SOLISTRAND* and STRATO- THERM* Crimping Heads Used with Double Action Battery Powered Hand Tool Kits [ ]

Transcription

1 SOLISTRAND* and STRATO- THERM* Crmpng Heads Used wth Double Acton Battery Powered Hand Tool Kts 80- [ ] Instructon Sheet OCT 0 Crmp Head Mountng Holes Battery Powered Crmp Tool Battery Lock Retract Button DAHT Adapter Assembly -Crmpng Chambers -Crmpng Chambers Battery Cartrdge 789- Typcal DAHT Crmp Head (Ref) Quck-Release Pns Fgure. INTRODUCTION Crmpng Heads -67-0, and are desgned to crmp SOLISTRAND and STRATO-THERM Termnals and Splces, and PLASTI-GRIP* Termnals and Splces onto sold or stranded copper wre sze 6-0 AWG. Refer to Fgure. The crmpng heads are used wth Double Acton Battery Powered Hand Tool Kts 80-[ ]. The crmpng heads can also be used wth the 66 Double Acton Pneumatc Tool Adapter 6-. 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.. HEAD INSTALLATION AND REMOVAL Crmpng heads are coated wth a preservatve to prevent rust and corroson. Wpe ths preservatve from the head, partcularly from the crmpng surfaces... Installaton 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. 00 Tyco Electroncs Corporaton, Berwyn, PA TOOLING ASSISTANCE CENTER All Rghts Reserved PRODUCT INFORMATION TE logo and Tyco Electroncs are trademarks. *Trademark. Other products, logos, and 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 LOC B

2 08-00 Wre Strp Length Termnal Strap Type Butt Splce Parallel Splce Wre Barrel Note: Not to Scale HEAD WIRE SIZE (AWG) RANGE (and Termnal Sze) USE TOOL CHAMBER MARKED TERMINAL (Standard) [.7-.0] [.0-.8] Fgure TERMINAL (Long Barrel) [.7-.0] [.0-.8] [.0-.8] - - WIRE STRIP LENGTH BUTT SPLICE PARALLEL SPLICE [.0-.8] [.-.] [.-.6] [.-.7] [.7-.0] [.0-.] [.7-.0] [.0-.8] [.-.] - -. Remove quck pns from the adapter assembly. Refer to Fgure.. Insert crmpng head nto the adapter assembly.. 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. Remove the quck pns from the crmpng head; then remove the crmpng head from the tool holder.. 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.. 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. For termnals, make sure that the flat sde of the tongue faces the anvl. For splces, make sure that the brazed seam, (when vsble), s towards the ndenter. 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 or splce makng sure the wre nsulaton does not enter the wre barrel.. 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. To crmp the other half of the butt splce, poston the uncrmped wre barrel nto the crmpng chamber, and repeat the crmpng procedure. If the splce cannot be turned for crmpng the other half, rotate the crmpng head. 7. Refer to Secton and Fgure for crmp nspecton. of

3 08-00 Termnal Wre Barrel Centered n Crmpng Chamber Butt Splce Flat Sde of Termnal Tongue Facng Anvl Wre Barrel Centered n Crmpng Chamber Parallel Splce Brazed Seam on Splce Toward Indenter Wre Barrel Centered n Crmpng Chamber. CRIMP INSPECTION Fgure Inspect crmped termnals and splces by checkng the features descrbed n Fgure. 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.. 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 lntfree 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.. 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.) and a crmpng chamber nspecton (Paragraph 6.). 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.. Check all bearng surfaces for wear.. Inspect crmp area for flattened, chpped, or broken areas. Replace worn or damaged parts. of

4 08-00 Termnal 6 Wre Range Stamped Under Tongue Parallel Splce Wre Range Stamped Under Tongue Slght Hole or Stranded Type Butt Splce Wre Range Stamped Here Strap Type Wre Range Stamped Here Crmps centered. Crmps may be off center BUT NOT OFF END OF WIRE BARREL. Wre sze matches wre range or sze stamped on termnal or splce and tool. Wre nsulaton does not enter wre barrel. Wre s vsble through nspecton hole of butt splces. Wre s flush wth or extends slghtly beyond end of wre barrel. On parallel splces, bare wre ends must be flush wth or extended slghtly beyond end of wre barrel. Crmped off end of splce or termnal wre barrel. Wre sze does not match wre sze or range stamped on termnal or splce or tool. Wre nsulaton entered wre barrel of termnal or splce. CHECK FOR INCORRECT STRIP LENGTH. Wre not nserted far enough n termnal or splce. End of wre must be vsble through nspecton hole of butt splces, and be flush wth or extend slghtly beyond end of wre barrel. Excessve flash on termnal or splce ndcates damaged jaws or wrong wre, splce, or toolng combnaton was used. 6 Ncked or mssng strands. Fgure 6.. Lubrcaton Lubrcate all pns, pvot ponts, and bearng surfaces wth a hgh qualty grease. Tyco Electroncs recommends the use of Molykote 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. Tyco Electroncs does not manufacture or market these gages. of

5 08-00 Dm. Jaw Closure Confguraton HEAD Suggested Plug Gage Desgn.7 [.0] Mn. Typ. CHAMBER MARKING Element GAGE ELEMENT DIMENSIONS.9-.0 [.00-.0] [ ] [ ] [ ] [.00-.0] [ ] [ ] [ ] Crmpng Chamber element must pass completely through crmpng chamber. 0-8 [.00] Mn. Typ. Fgure NO-.-.7 [ ] [ ] [ ].8-.0 [ ].-. [ ] [ ] [ ] [ ] NO- Element NO- Dm. RADIUS.7 [.06].7 [.06].6 [.09].7 [.06].98 [.078].76 [.09].00 [.09].9 [.07] NO- element may enter partally, but must not pass completely through the crmpng chamber. 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.. Algn element wth wre barrel crmpng secton. Push element straght nto crmpng chamber wthout usng force. The element must pass completely through the chamber as shown n Fgure.. Algn the NO- element and try to nsert t nto the chamber. The element may start entry, but t must not pass completely through the crmpng chamber. Jaws The jaws n tool are not symmetrcally located; make sure that the tool conforms to the symmetry requrements shown n Fgure 6. Symmetry Requrements for Tool [.00] Mn (Typ) Fgure 6 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 REPLACEMENT AND REPAIR Order replacement heads through your Tyco Electroncs Representatve, or call , or send a facsmle of your purchase order to , or wrte to: CUSTOMER SERVICE (8-) TYCO ELECTRONICS CORPORATION P.O. BOX 608 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 Revsons to ths nstructon sheet nclude: Updated document to corporate requrements. of