Instruction Sheet PIDG* and PLASTI- GRIP* Terminal and Splice Crimping Heads

Transcription

1 Instructon Sheet * and PLASTI- GRIP* Termnal and Splce Crmpng Heads 08 DEC 0 Battery Powered Crmp Tool Battery Lock Retract Button Crmp Head Mountng Holes DAHT Adapter Assembly Battery Cartrdge Typcal DAHT Crmp Head (Ref) Quck -Release Pns Fgure. INTRODUCTION Crmpng Heads , , , , , , and are desgned to crmp Termnals and Splces, and PLASTI--GRIP Termnals and Splces onto sold or stranded copper wre sze 6-- AWG. Refer to Fgure. The crmpng heads are used wth Double Acton Battery Powered Hand Tool Kts 380--[ ]. The crmpng heads can also be used wth the 66 Double Acton Pneumatc Tool Adapter Ths nstructon sheet provdes recommended procedures for wre preparaton, crmpng head nstallaton, crmpng, and mantenance and nspecton. For nformaton concernng tool setup and operaton, refer to Customer Manual packaged wth the battery tool kt. Dmensons are n metrc unts wth [nches n brackets]. Fgures and llustratons are for reference only and are not drawn to scale. Reasons for ressue are provded n Secton 8, REVISION SUMMARY.. DESCRIPTION The crmpng head conssts of ntegral jaws whch close n an arc--lke moton. After an operator locates the termnal or splce between the crmpng jaws and nserts the strpped wre, the tool s actvated to crmp the termnal or splce to the wre. E00 Tyco Electroncs Corporaton, Berwyn, PA TOOLING ASSISTANCE CENTER All Rghts Reserved PRODUCT INFORMATION TE logo and Tyco Electroncs are trademarks. *Trademark. Other product names, logos, or company names mght be trademarks of ther respectve owners. Ths controlled document s subject to change. For latest revson and Regonal Customer Servce, vst our webste at of 9 LOC B

2 PLASTI -GRIP Termnal Type Termnal 3 Equally Spaced Strpes on Nylon Insulaton Restrctng Butt Splce PRODUCT Termnals and Splces Termnals and Splces and PLASTI -GRIP Termnals PRODUCT CRIMPING DOT CODE WIRE SIZE RANGE (AWG) -6-0 Dot 6 - Yellow CRIMPING Dot -6 (Commercal) TERMINAL/SPLICE WIRE STRIP LENGTH INSULATION TERMINALS SPLICES COLOR CODE Mn. Max. Mn. Max. Red Dots 6 - Blue DOT CODE -6-0 Dot WIRE SIZE RANGE (AWG) [ ] Nylon [ ] Insulaton Dot Restrctng Termnals [ ] [ ] [ ] Dots [ ] : Refer to Tyco Electroncs Catalog 80 for product part numbers. 3. INSTALLATION AND REMOVAL [.6].6 [.03].6 [.03].78 [.88].9 [.3].9 [.3].37 [.7] 6.3 [.0] 6.3 [.0].6 [.03] 7. [.8] 7. [.8] INSULATION TERMINAL/SPLICE WIRE STRIP LENGTH DIAMETER RANGE INSULATION COLOR CODE Mn. Max Yellow wth Black.7.6 [ ] Strpe [.87] [.9] Yellow wth Blue [ ] Strpe Fgure 3.. Installaton Yellow wth Blue Strpe RedwthGreen Strpe RedwthRed Strpe RedwthWhte Strpe Blue wth Blue Strpe Blue wth Green Strpe [.0] [.8] 3.. Head Selecton The crmpng heads are coded to match the termnal and splce nsulaton color. Observe the embossed dots on the nsulaton of fnshed crmps to ensure that the correct combnaton of termnal or splce and head was used. See Fgure. Crmpng heads are coated wth a preservatve to prevent rust and corroson. Wpe ths preservatve from the head, partcularly from the crmpng surfaces. To avod personal njury, be sure to exercse extreme cauton when handlng the crmp tool. Avod accdentally depressng the trgger control when nstallng or removng crmp heads. DO NOT operate the battery tool wthout the proper crmpng head nstalled. After crmpng head s nstalled, make sure that the quck pns are properly nserted to avod personal njury and damage to the tool. of 9 Tyco Electroncs Corporaton

3 Remove quck pns from the adapter assembly. RefertoFgure.. Insert crmpng head nto the adapter assembly. 3. After the crmpng head s properly algned, nsert the quck pns through the two holes n the adapter and through the holes n the crmp head Removal The quck pns wll snap nto poston when they are properly nserted. To avod personal njury, ALWAYS dsconnect the battery from the tool before removng crmpng head. and PLASTI -GRIP Termnals C B C B Nylon Insulaton Termnal Restrctng Termnal C B PLASTI -GRIP Termnal Termnal Tongue Postoned Under B Equals Wre Barrel C Equals Insulaton Barrel Remove the quck pns from the crmpng head; then remove the crmpng head from the tool holder.. CRIMPING PROCEDURES To avod personal njury, ALWAYS keep fngers clear of crmpng jaws when operatng the tool. Never place anythng wthn the crmpng jaws except Tyco Electroncs termnals or splces. Wre Barrel Aganst Fgure 3.. Termnal Crmpng Procedure. Strp wre to dmensons shown n Fgure. DO NOT nck wre strand or use wres wth ncked or mssng conductor strands.. Center the termnal or splce wre barrel n the approprate crmp chamber. See Fgure Depress the trgger to advance the movng ram. Ths closes the crmp jaws n order to hold the termnal n place. DO NOT deform the wre barrel.. Insert strpped wre nto termnal untl the end of the conductor butts aganst the locator as shown n Fgure 3.. Actvate the tool to complete the crmp. The crmp tool automatcally returns to the frst poston of the cycle when the crmp s complete. 6. Refer to Secton and Fgure 6 for crmp nspecton... Butt Splce Crmpng Procedure. Strp wre to dmensons shown n Fgure. DO NOT nck wre strand or use wres wth ncked or mssng conductor strands.. Poston splce between crmpng jaws so that the wndow ndent sldes under the locator of crmp head. See Fgure A. 3. Depress the trgger to advance the movng ram. Ths closes the crmp jaws to hold the termnal n place. DO NOT deform the wre barrel.. Insert strpped wre nto wre barrel of splce untl the end of the conductor s aganst the splce wre stop. See Fgure A.. Actvate tool to complete the crmp. 6. To crmp the other half of the butt splce, reposton t n the crmpng jaws and repeat Steps through. If the splce cannot be turned, rotate crmpng head. See Fgure B. Tyco Electroncs Corporaton 3 of 9

4 A 7. Refer to Secton and Fgure 6 for crmp nspecton. B Equals Wre Barrel C Equals Insulaton Barrel Butt Splce C B Wndow Indent Splce Wre Stop The nsulaton crmpng secton of the crmpng head has three postons: Tght; Medum; and 3 Loose.. Insert nsulaton adjustment pns n Poston 3. SeeFgure. Always place both adjustment pns n the same poston. See Fgure.. Place termnal or splce n crmpng jaws, as shown n Fgures 3 and. Wndow Indent Faces Indenter and Sldes Under (A) Frst Crmp 3. Insert unstrpped wre only nto the nsulaton barrel of the termnal or splce. See Fgures 3 and.. Crmp termnal or splce as descrbed n Paragraph. or... Remove termnal or splce. Bend wre forward and then backward. The termnal or splce should retan ts grp on the wre. If the wre pulls out, reposton the nsulaton adjustment pns n the next tghter poston and repeat crmpng procedure. End of Conductor Butts Aganst Splce Wre Stop 6. Repeat adjustment as necessary untl desred nsulaton grp s obtaned. DO NOT use a tghter settng than requred. B (B) Second Crmp Postons Wndow Indent on Splce Sldes Under End of Conductor Butts Aganst Splce Wre Stop Fgure.3. Insulaton Crmp Adjustment A. Termnals and Splces termnals and splces contan a wre nsulaton grp. Insulaton Adjustment Pn(s) (Ref) B. PLASTI- GRIP Termnals 3 3 Fgure PLASTI -GRIP termnals contan only a wre nsulaton support. of 9 Tyco Electroncs Corporaton

5 The nsulaton crmpng secton of the crmpng head has three postons: Tght; Medum; and 3 Loose. Poston 3 s for wre havng a large nsulaton dameter; Poston s for wre havng a medum nsulaton dameter; and Poston s for wre havng a small nsulaton dameter.. Perform nsulaton crmp adjustment by placng adjustment pns n Poston 3 (loose), as shown n Fgure.. Crmp the termnal as descrbed n Paragraph., Termnal Crmpng Procedure. 3. Remove crmped termnal from crmpng jaws and vsually nspect the nsulaton barrel crmp of the termnal. The nsulaton barrel crmp should be n contact wth and should support the wre nsulaton. If the nsulaton barrel crmp does not provde support for wre nsulaton, place adjustment pns n Poston (medum) and repeat the crmp procedure.. Repeat adjustment as necessary untl desred nsulaton support s obtaned. DO NOT use a tghter settng than requred.. CRIMP INSPECTION Inspect crmped termnals and splces by checkng the features descrbed n Fgure 6. Use only termnals or splces that meet the condtons shown n the ACCEPT column. REJECT termnatons can be avoded through careful use of nstructons n Secton, and by performng regular head mantenance, as descrbed n Secton MAINTENANCE AND INSPECTION To avod personal njury, ALWAYS dsconnect the battery from the tool before performng mantenance or nspecton. Tyco Electroncs recommends that a mantenance and nspecton program be performed perodcally to ensure dependable and unform termnatons. The crmpng head should be nspected once a month. Frequency of nspecton should be adjusted to sut your requrements through experence. Frequency of nspecton depends on:. The care, amount of use, and handlng of the crmpng head.. The type and sze of the product crmped. 3. The degree of operator skll.. The presence of abnormal amounts of dust and drt.. Your own establshed standards. Each crmpng head s thoroughly nspected before packagng. Snce there s the possblty of crmpng head damage durng shpment, new crmpng heads should be nspected mmedately upon arrval at your faclty. 6.. Daly Mantenance Tyco Electroncs recommends that each operator be responsble for the followng steps of daly mantenance:. Remove dust, mosture, and other contamnants wth a clean, soft brush, or a lnt--free cloth. Do NOT use objects that could damage the head.. Make sure that all pns, rngs, and other components are n place and secure. To avod personal njury and damage to the tool, make sure quck pns are properly nserted. 3. Make certan all surfaces are protected wth a thn coat of any good SAE 0 motor ol. Do NOT ol excessvely.. When the head assembly s not n use, store t n a clean dry, area. 6.. Perodc Inspecton Regular nspectons should be performed by qualty control personnel. A record of scheduled nspectons should reman wth the crmpng heads or be suppled to supervsory personnel responsble for the crmpng heads. Though recommendatons call for at least one nspecton a month, the frequency should be based on amount of use, workng condtons, operator tranng and skll, and your establshed company polces. These nspectons should nclude a vsual nspecton (Paragraph 6.3) and a crmpng chamber nspecton (Paragraph 6.) Vsual Inspecton. Remove all lubrcaton and accumulated flm by mmersng the crmpng head n a sutable commercal degreaser that wll not affect pant or plastc.. Make certan all components are n place. If replacements are necessary, refer to Fgure Check all bearng surfaces for wear.. Inspect crmp area for flattened, chpped, or broken areas. Replace worn or damaged parts. Tyco Electroncs Corporaton of 9

6 Crmp Inspecton ACCEPT REJECT 8 3 Wre Stop Insulaton Restrctng Termnals and PLASTI -GRIP Termnals Wre Range Stamped Under Tongue Butt Splce Wre Range Stamped Under Tongue Wre Range Stamped Here Wre Range Stamped Here Insulaton barrel s n frm contact wth wre nsulaton. Correct color code, dot code, and tool combnaton. 3 Wre sze s wthn wre range stamped on termnal tongue or splce. Crmp centered on wre barrel. End of conductor s flush wth, or extends beyond end of termnal wre barrel. 6 End of conductor aganst wre stop of splce. : If conductor s not aganst wre stop, conductor must at least be flush wth, or extend slghtly beyond wre barrel of splce. 7 Wre nsulaton does not enter wre barrel. Fgure 6 Wre nsulaton extruded. (Insulaton crmp too tght on termnals.) See Paragraph.3. Wrong dot code and color code combnaton. See chart, Fgure. 3 Wre sze s not wthn wre range stamped on termnal tongue or splce. Crmp not centered on wre barrel. (Termnal was not butted aganst locator. See Fgure 3.) End of conductor s not flush wth or extendng beyond end of wre barrel. (Check for correct strp length.) 6 Excessve flash or extruded nsulaton. (Wrong tool, termnal, or splce combnaton used, or damaged des.) See Fgure. 7 Ncked or mssng conductor strands. 8 Wre not fully nserted or wrong strp length. 9 Wre nsulaton entered wre barrel. Check for correct wre sze or strp length. 6 of 9 Tyco Electroncs Corporaton

7 Lubrcaton Lubrcate all pns, pvot ponts, and bearng surfaces wth a hgh qualty grease. Tyco Electroncs recommends the use of MolykoteS grease, whch s a commercally avalable lubrcant. Lubrcate accordng to the followng schedule: Head used n daly producton -- lubrcate daly Head used daly (occasonal) -- lubrcate weekly Head used weekly -- lubrcate monthly Wpe excess grease from crmpng head, partcularly from jaw closure areas. Grease transferred from jaw closure area onto certan termnatons may affect the electrcal characterstcs of an applcaton. 6.. Gagng the Crmpng Chamber Ths nspecton requres the use of plug gages conformng to the dmensons shown n Fgure 7. Tyco Electroncs does not manufacture or market these gages. GO Da Suggested Plug Gage Desgn Wre Barrel Crmp Jaw Closure Confguraton CRIMPING [.0] Mn. Typ. NO -GO Da GAGE ELEMENT JAW DIAMETERS CLOSURE DIMENSIONS GO NO -GO [ ] [ ] [ ] SMolykote s a trademark [ ] [ ] [ ] Fgure 7 (cont d) [.9 -.0] [.9 -.0] [ ] GO Dm. Suggested Plug Gage Desgn Insulaton Crmp Jaw Closure Confguraton CRIMPING GO 6.3 [.0] Typ. NO GO NO -GO Dm. JAW GAGE ELEMENT CLOSURE DIAMETERS DIMENSIONS GO NO -GO [ ] [ ] [ ] [ ] [ ] [ ] [ ] [ ] ] [ ].3 -. [ ] Fgure 7 (end) 3.8 [.] [ ] [ ]. -. [ ] [ ] [ ] Dsconnect the battery and remove crmpng head from tool before nspectng crmpng chambers.. Remove ol and drt from the jaw bottomng surfaces and plug gage element surfaces.. Close wre barrel crmpng jaws untl they are bottomed, but not under pressure. 3. Algn GO element wth wre barrel crmpng secton. Push element straght nto crmpng chamber wthout usng force. The GO element must pass completely through the chamber as shown n Fgure 8A.. Algn the NO--GO element and try to nsert t nto the chamber. The element may start entry, but t must not pass completely through the crmpng chamber.. Repeat ths procedure for the nsulaton crmpng secton usng a plug gage as shown n Fgure 8B. If the crmpng chamber passes the gage nspecton, the crmpng head s consdered dmensonally correct and should be lubrcated wth a THIN coat of any good SAE 0 motor ol. If the crmpng chamber does not conform to the plug gage condtons, contact your local Tyco Electroncs Feld Representatve or refer to Secton 7, REPLACEMENT AND REPAIR. For addtonal nformaton about the use of a plug gage, see Instructon Sheet Tyco Electroncs Corporaton 7 of 9

8 REPLACEMENT AND REPAIR Replacement parts and recommended spares are lsted n Fgure 9. The recommended spares should be stocked for mmedate replacement. Order replacement parts through your Tyco Electroncs Representatve, or call , or send a facsmle of your purchase order to , or wrte to: Detal A Inspecton of Wre Barrel Crmpng Secton CUSTOMER SERVICE (38--3) TYCO ELECTRONICS CORPORATION P.O. BOX 3608 HARRISBURG, PA For further repar and replacement nformaton, call the Tyco Electroncs Toolng Assstance Center at the number at the bottom of page. 8. REVISION SUMMARY S Updated document to corporate requrements Detal B Inspecton of Insulaton Crmpng Secton Adjustment Pns n Poston (Ref) Wre Barrel Jaws Bottomed But Not Under Pressure Insulaton Jaws Bottomed But Not Under Pressure GO Element Must Pass Completely Through the Crmpng Chamber NO -GO Element May Enter Partally, But Must Not Pass Through the Crmpng Chamber Fgure 8 8 of 9 Tyco Electroncs Corporaton

9 CUSTOMER REPLACEMENT PARTS PART NUMBER FOR CRIMPING ITEM NO DESCRIPTION QTY PER LOCATOR SCREW, 8-3 x 8.38 [.330] HOUSING, Stop SPRING, Compresson PIN, Adjustment Fgure 9 Tyco Electroncs Corporaton 9 of 9