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PIDG* and PLASTI- GRIP* Terminal 408- -10029 LOC B 1 of 9E2010 Tyco Electronics Corporation, Berwyn, PA All Rights Reserved TE logo and Tyco Electronics are trademarks. *Trademark. Other product names, logos, or company names might 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.tycoelectronics.com
08 DEC 10 Rev Band Splice Crimping Heads
Crimp Head (Ref) Quick- -Release Pins DAHT Adapter Assembly 1. INTRODUCTION 1- -525691- -0 are designed to crimp PIDG Terminals and Splices, and PLASTI- -GRIP Terminals and Splices onto solid or stranded copper wire size 26- -14 AWG. Refer to Figure 2. The crimping heads are used with Double Action Battery Powered Hand Tool The crimping heads can also be used with the
626 Double Action Pneumatic Tool Adapter
1213563- -1. This instruction sheet provides recommended procedures for wire preparation, crimping head installation, crimping, and maintenance and inspection. For information concerning tool setup and operation, refer to Customer Manual 409- -10056 packaged with the battery tool kit. Dimensions 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 The crimping head consists of integral jaws which close in an arc- -like motion. After an operator locates the terminal or splice between the crimping jaws and inserts the stripped wire, the tool is activated to crimp the terminal or splice to the wire. NOTE i NOTE i
408- 10029PIDG and PLASTI- GRIP Terminal and Splice Crimping Heads Rev B2 of 9 Tyco Electronics Corporation PLASTI- -GRIP Terminal PIDG Type Terminal PIDG Butt Splice
3 Equally Spaced Stripes on
Nylon Insulation Restricting CRIMPING DOT WIRE SIZE TERMINAL/SPLICE WIRE STRIP LENGTH PRODUCT CRIMPING HEAD DOT CODE WIRE SIZE RANGE TERMINAL/SPLICE INSULATION TERMINALS SPLICESPRODUCT HEAD CODE RANGE (AWG) INSULATION COLOR CODE Min. Max. Min. Max. PIDG Terminals and Splices 1- -46121- -0 1D o t 26- -22 Yellow 3.97 [.156] 4.78 [.188] 4.37 [.172] 5.16 [.203] PIDG Terminals and Splices and 1- -47386- -0 1- -47386- -4 1- -525690- -0 1D o t 22- -16 (Commercial) Red 5.16 [.203] 5.94 [.234] 6.35 [.250] 7.14 [.281] and PLASTI- -GRIP Terminals 1- -47387- -0 1- -47387- -7 1- -525691- -0 2D o t s 16- -14 Blue 5.16 [.203] 5.94 [.234] 6.35 [.250] 7.14 [.281] PRODUCT CRIMPING HEAD DOT CODE WIRE SIZE RANGE INSULATION DIAMETER RANGE TERMINAL/SPLICE INSULATION WIRE STRIP LENGTHPRODUCT HEAD CODE RANGE (AWG) DIAMETER RANGE INSULATION COLOR CODE Min. Max. 26 0.66- -1.40 Yellow with Black 4.75 5.56 1 46121 0 1 Dot 26 0.66 1.40 [.026- -.055] Yellow with Black Stripe 4.75 [.187] 5.56 24 0.79- -1.40 [.031- -.055] Yellow with Blue Stripe 24 0.79- -1.40 [.031- -.055] Yellow with Blue Stripe PIDG Nylon Insulation 1- -47386- -0 1 47386 4 1 Dot 22 0.97- -2.79 [.038- -.110] R e dw i t hG r e e n Stripe Insulation Restricting Terminals 1- -47386- -4 1- -525690- -0
1 Dot
20 1.17- -2.79 [.046- -.110] R e dw i t hR e d Stripe 6.35 [.250] 7.14 [.281] 18 1.42- -2.79 [.056- -.110] R e dw i t hW h i t e Stripe [.250] [.281] 1- -47387- -0 1 47387 7 2 Dots 16 1.60- -3.30 [.063- -.130] Blue with Blue Stripe 1- -47387- -7 1- -525691- -0
2 Dots
14 1.98- -3.30 [.078- -.130] Blue with Green Stripe NOTE: Refer to Tyco Electronics Catalog 82042 for product part numbers. Figure 2 3. HEAD INSTALLATION AND REMOVAL 3.1. Head Selection The crimping heads are coded to match the terminal and splice insulation color. Observe the embossed dots on the insulation of finished crimps to ensure that the correct combination of terminal or splice and head was used. See Figure 2. Crimping heads are coated with a preservative to prevent rust and corrosion. Wipe this preservative from the head, particularly from the crimping surfaces. 3.2. Installation To avoid personal injury, be sure to exercise extreme caution when handling the crimp tool. Avoid accidentally depressing the trigger control when installing or removing crimpheads. DO NOT operate the battery tool without the proper crimping head installed. After crimping head is installed, make sure that the quick pins are properly inserted to avoid personal injury and damage to the tool. NOTE i DANGER DANGER
408- 10029PIDG and PLASTI- GRIP Terminal and Splice Crimping Heads 5 of 9Rev B Tyco Electronics Corporation The insulation crimping section of the crimping head has three positions: 1—Tight; 2—Medium; and 3—Loose. Position 3 is for wire having a large insulation diameter; Position 2 is for wire having a medium insulation diameter; and Position 1 is for wire having a small insulation diameter. 1. Perform insulation crimp adjustment by placing adjustment pins in Position 3 (loose), as shown in Figure 5. 2. Crimp the terminal as described in Paragraph 4.1, Terminal Crimping Procedure. 3. Remove crimped terminal from crimping jaws and visually inspect the insulation barrel crimp of the terminal. The insulation barrel crimp should be in contact with and should support the wire insulation. If the insulation barrel crimp does not provide “support” for wire insulation, place adjustment pins in Position 2 (medium) and repeat the crimp procedure. 4. Repeat adjustment as necessary until desired insulation support is obtained. DO NOT use a tighter setting than required. 5. CRIMP INSPECTION Inspect crimped terminals and splices by checking the features described in Figure 6. Use only terminals or splices that meet the conditions shown in the “ACCEPT” column. “REJECT” terminations can be avoided through careful use of instructions in Section 4, and by performing regular head maintenance, as described in Section 6. 6. MAINTENANCE AND INSPECTION To avoid personal injury, ALWAYS disconnect the battery from the tool before performing maintenance or inspection. Tyco Electronics recommends that a maintenance and inspection program be performed periodically to ensure dependable and uniform terminations. The crimping head should be inspected once a month. Frequency of inspection should be adjusted to suit your requirements through experience. Frequency of inspection depends on: 1. The care, amount of use, and handling of the crimping head. 2. The type and size of the product crimped. 3. The degree of operator skill. 4. The presence of abnormal amounts of dust and dirt. 5. Your own established standards. Each crimping head is thoroughly inspected before packaging. Since there is the possibility of crimping head damage during shipment, new crimping heads should be inspected immediately upon arrival at your facility. 6.1. Daily Maintenance Tyco Electronics recommends that each operator be responsible for the following steps of daily maintenance: 1. Remove dust, moisture, and other contaminants with a clean, soft brush, or a lint- -free cloth. Do NOT use objects that could damage the head. 2. Make sure that all pins, rings, and other components are in place and secure. To avoid personal injury and damage to the tool, make sure quick pins are properly inserted. 3. Make certain all surfaces are protected with a thin coat of any good SAE 20 motor oil. Do NOT oil excessively. 4. When the head assembly is not in use, store it in a clean dry, area. 6.2. Periodic Inspection Regular inspections should be performed by quality control personnel. A record of scheduled inspections should remain with the crimping heads or be supplied to supervisory personnel responsible for the crimping heads. Though recommendations call for at least one inspection a month, the frequency should be based on amount of use, working conditions, operator training and skill, and your established company policies. These inspections should include a visual inspection (Paragraph 6.3) and a crimping chamber inspection (Paragraph 6.5). 6.3. Visual Inspection 1. Remove all lubrication and accumulated film by immersing the crimping head in a suitable commercial degreaser that will not affect paint or plastic. 2. Make certain all components are in place. If replacements are necessary, refer to Figure 9. 3. Check all bearing surfaces for wear. 4. Inspect crimp area for flattened, chipped, or broken areas. Replace worn or damaged parts. DANGER DANGER
408- 10029PIDG and PLASTI- GRIP Terminal and Splice Crimping Heads Rev B6 of 9 Tyco Electronics Corporation Figure 6 Crimp Inspection 1 Insulation barrel is in firm contact with wire insulation. 2 Correct color code, dot code, and tool combination.
3 Wire size is within wire range stamped on terminal tongue or
splice. 4 Crimp centered on wire barrel.
5 End of conductor is flush with, or extends beyond end of
terminal wire barrel. 6 End of conductor against wire stop of splice. NOTE: If conductor is not against wire stop, conductor must at least be flush with, or extend slightly beyond wire barrel of splice. 7 Wire insulation does not enter wire barrel. 1 Wire insulation extruded. (Insulation crimp too tight on PIDG terminals.) See Paragraph 4.3. 2 Wrong dot code and color code combination. See chart, Figure 2.
3 Wire size is not within wire range stamped on terminal tongue
or splice. 4 Crimp not centered on wire barrel. (Terminal was not butted against locator. See Figure 3.)
5 End of conductor is not flush with or extending beyond end of
wire barrel. (Check for correct strip length.) 6 Excessive flash or extruded insulation. (Wrong tool, terminal, or splice combination used, or damaged dies.) See Figure 2. 7 Nicked or missing conductor strands. 8 Wire not fully inserted or wrong strip length. 9 Wire insulation entered wire barrel. Check for correct wire size or strip length. Wire Range Stamped Under Tongue Wire Stop Wire Range Stamped Here Wire Range Stamped Under Tongue Wire Range Stamped Here 1 2 4 37 4 6 1 2 6 2 1 37 6 4 5 1 6 2621 5 2 1 8 2 5 2 1636 ACCEPT REJECT PIDG and PLASTI- -GRIP Terminals PIDG Butt Splice PIDG Insulation Restricting Terminals
408- 10029PIDG and PLASTI- GRIP Terminal and Splice Crimping Heads Rev B8 of 9 Tyco Electronics Corporation 7. REPLACEMENT AND REPAIR Replacement parts and recommended spares are listed in Figure 9. The recommended spares should be stocked for immediate replacement. 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 For further repair and replacement information, call the Tyco Electronics Tooling Assistance Center at the number at the bottom of page 1. 8. REVISION SUMMARY S Updated document to corporate requirements Figure 8 Detail A Inspection of Wire Barrel Crimping Section Detail B Inspection of Insulation Crimping Section Wire Barrel Jaws Bottomed But Not Under Pressure GO Element Must Pass Completely Through the Crimping Chamber NO- -GO Element May Enter Partially, But Must Not Pass Through the Crimping Chamber Adjustment Pins in Position 1 (Ref) Insulation Jaws Bottomed But Not Under Pressure
408- 10029PIDG and PLASTI- GRIP Terminal and Splice Crimping Heads 9 of 9Rev B Tyco Electronics Corporation CUSTOMER REPLACEMENT PARTS PART NUMBER FOR CRIMPING HEAD ITEM 1- -47386- -4 1- -47387- -7 1- -525690- -0 1- -525691- -0
DESCRIPTION
1 45965- -6 302993 3- -304052- -6 525355- -8 LOCATOR 1 3 302994 302994 302994 302994- -1 HOUSING, Stop 1 4 301201 301201 301201 301201 SPRING, Compression 1 5 39207 39207 39207 39207 PIN, Adjustment 2 Figure 9