Instruction Sheet “C”-HeadAssembly 2031450-1forUsewiththe 408--10311 Electro-HydraulicHandToolAssembly 16 MAY 11 RevC “C”--Head TE Connectivity Assembly Shoulder--Type SDE Crimp Die Set Electro--Hydraulic Hand Tool The “C”--Head Assemblyisa premiumgrade tool head and isdesigned primarilyforfield installation,repair, maintenance work,orprototyping in industrial,commercial,or Battery Battery Release institutional applications.Awide selection ofpowered application (Power Source) equipmentforextended use production isavailable. Figure 1 1. INTRODUCTION Reasons for revision may be found in Section 8, REVISION SUMMARY. “C”--Head Assembly 2031450--1 is designed to accept any TE shoulder--type SDE (Standard Die Envelope) 2. RECEIVING/INSPECTION die set. See Figure 1. The Electro--Hydraulic Hand Tool Kit 2031400--[ ] and “C”--Head Assembly 2031450--1 are thoroughly The Electro--Hydraulic Hand Tool and crimping dies inspected during and after assembly. Prior to must be ordered separately. packaging and shipping, a final series of tests and inspections are made to ensure proper function of the For specific die set information (including installation, tooling. The following inspection should be performed wire preparation, crimping procedures, maintenance as a safeguard against potential problems generated and inspection procedures, as well as repair and in transit. replacement procedures) refer to the instruction sheet supplied with the dies. For information concerning the 1. In a well--lighted area, carefully unpack the Electro--Hydraulic Hand Tool, refer to Customer tool and inspect each component as it is removed from the packaging. Manual 409--10095. 2. Thoroughly inspect each component for All dimensions on this instruction sheet are in evidence of damage that may have occurred in NOTE metric units [with inches in brackets]. Figures and transit. If any of the components are damaged, illustrations are for identification only, and are not file a claim against the carrier and notify TE i drawn to scale. immediately. E2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company TOOLING ASSISTANCE CENTER 1--800--722--1111 This controlled document is subject to change. 1 of 4 All Rights Reserved PRODUCT INFORMATION 1--800--522--6752 For latest revision and Regional Customer Service, *Trademark visit our website at www.te.com LOCB TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners. ORIGINAL INSTRUCTIONS 408-10311 Be sure to keep this instruction sheet, NOTE 3.2. Installation/RemovaloftheShoulder-TypeSDE the manual for the electro--hydraulic Dies (Figure 2 ) hand tool, and all drawings with the tool i for the benefit of operation and These instructions are meant to be used as an CAUTION maintenance personnel. example only. For specific instructions, refer to the instructions packaged with the dies. ! The Electro--Hydraulic tool and “C”--Head assembly should be inspected at regularly scheduled intervals, depending on care, degree of operator skill, the type and size of product being crimped, and environmental To avoid personal injury, be sure to exercise DANGER conditions. extreme caution when handling the Electro--Hydraulic Hand Tool. Remove the power source (and release the hydraulic pressure if 3. INSTALLATION/REMOVAL applicable ---- see 409--10095) before installing or Do not operate the Electro--Hydraulic Hand Tool CAUTION removing the dies. without the head and dies installed. Repeated operation in this manner may result in damage to ! Be sure to use ONLY TE shoulder--type crimping CAUTION the Electro--Hydraulic Hand Tool. dies. Although equipped with the required holes for pin--type dies, the use of such dies will result To avoid personal injury, be sure to exercise ! DANGER in failure. Use Closed--Head Assembly extreme caution when handling the 2031460--1 for pin--type dies. Electro--Hydraulic Hand Tool. Remove the power source (and release the hydraulic pressure, if applicable ---- see 409--10095) before installing or A. InstallationofDies removing the “C”--Head Assembly or dies. 1. Remove the two die retaining screws and bushing from the crimp head. 3.1. Installation/RemovaloftheCrimpingHead Assembly 2. Place the upper die in the upper jaw of the Refer to the Electro--Hydraulic hand tool manual tool head so that the largest indenter or (409--10095) for instructions on installing and terminal cavity is facing toward the throat of removing the “C”--Head. the “C” head (see Figure 2). Lower SDE Die Upper SDE Die Moving Jaw (Lower Jaw) Throat of “C”--Head Terminal Grip Thumb Button Stationary Jaw (Upper Jaw) Bushing Lower Die Retaining Screw Upper Die Retaining Screw Figure 2 2 of 4 Rev C 408-10311 3. Insert the die retaining screw through the It is not necessary to continue to hold the tool NOTE upper jaw and through the die. Tighten the trigger in order to retract the tooling. The tooling screw just enough to hold the die in place. Do will retract automatically. i NOT tighten the screw completely at this time. SeeFigure2. 5. Remove the terminated wire. 4. Place the lower die in the moving jaw of the crimp head so that the largest anvil is also To abort a crimp,press the pressure release NOTE facing toward the throat of the “C” head. device on the power tool. Information on the pressure release device is contained in 5. Slide the bushing over the die retaining i 409--10095, Section 6, PRESSURE screw and insert the die retaining screw RELEASE/RESET TOOL. through the lower jaw and through the die. Tighten the screw just enough to hold the die in place. Do NOT tighten the screw completely at this time. 5. PREVENTIVEMAINTENANCE 6. Release the lower jaw by pressing the DANGER To avoid personal injury, ALWAYS remove the terminal grip thumb--button to close the crimp power source (and release hydraulic pressure if jaws and fully seat the dies together. See applicable ---- see 409--10095) from the tool Figure 2. BEFORE performing any maintenance to the tool. 7. When the anvils and indenters are aligned, tighten the retaining screws. 5.1. DailyMaintenance B. RemovalofDies Perform the following maintenance on a daily basis: 1. Remove the die retaining screws and bushing. S Inspect the dies for wear or damage such as cracks, gouges or chips. If damage is found, 2. Lift the dies out of the “C”--Head Assembly. replace the die set. S Clean the tooling, removing accumulations of 4. OPERATION dirt and grease -- particularly in areas where contacts are crimped. Wipe clean with a The following procedure provides only general lint--free cloth. information concerning crimping. Refer to the instructions packaged with the dies for detailed 5.2. YearlyMaintenance information, including wire stripping dimensions and Once a year or every 10,000 cycles (whichever instructions for positioning terminals and splices in the comes first) return the “C”--Head Assembly crimp dies. head to TE for inspection. To avoid personal injury, keep fingers clear of the DANGER crimping area. 6. RETURN/REPAIR DANGER To avoid personal injury, ALWAYS remove the power source (and release hydraulic pressure, if To produce a crimp with TE SDE shoulder--type dies applicable ---- see 409--10095) from the tool in a “C”--Head Assembly using the Electro--Hydraulic BEFORE performing any maintenance on repair Hand Tool: to the tool. 1. Insert the contact into the appropriate die cavity. Order replacement parts through your TE 2. Press the terminal grip thumb button (Figure 2) Representative, or call 1.800.526.5142; or send a to advance the lower tooling and hold the contact facsimile of your purchase order to 1.717.986.7605; in place. Do not deform the terminal insulation or or write to: wire barrel. CUSTOMER SERVICE (38--35) 3. Place a pre--stripped wire in the barrel of the TYCO ELECTRONICS CORPORATION contact. PO BOX 3608 HARRISBURG PA 17105--3608 4. Squeeze the trigger until the jaws release -- indicating the crimp is complete. Then release the For repair services, call the Tooling Assistance Center trigger. at 1.800.722.1111. Rev C 3 of 4 408-10311 For spare parts, refer to the table in Figure 3: 7. RoHSINFORMATION Information on the presence and location of any substances subject to RoHS (Restriction on Hazardous Substances) can be found at the following SpareParts website: TEPartNumber Description Qty http://www.tycoelectronics.com/customersupport/rohs supportcenter/ 986964--1 Die Screw 2 Click on “Find Compliance Status” and enter 2031486--1 Head Retainer 1 equipment part number. 2063861--1 Friction Ring 1 8. REVISIONSUMMARY 986963--1 E--Ring 1 S Updated document to corporate requirements 1213501--1 Bushing 1 S Added bushing to artwork in Figure 2, S Added bushing terminology to Paragraph 3.2.A.1; 3.2.A.5; 3.2.B.1; and Figure 3 Figure 3 4 of 4 Rev C