408-8703 TEC | Alldatasheet
Document overview
- Manufacturer or author: Provided By ALLDATASHEET.COM(FREE DATASHEET DOWNLOAD SITE)
- PDF pages: 6
Technical content
Crimping Die Assemblies 408- -8703 LOC B 1 of 6E2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company All Rights Reserved *Trademark TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners. 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 atwww.te.com
18 APR 11 Rev B1583092- 1 through 1583098- 1
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. Indenter Nest Crimping Die Assemblies for AMPOWER* Terminals and Splices CRIMPING DIES WIRE SIZE HYDRAULIC CRIMP TOOLING ASSEMBLY INDENTER NEST AWG CMA RANGE mm2 HEADS HAND TOOLS 1583092- -1 1490351- -1 1490352- -1 6 20,800- -33,100 10.5- -16.8 1583093- -1 1490351- -2 1490352- -2 4 33,100- -52,600 16.8- -26.7 1490745- -1 1490746 1 1490748 11583094- -1 1490351- -3 1490352- -3 2 52,600- -83,700 26.7- -42.4 1490746- -1 1490747--1 1490748- -1 1490749--1 1583095- -1 1490351- -4 1490352- -4 1/0 83,700- -119,500 42.4- -60.6 1490747--1 1976230- -1 1490749--1 1583096- -1 1490351- -5 1490352- -5 2/0 119,500- -150,500 60.6- -76.3 1976230 1 1583097- -1 1490351- -6 1490352- -6 3/0 150,500- -190,000 76.3- -96.3 1490746- -1 1490749 11583098- -1 1490351- -7 1490352- -7 4/0 190,000- -231,000 96.3- -117 1490746 1 1976230- -1 1490749- -1 Figure 1 1. INTRODUCTION This instruction sheet covers application and maintenance procedures for the AMPOWER Crimping Die Assemblies listed in Figure 1. The die assemblies are used in Hydraulic Heads 1490745- -1, 1490746- -1, 1490747- -1, 1976230- -1 (not to be used with splices), and Hydraulic Hand Tools 1490748- -1 and 1490749- -1. See Figures 1 and 3. Basic instructions for the installation and removal of dies are covered in Section 3; wire preparation and crimping procedures are covered in Section 4; and Maintenance and Certification are covered in Section 6. All dimensions on this document are in metric units [with U.S. customary units in brackets]. Figures and illustrations are for identification only and are not drawn to scale. Read these instructions carefully prior to installing, removing, or using the dies. 2. DESCRIPTION T h eA M P O W E Rd i ea s s e m b l i e sl i s t e di nt h et a b l ei n Figure 1 are used to crimp AMPOWER terminals and splices. Wire strip length is provided in Figure 2. The die assemblies are single position sets, each consisting of an anvil subassembly and an indenter subassembly. Refer to Figure 1 to ensure compatibility of crimping dies and wire size. For instructions relative to the crimping head and the hydraulic power units, refer to the instructions packaged with them. ORIGINAL INSTRUCTIONS NOTE i
3.2. Die Removal Ensure that the possibility of accidental activation of the hydraulic power unit has been eliminated, and proceed as follows: 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 in the ram is exposed. 3. Depress the release button and slide the indenter out of the ream. 4. WIRE PREPARATION AND CRIMPING PROCEDURES 4.1. Wire Preparation 1. Select proper size terminal or splice for wire size being used. 2. Determine correct terminal or splice wire loading by referring to CMA (Circular Mill Area) range listed in the table in Figure 1. The total CMA of wires being used must be within the CMA range of the terminal or splice. 3. Strip the wire to the dimensions indicated in the table in Figure 2, taking care not to nick or cut the wire strands. 4.2. Crimping Procedure 1. Ensure that the wire size stamped on the terminal or splice corresponds to the wire size stamped on the stationary die. 2. Center the terminal or splice in the stationary die as shown in Figure 4. 3. Activate the power unit so that the moving die advances and holds the terminal or splice in place without deforming the wire barrel. 4. Insert the stripped wire until it bottoms in the terminal or butt splice. The end of the wire must be visible through the sight hole. Sight holes of butt splices must always face either the upper or lower die. 5. When inserting the stripped wires into a parallel splice, the ends of the wires must be at least flush with, or extend slightly beyond the end of the wire barrel. 6. Activate the power unit to complete the crimp. 7. To crimp the other half of the butt splice, remove and reposition the uncrimped half in the stationary die. Insert the wire until it bottoms against the splice sire stop (visible through the sight holes), and then crimp the splice. 8. Inspect the crimp by referring to Section 5, CRIMP INSPECTION, and to Figure 5. Figure 4 Terminal Butt Splice Parallel Splice End of Inserted Wire Must Be Visible Through Sight Hole Center Terminal Wire Barrel in Stationary Die Ends of Inserted Wires Must be Visible Through Sight Holes Center Half of Butt Splice in Stationary Die (Sight Holes Must Face Upper or Lower Die) Center Parallel Splice in Stationary Die NOTE i
- CRIMP INSPECTION Inspect crimped terminals and splices by checking the features described in Figure 5. Use only terminals and splices that meet the conditions shown in the “ACCEPT” column of Figure 5. Unacceptable terminals and splices, as depicted in the “REJECT” column of Figure 5 can be avoided through careful use of the instructions in Section 4 and by performing regularly scheduled die maintenance as described in Section 6. Figure 5 ACCEPT REJECT Terminal Parallel Splice Butt Splice 1 Crimps centered. Crimps may be off center BUT NOT OFF END OF WIRE BARREL. Embossed wire size matches CMA of wire being used and wire size stamped on terminal or splice. Insulation does not enter wire barrel. Wire is visible through sight hole of terminal or butt splice. On parallel splices, bare wire ends must be flush with or extended slightly beyond end of barrel. Crimped off end of splice or terminal wire barrel. Wire not inserted far enough in terminal or splice. End of wire must be visible through sight holes of terminals or butt splices. Wire insulation entered barrel of terminal or splice. CHECK FOR INCORRECT STRIP LENGTH. Excessive “flash” indicates wrong wire, splice, or tooling combination was used. 6 Nicked or missing strands. Embossed wire size does not match CMA of wire being used, or wire size stamped on terminal or splice.
Inspection of Die Closure with Plug GageDetail A Dies Bottomed But Not Under Pressure “GO” Gage Must Pass Completely Through the Die Closure “NO- -GO” Gage May Enter Partially, But Must Not Pass Completely Through the Die Closure Detail B 2. Mate the dies until it is evident that they have bottomed. Hold the dies in this position. 3. Hold gage in straight alignment with die closure and carefully try to insert, without forcing, the GO member. See Figure 8, Detail B. The GO member must pass completely through the die closure. 4. Try to insert the NO- -GO member. The NO- -GO member may enter partially, but must not pass completely through die closure. 5. If die closure meets GO/NO- -GOgage conditions, dies may be considered dimensionally correct. If die closure does not conform with GO/NO- -GOgage conditions, the dies must be replaced. 7. REPLACEMENT PARTS Worn or damaged dies may not be repaired. It is recommended that spare sets be stocked and controlled to prevent lost time. See Figure 9. Order replacement dies through your TE 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 For tool repair service, please contact a TE Representative at 1- -800- -526- -5136. 8. REVISION SUMMARY S Updated document to corporate requirements S Corrected table in Figure 1 Single Position Dies ITEM DESCRIPTION SINGLE POSITION DIES ITEM DESCRIPTION 1583092- -1 1583093- -1 1583094- -1 1583095- -1 1583096- -1 1583097- -1 1583098- -1