TE Connectivity 47820 Bedienungsanleitung

Instruction Sheet

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PRODUCT INFORMATION

1-800-522-6752

This controlled document is subject to change.

For latest revision and Regional Customer Service,

visit our website at www.te.com.

408-1729

22 NOV 16 Rev K

Crimping Die

Wire Size

(AWG)

Head or Tool

Part Number

Color Code Dot

47820

Red

Hydraulic Crimping Head 69051

Hydraulic Hand Tool 59974-1

47821

Blue

47822

Yellow

47823

Red

47824

Blue

1/0

Hydraulic Crimping Head 69066

47825

Yellow

2/0

47915

Red

3/0

47918

Blue

4/0

Figure 1

1. INTRODUCTION

Crimping Dies 47820 through 47823 are used with Crimping Head 69051 or Hand Tool 59974--1. Crimping

Dies 47824, 47825, 47915, and 47918 are used with Crimping Head 69066. The dies crimp pre-insulated

AMPOWER* terminals onto wire sizes 4 through 1/0 AWG, TERMINYL* terminals and splices onto wire sizes 8

through 4/0 AWG, TERMINYL splices with step-down adapters onto wire sizes 16-14 through 1/0 AWG, and

PLASTI-GRIP* terminals and splices onto wire sizes 8 through 4/0 AWG. Refer to Figure 1 to ensure

compatibility of crimping die, head or tool, and wire size.

NOTE

Dimensions in this document are in millimeters [with inches in brackets]. Figures and illustrations are for reference only and

are not drawn to scale.

For detailed information about the head or tool, refer to the instructions packaged with the head or tool.

Reasons for reissue of this instruction sheet are provided in Section 8, REVISION SUMMARY.

2. DESCRIPTION (FIGURE 1)

Each crimping die consists of a stationary die (nest) and a moving die (anvil). The stationary die features a

locator. Each die contains a color code dot that matches the color code of the terminal and splice. When

mated, the dies form a crimping chamber.

Crimping Dies; PN 47820 thru

47825, 47915, and 47918

Crimping Dies; PN 47820 thru 47825, 47915, and 47918 (Typical)

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3. DIE INSTALLATION AND REMOVAL

DANGER

To avoid personal injury, ALWAYS release hydraulic pressure to hose or control and disconnect power unit from power supply

before installing or removing dies.

3.1. Installation

1. Remove latch pin and open yoke on crimping head (see Figure 2).

Figure 2

2. Loosen the setscrew in the yoke.

3. Insert the shank of the stationary die into the yoke, and tighten the setscrew.

NOTE

The stationary die has a large shank and the moving die has a small shank, as shown in Figure 2.

4. Extend the ram until the ram setscrew is visible.

5. Loosen the setscrew in the ram.

6. Insert the shank of the moving die into the ram, and tighten the setscrew.

CAUTION

To avoid damage to the dies, be sure the moving and stationary dies are properly oriented.

7. Activate the tool or power unit to allow the ram to return to the “down” position.

8. Close the yoke and insert the latch pin.

3.2. Removal

1. Remove latch pin and open yoke on crimping head.

2. Loosen the setscrew in the yoke, and remove the stationary die.

3. Extend the ram until the ram setscrew is visible.

4. Loosen setscrew in ram and remove moving die.

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4. CRIMPING PROCEDURE

4.1. Crimping Terminals

DANGER

Avoid personal injury. When operating tool or power unit, exercise caution while holding terminals or wire near crimping area.

1. Strip wire to the dimensions listed in Figure 3.

Do not nick or cut the wire strands.

Figure 3

2. Select the proper color-coded terminal for the wire size. The wire size stamped on the terminal

tongue and on the crimping die must match the wire size selected.

3. Insert stripped wire fully into terminal wire barrel. The end of the conductor must not protrude more

than 1.60 mm [.063 in.] beyond the edge of the wire barrel.

CAUTION

Do NOT turn or twist the wire or terminal during insertion.

4. Remove crimping head latch pin and open yoke.

5. Place the terminal in the stationary die with the edge of the wire barrel resting against the locator and

the bottom of the terminal tongue facing the stationary die. See Figure 4.

Figure 4

Bottom of

Terminal Tongue

Facing Stationary

Die

Edge of Wire Barrel

Resting Against Locator

408-1729

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6. Holding the terminal in place, close the yoke and insert the latch pin.

CAUTION

Be sure latch pin is fully inserted, otherwise damage to the die and tool or head will occur when the tool or power unit is

activated.

7. Holding wire in place, activate tool or power unit to complete crimp.

8. When crimp is completed, remove the latch pin, open the yoke, and remove the terminal.

NOTE

If terminal sticks in die after crimping, apply a rocking action to the terminal to remove it from the die. Wipe light oil on the dies

to prevent sticking, or use spray dry lubricant.

9. Inspect the crimp according to Section 5.

4.2. Crimping Splices without Step-Down Adapter

DANGER

Avoid personal injury. When operating tool or power unit, exercise caution while holding splice or wire near the crimping area.

1. Strip wires to the dimensions listed in Figure 3.

Do not nick or cut the wire strands.

2. Select the proper color-coded splice for the wire size. The wire size stamped on the splice and on

the crimping die must match the wire size selected.

3. Insert the stripped wire into the wire barrel of the end of the splice to be crimped until the wire bottoms

against the wire stop within the splice.

4. Remove crimping head latch pin and open yoke.

5. Place the splice in the stationary die. Grasp the end of the splice to be crimped and point the opposite

end toward the top of the head yoke at a 30° (approximate) angle. Rotate the end of the splice to be

crimped into the die. Position the edge of the window indent against the locator. Refer to Figure 5.

Figure 5

Top of Yoke

Edge of Window Indent

Resting Against Locator

Rotate End of Splice to be

Crimped into Stationary Die

End of Splice

Pointed Toward

Top of Yoke at

Approximately

30°Angle

408-1729

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6. Holding the splice in place, close the yoke and insert the latch pin.

CAUTION

Be sure latch pin is fully inserted, otherwise damage to the dies and tool or head will occur when the tool is activated.

7. Holding wire in place, activate tool or power unit to complete first wire barrel crimp.

8. When crimp is completed, remove latch pin, open yoke and remove the splice.

NOTE

If splice sticks in die after crimping, apply a rocking action to the splice to remove it from the die. Wipe light oil on dies to

reduce sticking, or use spray dry lubricant.

9. To crimp the other half of splice, reposition un-crimped end of splice in the stationary die and follow

the same procedure used to crimp the first half of splice.

10. Inspect the crimp according to Section 5.

4.3. Crimping Splices with Step-Down Adapter

DANGER

Avoid personal injury. When operating tool or power unit, exercise caution while holding splice or wire near the crimping area.

1. Strip wires to the dimensions listed in Figure 3.

Do not nick or cut the wire strands.

2. Select the proper splice, adapter, and crimping die for the wire size (see Figure 6).

NOTE

Note that the end of the splice containing the adapter has a different color code. Use the crimping die for the larger wire size to

crimp both ends of the splice. For example, use Crimping Die 47820 (for wire size 8 AWG) to crimp both ends of the splice

with step-down adapter for stepping down from wire size 8 to 16-14 AWG.

Figure 6

3. Insert stripped wire into the wire barrel of the end of the splice to be crimped until the wire bottoms

against the wire stop within the splice (refer to Figure 3).

4. Remove crimping head latch pin and open yoke.

5. Place the splice in the stationary die. Grasp the end of the splice to be crimped and point the opposite

end toward the top of the head yoke at a 30° (approximate) angle. Rotate the end of the splice to be

crimped into the die. Position the edge of the window indent against the locator. Refer to Figure 5.

408-1729

Rev K

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6. Holding the splice in place, close the yoke and insert the latch pin.

CAUTION

Be sure latch pin is fully inserted, or damage to the dies and tool or head will occur when the tool is activated.

7. Holding the wire in place, activate tool or power unit to complete first wire barrel crimp.

8. When crimp is completed, remove latch pin, open yoke and remove splice.

NOTE

If splice sticks in die after crimping, apply a rocking action to the splice to remove it from the die. Wipe light oil on dies to

reduce sticking, or use spray dry lubricant.

9. To crimp the other half of splice, reposition un-crimped end of splice in the stationary die and follow

the same procedure used to crimp the first half of splice.

10. Inspect the crimp according to Section 5.

4.4. Crimping PLASTI-GRIP Butt Splices

DANGER

Avoid personal injury. When operating tool or power unit, exercise caution while holding butt splices or wire near crimping

area.

1. Strip wires to the dimensions listed in Figure 3.

Do not nick or cut the wire strands.

2. Select the proper color-coded butt splice for the wire size. The wire size stamped on the butt splice

and on the crimping die must match the wire size selected.

3. Remove crimping head latch pin and open yoke. Remove the stationary die from the yoke, then

remove the locator from the stationary die. Re-assemble the stationary die onto the yoke.

CAUTION

To avoid damage to the dies, be sure the stationary die is properly oriented with the moving die.

4. Insert the stripped wire into the wire barrel of the end of the butt splice to be crimped until the wire

bottoms against the wire stop within the splice.

5. Place the butt splice in the stationary die with the wire barrel of the end of the splice to be crimped

centered over the crimping chamber (see Figure 7).

Figure 7

6. Holding butt splice in place, close the yoke and insert latch pin.

CAUTION

Be sure latch pin is fully inserted, otherwise damage to the die and tool or head will occur when the tool or power unit is

activated.

7. Holding wire in place, activate tool or power unit to complete first wire barrel crimp.

408-1729

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8. When crimp is completed, remove latch pin, open yoke, and remove the butt splice.

NOTE

If butt splice sticks in die after crimping, apply a rocking action to the butt splice to remove it from the die. Wipe light oil on dies

to reduce sticking, or use spray dry lubricant.

9. To crimp the other half of butt splice, reposition un-crimped end of splice in the stationary die and

follow the same procedure used to crimp the first half of splice.

NOTE

Be sure to re-assemble locator onto stationary die after crimping PLASTI-GRIP butt splices.

10. Inspect the crimp according to Section 5.

5. CRIMP INSPECTION

Inspect crimped terminals and splices by checking the features described in Figure 9. Use only the terminals

and splices that meet the conditions shown in the “ACCEPT” column.

6. MAINTENANCE / INSPECTION

DANGER

To avoid personal injury, ALWAYS release hydraulic pressure to hose or control and disconnect power unit from power supply

before performing maintenance or inspection procedure.

Each crimping die is thoroughly inspected before packaging. Since there is a possibility of damage during

shipment, the crimping die should be inspected immediately upon arrival at your facility.

Regular inspections should be performed by quality control personnel. A record of scheduled inspections

should remain with the dies and/or be supplied to supervisory personnel responsible for the dies. Though

recommendations call for at least one inspection a month, the inspection frequency should be based on the

amount of use, ambient working conditions, operator training and skill, and established company standards.

CAUTION

Regular inspections should include checking torque setting of (4) screws in accordance with Figure 8.

Crimping Die

Wire Size

(AWG)

Screw Torque Setting

Specification

(inch-pounds)

Crimping Die

Wire Size

(AWG)

Screw Torque Setting

Specification

(inch-pounds)

47820

47824

1/0

47821

47825

2/0

47822

47915

3/0

47823

47918

4/0

Figure 8

Torque (4) Screws in

Accordance with Figure 8.

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Rev K

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Figure 9

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Rev K

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6.1. Daily Maintenance

It is recommended that each operator of the dies be made aware of-and responsible for-the following steps of

daily maintenance:

1. Remove dust, dirt, and other contaminants with a clean brush, or a soft, lint--free cloth. Do NOT use

objects that could damage the dies.

2. Make certain the dies are protected with a THIN coat of any good SAE 20 motor oil. Do not oil

excessively.

3. When the dies are not in use, mate them and store in a clean, dry area.

6.2. Visual Inspection

1. Remove all lubrication and accumulated film by immersing the dies in a suitable commercial

degreaser that will not affect paint or plastic material.

2. Make sure all die components are in place. If replacements are necessary, refer to the replacement

parts listed in Figure 12.

3. Check components for wear. Remove and replace worn components.

4. Inspect the crimp area for flattened, chipped, cracked, worn, or broken areas. If damage is evident,

the dies must be repaired before returning them to service (see Section 7, REPLACEMENT AND

REPAIR).

6.3. Gaging the Crimping Chamber

The die closure inspection is accomplished using plug gages. A suggested gage design and the GO and NO-

GO diameters of the plug gage elements are shown in Figure 10.

Figure 10

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The following procedure is recommended for inspecting the die closures:

1. Mate the dies until it is evident that they have bottomed. Hold the dies in this position.

2. Align the GO element with the crimping chamber. Push element straight into the crimping chamber

without using force. The GO element must pass completely through the crimping chamber as shown

in Figure 11.

3. Align the NO-GO element and try to insert it straight into the crimping chamber. The NO-GO element

may start entry but must not pass completely through as shown in Figure 11.

If the crimping chamber conforms to the gage inspection, the crimping die is considered dimensionally correct

and should be lubricated with a THIN coat of SAE 20 motor oil.

If the crimping chamber DOES NOT conform to the gage inspection not, the dies must be repaired before

returning them to service (see Section 7, REPLACEMENT AND REPAIR).

For additional information concerning the use of a plug gage, refer to Instruction Sheet 408-7424.

Figure 11

7. REPLACEMENT AND REPAIR

The parts listed in Figure 12 are customer-replaceable. A complete inventory can be stocked and controlled to

prevent lost time when replacement of parts is necessary. Order replacement parts through your TE

Connectivity 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 (038-035)

TE CONNECTIVITY CORPORATION

P.O. BOX 3608

HARRISBURG, PA 17105—3608

NOTE

Dies may be returned for evaluation and repair.

For die repair service, contact a TE Representative at 1-800-526-5136.

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