Tyco Electronics DYNA-CRIMP User manual

Instruction heet

DYNA-CRIMP*

Crimping H ad 408-2450

(was I 2450)

LOC B

of 4

2008 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 A I TANCE CENTER 1-800-722-1111

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

For latest revision and Regional Customer ervice,

visit our website at

www.tyco l ctronics.com

20 MAY 08 Rev A

69051

Yoke

Cylinder

Head

Removable

Latch Pin

Cylinder

Dust Cap (Ref)

Quick-Disconnect

Coupling

Ram

Pivot

etscrew

DYNA-CRIMP

Crimping Head

69051

Figure 1

1. INTRODUCTION

This instruction sheet provides instructions on product

application and a Maintenance and Inspection

procedure for the DYNA–CRIMP Crimping Head

69051. This tool is used to crimp:

AMPLI–BOND* Terminals, wire sizes 8–2

AWG. See Instruction Sheet 408–1758.

PLASTI–GRIP* Terminals, wire sizes 8–2

AWG. See Instruction Sheets 408–1729 and

408–1758.

Pre–Insulated AMPOWER* Terminals, wire

size 2. See Instruction Sheet 408–1758.

COPALUM* Terminals and Splices, wire sizes

8–4 (inhibitor filled) AWG. See Instruction

Sheet 408–2134.

TERMINYL* Terminals and Splices, wire sizes

8–2 AWG. See Instruction Sheet 408–1729.

Pre–Insulated AMPOWER Terminals wire sizes

4–2 AWG. See Instruction Sheet 408–1729.

Basic instructions on the use of this crimping head

are provided in Section 2, INSTRUCTIONS. Section 3

contains a Maintenance and Inspection Procedure

required to establish and maintain a tool certification

program.

2. INSTRUCTIONS

2.1. Attaching th Crimping H ad

If a coupling component for the hose assembly is

packaged inside the quick-disconnect coupler on

the head, it is to be used to replace the coupling

on a hose assembly not equipped with a

quick-disconnect coupler.

Avoid personal injury. Release hydraulic pressure

to hose or handle control. Disconnect electric

power unit from power supply.

1. Thoroughly clean coupling area of handle

control or hose assembly and crimping head.

2. Remove protective (dust) caps.

3. Mate both quick–disconnect couplers and

tighten collar of coupler assembly on crimping

head. See Figure 1.

Oil flow must be unobstructed between power

unit and crimping head. Ensure that all couplers

are fully mated and tightened.

If a crimping head must be removed after power

unit was in operation, pressure must be released

in the hydraulic system. When using hydraulic

power unit 69120- ], DISCONNECT POWER

UNIT FROM POWER SUPPLY. When using

hydraulic hand pump 314979-1, make sure to

depress pressure release lever.

2.2. Di Ins rtion and R moval

Avoid personal injury. When using power unit,

exercise caution to avoid accidentally depressing

the foot switch or handle control when changing

dies.

A. Di Ins rtion

1. Remove latch pin and open yoke. See Figure 2.

NOTE

DANGER

CAUTION

NOTE

DANGER

408-2450

DYNA-CRIMP Crimping Head 69051

Rev

of 4 Tyco Electronics Corporation

Figure 2

Yoke Set Scre

Large Shank on

Stationary Die

Small Shank on

Moving Die

Set Scre

Ram

Advanced

Latch Pin

Removed

Befo e dies a e inse ted, loosen the socket head

cap sc ews that hold the insulation c imping

section of the dies in place. If sc ews a e not

loosened, the dies may mot fit into the head of

the tool because of close clea ance. The

insulation c imp adjustment must be made

acco ding to the inst uction sheet packaged with

the dies.

2. Loosen set screw in yoke.

3. Insert stationary die (die with large shank) into

yoke as shown in Figure 2. Tighten the set screw.

4. Activate tool to advance ram until set screw is

visible.

5. Loosen set screw in ram and insert moving die

(die with small shank) into ram as shown in

Figure 2. Tighten set screw.

Be su e that moving die is p ope ly o iented with

stationa y die.

6. Return ram to the “down” position.

7. Close yoke and insert latch pin.

Ensu e that the latch pin is fully inse ted o

damage may occu to the yoke, dies, o latch pin.

B. Die Removal

1. Remove latch pin and open yoke.

2. Loosen set screw in yoke and remove stationary

die.

3. Raise ram to “full up” position. Loosen set screw

and remove moving die.

Latch pin kit 69709 is available as an accesso y

item. The latch pin is attached to the pivot pin by

a chain and the eby eliminates the possibility of

misplacing the latch pin.

2.3. Crimping Pro edure

Avoid pe sonal inju y. When ope ating powe unit,

exe cise caution while holding te minals, splices,

o wi e nea c imping a ea.

The following procedure provides only general

information concerning crimping. Refer to the

instruction material packaged with the dies and power

unit for more detailed information including wire

stripping dimensions and how to position terminals or

splices in the dies.

Neve ope ate the powe unit without having a

c imping head attached to the handle cont ol o

c imping head coupling.

1. Insert terminal or splice in stationary die

according to instructions packaged with the dies.

2. Activate power unit to advance dies and hold

terminal or splice in place.

3. Insert stripped wire into terminal or splice.

4. Activate power unit to complete the crimp.

3. MAINTENANCE/INSPECTION PROCEDURE

The following procedure includes information required

to disassemble, inspect, and repair the crimping

head. Tyco Electronics recommends that a

maintenance/inspection program be performed

periodically. Frequency of inspection is dependent

upon:

The care, amount of use, and handling of the

head

The type and size of the products crimped

The degree of operator skill

The presence of abnormal amounts of dust and

dirt.

All crimping heads are inspected before packaging.

Since there is a possibility of damage in shipment,

Tyco Electronics recommends that new heads be

inspected in accordance with Section 3 when

received in your plant. Refer to Paragraph 3.5 for

parts replacement information.

3.1. Cleaning

Remove accumulations of dirt and grease on the

crimping head, especially in the area where dies are

inserted. Clean entire head frequently with a clean

cloth.

NOTE

CAUTION

NOTE

DANGER

CAUTION

408-2450

DYNA-CRIMP Crimping Head 69051

of 4Rev

Tyco Electronics Corporation

Figure 3

Check for

E cessive

Wear at

Pivot Pin

Check these

Areas for Cracks

Check for

E cessive

Wear at

Latch Pin

Check Die

Areas for

Damage

Check these

Areas for Cracks

Dust Cap (Ref)

3.2. Visual Inspe tion

Inspect ssembled he d for nicks, scr tches, nd

cr cks. Inspect for cr cks especi lly t corners of

yoke nd round the top cylinder. See Figure 3.

Inspect the pivot pin nd l tch pin holes for we r.

When the he d is dis ssembled, inspect met l

surf ces for nicks, cr cks, scr tches, nd

excessive we r, especi lly where sliding cont ct

occurs. Perform inspection s noted during

dis ssembly procedures in P r gr ph 3.4.

3.3. Crimping Head Che k-Out Pro edure

If 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 the

ram does not retract, refer to Paragraph 3.4.

3.4. Crimping Head Disassembly Pro edure

Avoid person l injury. When using hydr ulic

power unit 69120-[ ], DISCONNECT POWER

UNIT FROM POWER SUPPLY. When using

hydr ulic h nd pump 314979-1, m ke sure to

depress pressure rele se lever.

1. Remove crimping head from handle control or

coupling and place in a vise. Use a suitable

material to protect the finish on the head.

2. Remove the set screw (Item 7) that secures the

head assembly to the cylinder. See Figure 4.

3. Turn the head assembly counterclockwise to

remove it from the cylinder.

4. Remove the piston (Item 5) and piston return

spring (Item 6). Inspect for broken or weak piston

return spring (Item 6) and deteriorated or torn

piston“O” ring (Item 3) and back–up ring (Item 4).

Replace with new parts if damaged.

5. Apply a thin film of hydraulic fluid (same type

used in power unit reservoir) on the surface of the

“O” ring and back–up ring.

6. Install piston and piston return spring (Item 6) in

the cylinder.

7. Align keyway on ram with key screw (Item 10a)

in the head. Screw head into cylinder and tighten

by hand.

8. Loosen the head until the set screw hole in

cylinder aligns with the hole in head.

9. Install set screw (Item 7) in the side of the

cylinder. Be sure set screw is installed through the

cylinder and against the threads of the head.

10. Attach crimping head to handle control or

coupling. Refer to Paragraph 2.1.

3.5. Repla ement Parts

It may be advantageous to stock certain replaceable

parts to prevent loss of production time. All parts

listed in Figure 4 can be replaced by the customer.

However, due to the precision design of this tool,

certain parts cannot be interchanged. These parts are

indicated in the parts list for Figure 4. For major repair

service or adjustment, contact your local Tyco

Electronics Representative or call 1 800 526–5142 or

send a facsimile of your replacement purchase order

to 1 717 986–7605 or by contacting:

CUSTOMER SERVICE (38–35)

TYCO ELECTRONICS CORPORATION

P.O. BOX 3608

HARRISBURG PA 17105–360

4. REVISION SUMMARY

Updated document to corporate requirements

Deleted “MOD AD” in all instances

Added new information to Paragraph 3.5

New format

NOTE

DANGER

408-2450

DYNA-CRIMP Crimping H ad 69051

Rev

of 4 Tyco Electronics Corporation

10c

10f

10b

10a

10e

10d

ITEM

NO. PART

NUMBER DESCRIPTION QTY PER

TOOL

1 311470-1 COU LER, Quick-Disconnect, Cylinder Half 1

2 --- --- ---

3 2-21053-5 O" RING, [1.625 O.D. x 1.375 I.D. x .125] Width 1

4 1-21107-1 RING, Back-Up 1

5 48736 ISTON 1

6 301703 S RING, iston Return 1

7 21061-1 SCREW, Socket Set (Cone oint) 4-40 UNC x [.125 in.] Long 1

8 48734-1 CYLINDER BODY 1

9 4-21012-0 SCREW, Socket Set Self-Locking (Flat oint) 8-32 UNC x [.250 in.] Long 2

{

305438 CYLINDER HEAD AND YOKE ASSEMBLY,

(Normally shipped with the following hardware parts already installed) 1

10a

}

10b

}

10c

}

10d

}

10e

}

10f

}

7-305927-6

21025-5

306209-1

301744

21045-6

4-21012-0

SCREW, Key

LOCK WASHER, Internal Tooth

IN, Latch

IN, ivot

RING, Retaining

SCREW, Socket Set Self-Locking (Flat- oint) 8-32 UNC x [.250 in.] Long

{

The head and yoke components (Item 10) are machine fit and must be replaced as an assembly. Order part no. 305438.

}

These parts may be replaced by the customer when head and yoke components (Item 10) do not need replacement.

Figure 4

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