Tyco Electronics 2063811-1 Bedienungsanleitung

Instruction Sheet

Hand Crimping Tool

2063811- 1 for STRATO- THERM* 408--10367

LOC B

1of 5

E2010 Tyco Electronics Corporation, Berwyn, PA

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 at www.tycoelectronics.com

GTrademark of E.I. Du Pont de Nemours & Co.

11 JUN 10 Rev APre- Insulated Spare Wire Caps

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.

Figure 1

Color Coded to Indicate Wire

Insulation Diameter Range of Cap

Unstripped Wire

Color Code of

Crimping Dies

Crimping Die

Color Codes

“A”

Ring

“B”

Ring

Spare

Wire Cap

Orange

Green

White

1. INTRODUCTION

This instruction sheet covers the application,

maintenance, and inspection of Hand Crimping Tool

2063811--1, which is used to apply STRATO--THERM

pre--insulated spare wire caps on unstripped

TEFLONGinsulated wire having an insulation

diameter range of 0.91 -- 3.50 mm [.036 --.138 in.].

Read this sheet thoroughly before proceeding. Refer

to Catalog 82011 for product part numbers, wire

insulation diameter, and proper color codes.

Dimensions on this sheet are in millimeters [with

inch equivalent dimensions in brackets]. Figures

and illustrations are for identification only and are

not drawn to scale.

Reasons for reissue are provided in Section 7,

REVISION SUMMARY.

2. DESCRIPTION

The tool features three crimping areas, tool handles,

and a CERTI--CRIMP* Hand Crimping Tool Ratchet

Control. Tool dies and spare wire cap rings are color

coded for a given wire insulation diameter range.

Crimp the color coded ring (“B”) in the matching color

coded dies. See Figures 1 and 2. Example: If

insulation diameter of wire is within a range of 1.422

to 1.63 mm [.056 --.064 in.], use ring “A.”

3. CRIMPING PROCEDURE

To apply the wire cap, proceed as follows:

1. Open crimping dies by closing handles until

CERTI--CRIMP ratchet releases. Note that, once

ratchet is engaged, handles cannot be opened until

they are first fully closed.

2. Place cap in matching color coded dies (ring “B”

on cap must match die color code). Be sure cap is

fully bottomed in tool and rings are centered in

crimping dies. See Figure 3.

Figure 2

Cap Bottomed

and Rings

Centered in

Dies

Ring “B”

Matches

Color

Code of

Dies

Unstripped

Wire

3. Close handles until cap is firmly in place. Do

NOT deform cap.

4. Insert UNSTRIPPED wire all the way into cap.

5. To complete crimp, close handles until

CERTI--CRIMP ratchet releases. Open the handles

and remove the crimped cap.

6. Refer to Section 4 and Figure 3 for spare wire

cap crimp inspection procedure.

7. “REJECT” spare wire caps can be avoided

through careful use of instructions in Section 2,

and by performing regular tool maintenance as

instructed in Section 5.

4. CRIMP INSPECTION

1. Inspect crimped spare wire caps by checking

the features described in Figure 3.

NOTE

408- 10367

STRATO- THERM Wire Cap Crimping Tool 2063811- 1

Rev A2 of 5 Tyco Electronics Corporation

2. Use only the spare wire caps that meet the

conditions shown in “ACCEPT” column.

3. “REJECT” spare wire caps can be avoided

through careful use of instructions in Section 3,

and by performing regular tool maintenance as

instructed in Section 5.

5. MAINTENANCE AND INSPECTION PROCEDURE

Tyco Electronics recommends that a

maintenance/inspection program be performed

periodically to ensure dependable and uniform

terminations. The tool should be inspected at least

once per month. Frequency of inspections depends

on:

SThe care, amount of use, and handling of the

tool.

SThe type and size of products crimped.

SThe degree of operator skill.

SThe presence of abnormal amounts of dust and

dirt.

SYour own established standards.

The hand tool is inspected before being shipped;

however, Tyco Electronics recommends that the tool

be inspected immediately upon arrival to ensure that

the tool has not been damaged during shipment.

5.1. Daily Maintenance

1. Hand tool should be immersed (handles partially

closed) in a reliable commercial degreasing

compound to remove accumulated dirt, grease,

and foreign matter. When degreasing compound is

not available, tool may be wiped clean with a soft,

lint--free cloth. Do NOT use hard or abrasive

objects that could damage the tool.

2. Make certain that the retaining pins are in place

and that they are secured with retaining rings.

3. When the tool is not in use, keep handles closed

to prevent objects from becoming lodged in the

crimping jaws. Store the tool in a clean, dry area.

4Ring “B”

Ring “A”

4Ring “B”

Ring “A”

Reject

1.Wire fully bottomed in cap. 1. Wire not fully bottomed in cap.

2. Full length of both rings crimped (cap was bottomed in tool and

rings centered in dies).

2. Full length of rings not crimped (Cap was not fully bottomed in

tool; see Figure 2).

3. Ring “B” color code matches color code of dies. 3. Ring “B” color code did not match color code of dies.

4. Wire insulation diameter is within range of color coded (Ring

“A”) cap. See Figure 1.

4. Wire insulation diameter is not within range of color coded

(Ring “A”) cap. See Figure 1.

5. Excessive flash or cracked ring. Wire insulation diameter too

large (see Figure 1) or damaged dies.

Figure 3

408- 10367

STRATO- THERM Wire Cap Crimping Tool 2063811- 1

3of 5Rev ATyco Electronics Corporation

Figure 4

Broken Edge

or Corner

Pitted

Area

4. All pins, pivot points, and bearing surfaces

should be protected with a THIN coat of any good

SAE 20 motor oil. Do NOT oil excessively.

5.2. Periodic Inspection

A. Lubrication

Lubricate all pins, pivot points, and bearing surfaces

with SAE 20 motor oil as follows:

Tool used in daily production -- lubricate daily

Tool used daily (occasional) -- lubricate weekly

Tool used weekly -- lubricate monthly

Wipe excess oil from tool, particularly from crimping

jaws. Oil transferred from the crimping area onto

certain terminations may affect the electrical

characteristics of an application.

B. Visual Inspection

1. Inspect the tool for missing parts or retaining

rings. If parts are missing or defective, see Section

6, REPLACEMENT AND REPAIR.

2. Inspect head assembly for worn, cracked, or

broken jaws. See Figure 4. If damage is evident,

return the tool to Tyco Electronics for evaluation

and repair. See Section 6, REPLACEMENT AND

REPAIR.

C. Gaging the Crimping Chamber

Each tool is inspected for proper die closure before

packaging. An inspection should be performed

periodically to check the die closure for excessive

wear.

The die closure inspection is accomplished using plug

gages. Tyco Electronics neither manufactures nor

sells plug gages. Suggested designs and dimensions

for the plug gage elements are listed in Figure 5. The

following procedure is recommended for inspecting

the three die closures.

1. Clean oil or dirt from the die closure and plug

gage elements.

2. Close handles of tool until crimping dies are

bottomed. Do not apply additional pressure to tool

handles.

Suggested Plug Gage Design

NO--GO Dim. “A”

GO Dim. “A”

Die Closure

Crimp Configuration

25.4 mm

[1.0 in.]

DIE COLOR GAGE ELEMENT DIM’S. “A”

CODE GO NO--GO

Green 3.124 -- 3.132

[.1230 --1233]

3.274 -- 3.277

[.1289--.1290] 1.30 [.051] 1.47 [.051]

Orange 3.404 --3.411

[.1340--[.1343

3.553 -- 3.556

[.1399--.1400] 1.57 [.062] 1.57 [.062]

White 4.445 -- 4.452

[.1750--.1753]

4.595 -- 4.597

[.1809--.1810] 2.03 [.080] 2.03 [.080]

Figure 5

408- 10367

STRATO- THERM Wire Cap Crimping Tool 2063811- 1

Rev A4 of 5 Tyco Electronics Corporation

Figure 6

“GO” element must pass

completely through the

die closure.

“NO--GO” element may

enter partially, but must not

pass completely through the

die closure.

Inspection of Die Closures with Plug Gage

Dies are

Bottomed

But Not

Under

Pressure

Flats on Gage

Parallel to

Length

of Tool

3. With crimping dies bottomed, check the selected

die closure using the proper plug gage. Hold gage

in straight alignment with the die closure and

carefully try to insert, without forcing, the GO

element. See Figure 6. The GO element must pass

completely through the die closure. See Figure 6.

4. Try to insert the NO--GO element. The NO--GO

element may enter partially, but must not pass

completely through the die closure. See Figure 6.

5. If all three closures meet the plug gage

conditions, The die closures may be considered

dimensionally correct. If you find that the die

closures do not conform to the gage conditions,

contact your local Tyco Electronics Representative.

D. CERTI- CRIMP Ratchet Inspection

Check the CERTI--CRIMP Hand Crimping Tool

Ratchet Control to ensure that ratchet does not

release prematurely, allowing dies to open before they

have fully bottomed. Obtain a 0.025 mm [.001 in.]

shim that is suitable for checking the clearance

between the bottoming surfaces of the dies. To check

the ratchet feature:

1. Thoroughly clean bottoming surfaces of dies.

2. Position the terminal and wire between the

crimping jaws, as described in Section 3,

CRIMPING PROCEDURE.

3. Hold the wire in place and squeeze the handles

until the CERTI--CRIMP ratchet releases. Hold the

handles in this position, maintaining just enough

force to keep the jaws closed.

4. Check the clearance between the bottoming

surfaces of the crimping jaws. If the clearance is

0.025 mm [.001 in.] or less, the ratchet is

satisfactory. If clearance exceeds 0.025 mm

[.001 in.], the ratchet is out of adjustment and

must be repaired. See Section 6, REPLACEMENT

AND REPAIR.

6. REPLACEMENT AND REPAIR

The parts listed in Figure 7 are customer--

replaceable. A complete inventory can be stocked

and controlled to prevent lost time when replacement

of parts is necessary. Parts other than those listed in

Figure 7 must be replaced by Tyco Electronics to

ensure quality and reliability of the tool. Order

replacement parts through your Tyco Electronics

Representative, or call 1--800--526--5142, or send a

facsimile of your purchase order to 717--986--7605, or

write to:

CUSTOMER SERVICE (038--035)

TYCO ELECTRONICS CORPORATION

P.O. BOX 3608

HARRISBURG, PA 17105--3608

7. REVISION SUMMARY

SInitial release of document

408- 10367

STRATO- THERM Wire Cap Crimping Tool 2063811- 1

5of 5Rev ATyco Electronics Corporation

REPLACEABLE PARTS

ITEM PART NUMBER DESCRIPTION QTY PER TOOL

121045--3 RING, Retaining 4

Figure 7

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