Instruction Sheet  Crimping Dies for SOLISTRAND* 408-9786 Terminals and Splices 19 OCT 11 Rev D PROPER USE GUIDELINES 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. Crimping Dies for Head Numbers 69065, 69067, Push Nest Into Yoke and Hand Tool 59973-1 Yoke Push Indenter Into Ram Place Screwdriver Here Nest to Remove Dies Indenter Ram Advanced Latch Pin Removed Hydraulic Hand Tool 59973-1 Figure 1 yoke of the crimping head and the indenter is 1. INTRODUCTION positioned in the ram of the tool, in all applications. This instruction sheet provides instruction on application and maintenance and inspection 3. DIE INSTALLATION AND REMOVAL procedures for dies that crimp SOLISTRAND ring tongue terminals, butt splices, and parallel splices. Refer to Figure 2 and determine the correct die These dies are used to crimp product on solid or assembly, wire size, proper product number, and stranded copper wires 6.637-117.049 mm²  which tool head is correct to use. [13.1-231 MCM]. The dies are used in Hydraulic AVOID PERSONAL INJURY. Exercise extreme DANGER Heads 69065, 69067 and Hydraulic Hand Tool  caution when using power unit. Avoid depressing 59973-1. STOP foot switch or trigger control when installing or Read these instructions, and all applicable references, removing die assemblies. before inserting any die assemblies and crimping any 3.1. Die Installation terminals. See Figure 2. 1. Remove latch pin on head of crimping head and Dimensions on this document are in metric units NOTE open yoke. with [U.S. customary units in brackets}. Figures and illustrations are for reference only and are not 2. Push nest into yoke until nest snaps into position. i drawn to scale. 3. Activate power unit to advance ram to Reason for revision is give in Section 7, REVISION approximate position shown in Figure 1. SUMMARY. 4. Push indenter in ram until indenter snaps into position. 2. DESCRIPTION (Figure 1) 5. Return ram to the down position. Each die assembly consists of a nest and an indenter, ordered separately, which are retained in the crimping 6. Close yoke and insert latch pin. head by ball plungers. The nest is positioned in the © 2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. 1 of 6 All Rights Reserved PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, *Trademark visit our website at www.te.com LOC B TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners. 408-9786 NOMINAL WIRE SIZE DIES mm² [CIRCULAR TYPICAL TOOL OR MILL AREA RANGE) PRODUCT HEAD NUMBER mm² AWG NEST INDENTER 48126■ 48355■ 6.637-10.539 33463 7-8 8 [13,100-20,800] RTT♦ 48128-1• 48127-1• 48128■ 48127■ 10.539-16.771 33466 13-15 6 [20,800-33,100] RTT♦ 48129-1• 48127-1• 48129■ 48127■ 16.771-26.653 34323 21 4 [33,100-52,600] BS† 48130-1• 48127-1• Head Number 69065 (408-2452) 48130■ 48127■ 26.653-42.411 35187 34-35 2 [52,600-83,700] PS▲ 48132-1• 48131-1• 69067 (408-2454) 48132■ 48131■ 42.411-60.551 36946 Hand Tool 59973-1 (408- 59-60 1/0 [83,700-119,500] PS▲ 6803) 48133-1• 48131-1• 72.259-96.274 36948 67-70 2/0 48133 [150,500-190,000] PS▲ 96.274-117.049 36927 80-95 3/0 48134 48131 [190,000-231,000] RTT♦ 96.274-117.049 36932 100-125 4/0 300430 [190,000-231,000] RTT♦ RTT♦ = Ring Tongue Terminals BS† + Butt Splice PS▲ = Parallel Splice ■ = also Dies for STRATO-THERM* Heat Resistant Terminals • = Dies for Heavy Duty Terminals Figure 2 Ensure the latch pin is fully inserted or damage used with the wire size or range stamped on the CAUTION may occur to the yoke, dies, or latch pin. nest and indenter. ! 2. Center terminal or splice in nest as shown in Figure 4. For best results, when brazed seam on 3.2. Die Removal terminal or splice is visible, position seam toward indenter. 1. Remove latch pin and open yoke. 3. Activate power unit so that ram advances and 2. Insert blade of screwdriver under nest and pry holds terminal or splice in place. Do NOT deform nest out of yoke. terminal or splice wire barrel. 3. Raise ram to full up position. 4. Insert stripped wire into terminal or parallel splice 4. Insert blade of screwdriver under nest and pry until end of conductor is flush with or extended indenter out of ram. slightly beyond end of wire barrel. 5. Insert stripped wire into butt splice until end of 4. WIRE STRIPPING AND CRIMPING PROCEDURE conductor butts against splice wire stop. 4.1. Wire Stripping 6. Activate power unit to complete the crimp. Strip wire to dimensions listed in Figure 3. Do NOT If the terminal sticks in the die after crimping, grasp NOTE nick or cut wire strands. the wire close to the crimp and apply a rocking motion to remove the die. AVOID PERSONAL INJURY. When operating i DANGER power unit, exercise caution while holding STOP terminals, splices, or wire near crimping area. 7. For butt splice, repeat steps 5 and 6 for other wire barrel. 4.2. Crimping Procedure 8. Refer to Paragraph 5.1, Crimp Inspection, for standard terminal, butt and parallel splice crimp 1. Ensure the wire range or size stamped on the inspection procedure. terminal or splice corresponds with the size being Rev D 2 of 6 408-9786 NOMINAL WIRE STRIP LENGTHS mm [in.] SIZE mm² [CIRCULAR MILL RING TONGUE TERMINALS BUTT SPLICES PARALLEL SPLICES AREA) mm² AWG MIN. MAX. MIN. MAX. MIN MAX. 6.637-10.539 7-8 8 8.334 [.328] 9.128 [.359] 10.319 [.406] 11.112 [.437] 10.319 [.406] 11.112 [.437] [13,100-20,800] 10.539-16.771 13-15 6 9.922 [.391] 13.255 [.522] 11.906 [.469] 12.700 [.500] 11.112 [.437] 11.906 [.469] [20,800-33,100] 16.771-26.653 21 4 11.509 [.453] 12.302 [.484] 13.493 [.531] 14.288 [.563] 13.493 [.531] 14.288 [.563] [33,100-52,600] 26.653-42.411 34-35 2 13.096 [.516] 13.890 [.547] 15.081 [.594] 15.875 [.625] 15.081 [.594] 15.875 [.625] [52,600-83,700] 42.411-60.551 59-60 1/0 18.653 [.734] 20.240 [.797] 15.875 [.625] 17.462 [.687] 17.462 [.687] 19.050 [.750] [83,700-119,500] 60.551-72.259 67-70 2/0 18.653 [.734] 20.240 [.797] 15.875 [.625] 17.462 [.687] 17.462 [.687] 19.050 [.750] [119,500-150,500] 72.259-96.274 80-95 3/0 19.050 [.750] 20.637 [.812] 17.463 [.688] 19.050 [.750] 17.463 [.688] 19.050 [.750] [150,500-190,000] 96.274-117.049 100-125 4/0 19.446 [.766] 20.637 [.812] 17.463 [.688] 10.050 [.750] 10.050 [.750] 20.637 [.812] [190,000-231,000] Figure 3 Inspection Holes of Center Terminal or Terminal or Butt Splice Wire Barrel Splice Must Face in Next Either Die End of Wire Visible Through Inspection Hole Ends of Wires Flush with or Extended Beyond Brazed Seam (Typ) End of Barrel Figure 4 Rev D 3 of 6 408-9786 5. INSPECTION/MAINTENANCE quality and reliability of the crimping die assemblies. Customer-replaceable parts are listed in Figure 2. A Disconnect power supply before performing DANGER complete inventory should be stocked and controlled maintenance, adjustments, inspections, and to prevent lost time when replacement of parts is STOP repairs. necessary. 5.1. Crimp Inspection (Figure 5) These instructions have been approved by Design, The accompanying procedure is included as an aid Production, and Quality Control Engineers to provide NOTE to the tool operator ONLY. It is not intended to serve documented maintenance and inspection procedures. as a quality control procedure for qualifying finished Through Tyco Electronics Test Laboratories and the i crimps on SOLISTRAND Terminals or Splices. inspection of production assembly, the procedures described herein have been established to ensure Figure 5 Rev D 4 of 6 408-9786 Inspect crimped terminals or splices by checking the Pitted features described in Figure 5. Use only terminals or Broken splices that meet the conditions shown in the ACCEPT column. Terminals and splices displaying the features shown in the REJECT column can be avoided by careful use of these instructions and by performing the maintenance and inspection procedures described in Paragraphs in 5.2 and 5.3. 5.2. Daily Maintenance It is recommended that each operator of the dies be made aware of, and responsible for, the following steps of daily maintenance: Chipped 1. Remove dust, moisture, and other contaminants from the dies with a clean brush, or a clean, soft, lint-free cloth. Do NOT use objects that could damage the dies. 2. If dies are coated with oil or preservative, wipe clean - particularly in the crimping areas - before placing them in use. 3. When dies are not in use, make certain all surfaces are protected with a THIN coat of any good Figure 6 SAE No. 20 motor oil, and mate and store them in a clean, dry area. 2. Align the GO element with the wire barrel crimping chamber. Push the element straight into 5.3. Periodic Inspection the the crimping chamber without using force. The GO element must pass completely through the Regular inspections should be performed by quality crimping chamber. control personnel. A record of scheduled inspections should remain with the dies or be made available to 3. Align the NO-GO element and try to insert it supervisory personnel responsible for the dies. straight into the same crimping chamber. The NO- Though recommendations call for at least a monthly GO element may start entry but must not pass inspection, the inspection frequency should be based completely through. If the crimping chamber upon the amount of use, working conditions, operator conforms to the gage inspection, the dies are training and skill, and established company standards. considered dimensionally correct. If not, they must These inspections should be performed in the be replaced. For additional information regarding following sequence: the use of a plug gage, refer to Instruction Sheet 408-7424. A. Visual Inspection (Figure 6) 1. Remove all lubrication and accumulated film by 6. REPLACEMENT PARTS immersing the dies in a suitable degreaser that will Order replacement dies through your TE not affect paint or plastic. Representative, or call 1-800-526-5142, or send a 1. Check all surfaces for wear. Inspect the crimp facsimile of your purchase order to 717-986-7605, or area for flattened, chipped, cracked, worn, or write to: broken areas. If damage is evident, the die must be replaced. CUSTOMER SERVICE (038-035) TYCO ELECTRONICS CORPORATION B. Gaging the Crimping Chamber (Figures 7 and 8) PO BOX 3608 The inspection requires the use of a plug gage HARRISBURG PA 17105-3608 conforming to the dimensions in Figure 8. Tyco Electronics does not manufacture or market these 7. REVISION SUMMARY gages. Revisions to this instruction sheet include: Proceed as follows: • Changed company name and logo 1. Mate the dies until it is evident that they have bottomed. Hold the dies in this position. Rev D 5 of 6 408-9786 Dies for Head Numbers 69065, 69067, and Hand Tool 59973-1 “NO-GO" Element May Enter “GO" Element Must Pass Partially, but Must Not Pass Completely Through the Completely Through the Die Die Closure Closure Dies Bottomed but Not Under Pressure Figure 7 DIES DIE CLOSURE DIM. “A” GAGE ELEMENT DIM. “B" DIM. RADIUS “C" “R" NEST INDENTER GO NO-GO GO NO-GO 2.54 2.692 2.54-2.548 2.689-2.692 7.92 3.18 48126 48355 [.1000] [.1060] [.1000-.1003] [.1059-.1060] [.312] [.125] 3.911 4.115 3.911-3.919 4.112-4.115 11.09 4.34 48128-1 48127-1 [.1540] [.1620] [.1540-.1543] [.1619-.1620] [.437] [.171] 3.911 4.115 3.911-3.919 4.112-4.115 11.09 4.34 48128 48127 [.1540] [.1620] [.1540-.1543] [.1619-.1620] [.437] [.171] 4.699 4.902 4.699-4.706 4.899-4.902 11.09 5.54 48129-1 48127-1 [.1850] [.1930] [.1850-.1853] [.1929-.1930] [.437] [.218] 4.699 4.902 4.699-4.706 4.899-4.902 11.09 5.54 48129 48127 [.1850] [.1930] [.1850-.1853] [.1929-.1930] [.437] [.218] 5.410 5.613 5.410-5.418 5.610-5.613 11.09 6.35 48130-1 48127-1 [.2130] [.2210] [.2130-.2133] [.2209-.2210] [.437] [.250] 5.410 5.613 5.410-5.418 5.610-5.613 11.09 6.35 48130 48127 [.2130] [.2210] [.2130-.2133] [.2209-.2210] [.437] [.250] 6.172 6.375 6.172-6.179 6.372-6.375 11.09 7.52 48132-1 48127-1 [.2430] [.2510] [.2430-.2433] [.2509-.2510] [.437] [.296] 6.172 6.375 6.172-6.179 6.372-6.375 11.09 7.52 48132 48131 [.2430] [.2510] [.2430-.2433] [.2509-.2510] [.437] [.296] 6.959 7.163 6.959-6.967 7.160-7.163 14.27 8.33 48133-1 48131-1 [.2740] [.2820] [.2740-.2743] [.2819-.2820] [.562] [.328] 6.959 7.163 6.959-6.967 7.160-7.163 14.27 8.33 48133 48131 [.274] [.2820] [.2740-.2743] [.2819-.2820] [.562] [.328] 7.823 8.026 7.823-7.830 8.023-8.026 14.28 3.525 48134 48131 [.3080] [.3160] [.3080-.3083] [.3159-.3160] [.562] [.375] 8.788 8.991 8.788-8.796 8.989-8.991 14.28 10.693 300430 48131 [.3460] [.3540] [.3460-.3463] [.3539-.3540] [.562] [.421] Figure 8 Rev D 6 of 6