Tyco Electronics 696675-1 User manual

Instruction Sheet

SOLISTRAND*

Flag Terminal 408-8908

2004 Tyco Electronics Corporation, Harrisburg, PA

All International Rights Reserved

AMP and Tyco are trade arks. *Trade ark

Other products, logos, and co pany na es used are the property of their respective owners. LOC B

of 6

TOOLING ASSISTANCE CENTER 1-800-722-1111

FAX/PRODUCT INFO 1-800-522-6752

For Regional Custo er Service, visit our website at

www.tycoelectronics.com

This controlled docu ent is subject to change.

For latest revision, call the FAX/PRODUCT INFO nu ber.

24 SEP 04 Rev O

rimping Dies

PROPER USE GUIDELINES

Cu ulativeTrau aDisorderscanresultfro theprolongeduseof anuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolu e

applications. A wide selection of powered application equip ent for extended-use, production operations is available.

–

Hydraulic

Hand Tool

1490749-1

Tools Using Crimping Dies for

SOLISTRAND Flag Terminals

Hydraulic Head

1490746-1

Flag Terminal Die Set (Typical)

Nest

Indenter

PRODU T

DIES NOMINAL WIRE

SIZE MM

( MA) TOOLING

PRODU T

NEST INDENTER MM2AWG

()

RANGE HYDRAULI

HEAD HYDRAULI

HAND TOOL

696675-1 1752682-1

6 637 10 539

696679-1 1752682-2 1752681-2 7-8 8

637

539

[13 100

20 800]

322727-[ ] 1752680-8

[13

100-20

800]

321576 1752680-7 13-15 6 10.539-16.771

[20,800-33,100]

321060 1752680-6 1752681-3 21 4 16.771-26.653

[33,100-52,600]

321064 1752680-5 34-35 2 26.653-42.411

[52,600-83,700] 1490746-1 1490749-1

321066 1752680-4 59-60 1/0 42.411-60.511

[83,700-119,500]

321584 1752680-3

1752681 1

67-70 2/0 60.551-72.259

[119,500-150,500]

327887 1752680-2

1752681

80-95 3/0 72.259-96.274

[150,500-190,000]

321259-[ ] 1752680-1 100-125 4/0 96.274-117.049

[190,000-231,000]

Figure 1

1. INTRODU TION

This instruction sheet provides application

instructions, maintenance, and inspection procedures

for the dies listed in Figure 1. These dies crimp

SOLISTRAND Flag Terminals to solid or stranded

copper wire (also listed in Figure 1).

The dies are used in Hydraulic Head 1490746–1 and

Hydraulic Hand Tool 1490749–1. Refer to Figure 1.

408-8908

SOLISTRAND Flag Terminal Crimping Dies

Rev

of 6

All dimensions on this document are in metric

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

Figures are for reference only and are not drawn

to scale.

2. DESCRIPTION

Each die assembly consists of a nest and an indenter

(ordered separately) which are retained in the

crimping head by retainer pins. The nest is positioned

in the yoke of the crimping head, and the indenter is

positioned in the ram of the tool.

3. DIE INSTALLATION AND REMO AL

Refer to Figure 1 and determine the correct die

assembly, wire size, product number, and tool head to

use with the die assembly.

Never operate the tool with the dies removed.

3.1. Die Installation

(Figure 2)

To avoid personal injury be sure to exercise

extreme caution when using the power unit.

Avoid depressing the footswitch or trigger control

when installing or removing dies.

Figure 2

Nest

Indenter

Die Release Button

Ram (Advanced)

1. Depress the upper release button located in the

“C”–head.

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

Figure 2.

3. Release the button and rock the die back and

forth until the nest snaps into position.

4. Activate the power unit until the lower die

release button located in the ram is exposed.

5. Depress the release button.

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

Figure 2.

7. Release the button and rock the indenter back

and forth until the die snaps into position.

8. Return ram to the down position.

3.2. Die Removal

(Figure 2)

1. Depress the upper release button located in the

“C”–head and slide the nest out of the head.

2. Activate the power unit until the lower die

release button (located in the ram) is exposed.

3. Depress the release button and slide the

indenter out of the ram.

4. WIRE STRIPPING AND CRIMPING PROCEDURE

AVOID PERSONAL INJURY. Exercise extreme

caution when operating crimping head and

holding terminals or wire near the crimping dies.

4.1. Wire Stripping

Obtain the correct wire, flag terminal, and crimping

tool (with correct die assembly installed) for your

application. Strip wire insulation to the dimensions

indicated in Figure 3, taking care not to nick or cut

conductor(s), and proceed as follows:

4.2. Crimping Procedure

1. Ensure that wire size stamped on flag terminal

corresponds to wire size being used in the

application and wire size stamped on nest and

indenter.

2. Center flag terminal wire barrel in die nest.

When crimping flag terminals, hold tongue of flag

terminals against nest as shown in Figure 4. If

terminal locator is present, slide terminal into

terminal locator and press the tongue of the flag

terminal against the slope on the nest.

3. Activate power unit so that ram advances and

holds terminal in place but DOES NOT deform wire

barrel.

4. Insert stripped wire into terminal until end of

conductor is flush with or extended slightly beyond

end of wire barrel. See Figure 3.

5. Activate power unit to complete crimp.

If terminal sticks in die after crimping grasp wire

close to crimp and apply a rocking motion to

remove the die.

6. Refer to Paragraph 5.1, Crimp Inspection, for

terminal crimp inspection procedure.

NOTE

CAUTION

DANGER

NOTE

408-8908

SOLISTRAND Flag Terminal Crimping Dies

of 6Rev

Wire Barrel

Crimped

Flag Terminal

Die Set

Terminal

Strip Length Hydraulic Head (Typical)

PRODUCT

NOMINAL WIRE SI E STRIP LENGTH

PRODUCT

MM2AWG MINIMUM MAXIMUM

696 5-1

696 9-1 -8 8 9.53 [.3 5] 11.18 [.440]

322 2 -[ ]

3215 6 13-15 6 12. 0 [.500] 14.2 [.562]

321060 21 4 13.82 [.554] 15.48 [.609]

321064 34-35 2 1 .06 [.6 2] 18.65 [. 34]

321066 59-60 1/0 22.23 [.8 5] 23.81 [.93 ]

321584 6 - 0 2/0 23.81 [.93 ] 25.40 [1.000]

32 88 80-95 3/0 26.98 [1.062] 28.58 [1.125]

321259-[ ] 100-125 4/0 28.58 [1.125] 30.16 [1.18 ]

Figure 3

Figure 4

Hydraulic Head (Typical)

Center Terminal

Wire Barrel in Nest

Hold Flag Terminal

Tongue Against

Slope on Nest Until

Crimp is Started

5. MAINTENANCE AND INSPECTION

Disconnect power supply before performing

maintenance, adjustments, inspections, and

repairs.

5.1. Crimp Inspection

(Figure 5)

Inspect crimped terminals by checking the features

described in Figure 5. Use only terminals that meet

the conditions shown in the ACCEPT column.

Terminals 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

5.2 and 5.3.

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.

DANGER

408-8908

SOLISTRAND Flag Terminal Crimping Dies

Rev

of 6

Figure 5

ACCEPT REJECT

1. Crimps centered. Crimps may be off center but NOT off

end of wire barrel.

2. Wire size being used matches wire range or size stamped

on flag terminals or dies.

. Insulation does not enter wire barrel.

4. Inserted wire is flush with or extended slightly beyond end

of wire barrel.

1. Crimped off end of terminal.

2. Wire size being used does not match wire size or range

stamped on flag terminal.

. Wire not inserted far enough in terminal.

4. Insulation entered barrel of terminal. CHECK FOR

INCORRECT STRIP LENGTH.

5. Nicked or missing conductor strands.

FLAG TERMINAL

Wire Range

Stamped Here

Wire Range

Stamped Here

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. Periodi Inspe tion

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 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 Inspe tion

(Figure 6)

1. Remove all lubrication and accumulated film by

immersing the dies in a suitable degreaser that will

not affect paint or plastic material.

2. Check all surfaces for wear. Inspect the crimp

area for flattened, chipped, cracked, worn, or

broken areas. See Figure 6. If damage is evident,

the die must be replaced.

Figure 6

Broken

Chipped

Pitted

408-8908

SOLISTRAND Flag Terminal Crimping Dies

of 6Rev

B. Gaging the Crimping Cham er

(Figures 7 and 8)

This inspection requires the use of a plug gage

conforming to the dimensions in Figure 7. 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 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.

Suggested Plug Gage Design

A" Dim. R"

B" GO Dim. C" Dim. Typ

R"

0.80

[2.000]

Typ

Die Closure

Configuration

B" NO-GO Dim.

DIES DIE CLOSURE

DIMENSION A" GAGE ELEMENT

DIMENSION B" C"

DIMENSION

RADIUS



NEST INDENTER GO NO-GO GO NO-GO

DIMENSION

17 2682-1

17 2682-2 17 2681-2 2. 4 [1.000] 2.692 [.1060] 2. 4-2.

[

.1000-.1003

]

2.689-2.692

[

.10 9-.1060

]

12.70 [. 00] 3. 8 [.141]

17 2680-8

[]

17 2680-7 3. 1 [.1380] 3.708 [.1460] 3. 0 -3. 13

[.1380-.1383] 3.70 -3.708

[.14 9-.1460] 3.96 [.1 6]

17 2680-6 17 2681-3 4.140 [.1630] 4.343 [.1710] 4.140-4.147

[.1630-.1633] 4.340-4.343

[.1709-.1710] 11.099 [.437] 4.76 [.187]

17 2680- 4.9 3 [.19 0] .1 6 [.2030] 4.9 3-4.960

[.19 0-.19 3] .1 3- .1 6

[.2029-.2030] .94 [.234]

17 2680-4 6.172 [.2430] 6.37 [.2 10] 6.172-6.179

[.2430-.2433] 6.372-6.37

[.2 09-.2 10] 7. 2 [.296]

17 2680-3

17 2681 1

6.9 9 [.2740] 7.163 [.2820] 6.9 9-6.967

[.2740-.2743] 7.160-7.163

[.2819-.2820]

14 27 [ 62]

8.33 [.328]

17 2680-2

17 2681

7.823 [.3080] 8.026 [.3160] 7.823-7.830

[.3080-.3083] 8.023-8.026

[.31 9-.3160]

27 [

62]

9. 3 [.37 ]

17 2680-1 8.788 [.3460] 8.991 [.3 40] 8.788-8.796

[.3460-.3463] 8.989-8.991

[.3 39-.3 40] 10.89 [.421]

Figure 7

408-8908

SOLISTRAND Flag Terminal Crimping Dies

Rev

of 6

Figure 8

Terminal Dies (Typical)

Dies Bottomed but

Not Under Pressure

GO" lement Must Pass

Completely Through the

Die Closure

NO-G0" lement May nter

Partially, but Must Not Pass

Completely Through the Die

Closure

6. REPLACEMENT PARTS

Refer to Figure 1 when replacement of a die becomes

necessary, contact your local Tyco Electronics

Representative; call 1–800–526–5142; 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

7. RE ISION SUMMARY

Per EC 0990–0402–04:

Initial release of instruction sheet

This manual suits for next models

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