, then depress RUN switch.

See note below. When using foot control, depress

and release RESET pedal, then depress RUN

pedal.

Activat th control with short, quick strok s until

th di s hold th t rminal or splic . Th ram will

not r turn until th crimping cycl is compl t ,

xc pt by th following m thods:

D pr ss th pr ssur r l as button locat d on

th l ctrical control box.

Wh n using pow r unit 69120-[ ] d pr ss

DUMP switch or p dal.

3. Insert the stripped wire into the terminal or

splice.

4. Depress RUN switch or pedal until power unit

completes crimping cycle and ram returns to

neutral position.

If th t rminal or splic sticks in th di aft r

crimping, apply a rocking action to r mov it from

th di .

DANGER

CAUTION

NOTE

DANGER

NOTE

408-2454

Hydraulic Crimping Head 69067

of 4Rev

Tyco Electronics Corporation

Operating Procedure for Hydraulic Foot Pump 69325-3

Hydraulic Ha d Pump 69325-3 was superceded

by Hydraulic Ha d Pump 314979-1.

Keep the foot pump i a vertical positio . Never

operate the u it without havi g a crimpi g head

attached to the crimpi g head coupli g.

1. Insert the terminal or splice in the stationary die

according to the instruction sheet for the dies being

used. MAKE SURE THE LATCH PIN IS SECURE

before activating the power unit.

2. Pump the upper foot pedal to activate the unit.

Continue pumping until the movable die contact the

terminal or splice and holds it firmly in place. A

sudden decrease in effort required to push the

pedal down will be observed during the initial

build–up of pressure.

3. Insert the stripped wire.

4. Continue pumping until the pressure relief valve

is activated. A slight decrease in effort required to

push the pedal down, accompanied by a snapping

sound, indicates maximum required crimping

pressure has been reached.

5. Press and hold the return pedal until the ram

withdraws from the closed position just enough to

remove the crimped terminal or splice.

If a termi al or splice sticks i the die after

crimpi g, apply a rocki g actio to remove it from

the die.

6. INSPECTION/MAINTENANCE

To avoid perso al i jury, be sure hydraulic

pressure is released a d power supply is

disco ected before followi g i spectio a d

mai te a ce procedures, u less otherwise

specified i the procedure.

Each crimping head is assembled and inspected

before shipment. Tyco Electronics recommends that

the crimping head be inspected immediately upon

arrival, and at regularly scheduled intervals, to ensure

that the crimping head has not been damaged during

handling and use. 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. isual 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.

Figure 3

Check These Areas

for Cracks

Check for Excessive

Wear at Pivot Pin

and Latch Pin

Check Die

Areas for

Damage

2. Inspect pivot pin holes and latch pin holes for

wear. Replace parts as needed.

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 PARTS AND REPAIR).

6.3. Crimping Head Inspection Procedure

A. With Hydraulic Power Unit 69120-[ ]

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, press the pressure

release button on the electrical control box or, if the

NOTE

DANGER

408-2454

Hydraulic Crimping Head 69067

Rev

of 4 Tyco Electronics Corporation

unit has the dump feature, move the trigger to the

dump position and hold it for several seconds. This

will release any pressure in the hydraulic system. If

the ram returns, the trouble is not in the crimping

head. If it does not return, return the crimping head

for repairs.

B. ith Hydraulic Foot Pump 69325-3

Hydraulic Foot Pump 69325-3 was superceded

by Hydraulic Hand Pump 314979-1.

If the ram fails to return after the return pedal is

pressed, refer to the crimping head disassembly

procedure, beginning with Step 2.

7. REPLACEMENT PARTS AND REPAIR

The parts listed in Figure 4 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 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

Tools may be returned to Tyco Electronics for

evaluation and repair. For tool repair service, contact

a Tyco Electronics Representative at

1–800–526–5136.

8. REVISION SUMMARY

The following changes were made since the previous

release of this sheet:

Updated document to corporate requirements

Deleted text in Section 1, Paragraph

3.2.NOTE, Section 6, and Paragraph 6.3.A

Changed Foot Pump 314979–1 to Hand Pump

314979–1 in all instances

Deleted Paragraph 6.4

Deleted parts information in Figure 4

ITEM NUMBER PART NUMBER DESCRIPTION QTY PER HEAD

1 311471-1 COUPLER, Quick-Disconnect, Cylinder Half 1

9a 306209-2 PIN, Latch 1

9b 301516 PIN, Pivot 2

9c 21045-9 RING, Retaining 2

9d 301556 SPRING 2

9e 301555 SPACER 2

9f 23057-6 BALL PLUNGER 1

12 1-22667-4 SETSCRE , Socket, Self-locking, 1/4-20 x .250 in. Lg. 1

13 23057-4 BALL PLUNGER 1

Figure 4

NOTE

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