Tyco Electronics 48858-1 Bedienungsanleitung

Instruction Sheet

Crimping Dies 48858-1 through

48861-1 for AMPLI-BOND* and 408-1724

LOC B

of 6

2007 yco Electronics Corporation, Harrisburg, PA

All International Rights Reserved

E logo and yco Electronics are trademarks.

* rademark. Other products, logos, and company names used are the property of their respective owners.

OOLING ASSIS ANCE CEN ER 1-800-722-1111

PRODUC INFORMA ION 1-800-522-6752 his controlled document is subject to change.

For latest revision and Regional Customer Service,

visit our website at

www.tycoelectronics.com

28 NOV 07 Rev N

PLASTI-GRIP* Terminals

Standard Expansion Dies

Stationary Die Moving Die

Color Code Dot

IRE TERMINAL DIE SET

SIZE (A G) INSULATION DIAMETER (Max.) COLOR CODE PART NO. COLOR CODE

8 7.57 [.298] Red 48858-1 Red Dot

6 9.58 [.377] Blue 48859-1 Blue Dot

4 11.10 [.436] Yellow 48860-1 Yellow Dot

2 12.82 [.505] Red 48861-1 Red Dot

Figure 1

1. INTRODUCTION

This instruction sheet provides information on product

application and a maintenance and inspection

procedure for the crimping dies listed in Figure 1. The

dies are used in Hydraulic Crimping Heads 58422–1,

69066, 1752877–1, and 1752787–1. For detailed

information on the hydraulic power unit and hydraulic

crimping head, refer to the instructions packaged with

these tools.

These dies are designed to crimp AMPLI–BOND and

PLASTI–GRIP terminals on wire sizes 8 AWG to

2 AWG. Dies are coated with a preservative to

prevent rust and corrosion. Wipe preservative from

dies, particularly from crimping areas.

All dimensions in this document are in millimeters

[ ith inches in brackets]. Figures and illustrations

are for reference only and are not dra n to scale.

Reasons for reissue are provided in Section 6,

REVISION SUMMARY.

2. DIE INSTALLATION AND REMOVAL

Avoid personal injury. Exercise caution to avoid

accidentally depressing foot pedals or trigger

control of hydraulic po er unit hen installing or

removing dies.

2.1. Die Installation

1. Refer to the chart in Figure 1 and verify that you

have the proper die set for the terminal and wire

size being used.

2. Remove latch pin on head, then open yoke. See

Figure 2.

3. Loosen set screw in yoke.

4. Insert stationary die into well of yoke as shown

in Figure 2. Tighten set screw.

5. Activate power unit to advance ram until set

screw is visible.

Figure 2

Setscrew

Yoke

Latch Pin Removed

Stationary

Die

Moving Die

Ram Setscrew

Stop Plate

NOTE

DANGER

408-1724

Crimping Dies 48858-1 through 48861-1

Rev

of 6 Ty o Ele troni s Corporation

6. Loosen set screw in ram and insert moving die

into ram well as shown in Figure 2. Tighten set

screw.

Moving die must be properly oriented to mate

with stationary die.

7. Activate power unit to allow ram to return to the

“

down

” position.

2.2. Die Removal

1. Remove latch pin and open yoke.

2. Loosen set screw in yoke and remove stationary

die.

3. Raise ram to “

full up

” position. Loosen set screw

and remove moving die.

3. OPERATION

3.1. ire Stripping and Crimping Procedure

Avoid personal injury. When operating power unit,

e ercise caution while holding terminals or wire

near crimping area. Never place anything in the

dies e cept terminals.

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

NOT nick or cut conductor strands.

2. Insert stripped wire in terminal. End of wire must

be flush with or extend beyond edge of terminal

wire barrel.

PLASTI-GRIP Terminal

AMPLI-BOND Terminal

Wire Must be Flush or Extend

Beyond Edge of Wire Barrel

Wire Strip

Length (Typ)

IRE IRE STRIP LENGTH

IRE

SIZE

(A G)

AMPLI-BOND PLASTI-GRIP

(A G) MINIMUM MAXIMUM MINIMUM MAXIMUM

8 11.51 [.453] 12.29 [.484]

611.51 12.29 15.47 [.609] 16.26 [.640]

4[.453] [.484] 15.47 [.609] 16.26 [.640]

2 11.51 [.453] 12.29 [.484]

Figure 3

Figure 4

Stationary Die

Bottom of

Terminal Tongue

Fa es Stationary Die

Moving Die

Terminal Wire Barrel

Rests Against

Stop Plate

3. With yoke open, place terminal on dies. See

Figure 4.

4. Bottom of terminal tongue should face stationary

die and terminal wire barrel should rest against

stop plate as shown in Figure 4.

5. Close yoke and insert latch pin.

Ensure that latch pin is fully inserted or damage

may occur to yoke, dies, or latch pin.

6. Hold terminal in place and activate power unit to

complete crimp. Open yoke and remove crimped

terminal.

If terminal sticks in die after crimping, apply a

rocking action to remove it from die.

3.2. Insulation Crimp Adjustment

This adjustment is made to both stationary and

moving dies after they have been placed in crimping

head.

1. The dies have three insulation crimp positions.

The adjustment is made by moving a pin–key (see

Figure 5). When the pin–key is pushed all the way

in, the insulation crimping section of the die is in

the loose position; when the pin–key is halfway

out, the insulation crimping section of the die is in

the medium position; when the pin–key is all the

way out, the insulation crimping section of the die

is in the tight position.

NOTE

DANGER

NOTE

408-1724

Crimping Dies 48858-1 through 48861-1

of 6Rev

Tyco Electronics Corporation

2. To adjust the insulation crimp, loosen socket

head cap screws and push pin–key all the way in

so that insulation crimp section of the die is in the

loose position.

Figure 5

Stationary

Die

ire Barrel

Crimping Section

Moving

Die

Insulation Barrel

Crimping Section

Color Code

Pin-Key

Color Code

Socket Head

Cap Screws

Socket Head

Cap Screws Insulation Barrel

Crimping Section

Pin-Key

3. Press and hold insulation die down against the

pin–key. This will prevent the spring–loaded

pin–key from popping back.

4. Tighten socket head cap screws.

Make certain insulati n crimping secti ns f

m ving and stati nary dies are b th adjusted t

the same p siti n.

5. Perform a test crimp (refer to Paragraph 3.1).

AMPLI-BOND terminals pr vide a grip" n wire

insulati n. PLASTI-GRIP terminals pr vide nly

a supp rt" f r the wire.

6. Remove crimped terminal from dies and visually

inspect the insulation crimp portion of terminal. The

insulation crimp should “

grip

” wire insulation (when

using AMPLI–BOND terminals) or provide

“

support

” for wire insulation (when using

PLASTI–GRIP terminals).

7. If the insulation crimp does not grip or support

wire insulation as described in step 6, loosen

socket head cap screws and set the pin–keys in

the medium position. Then follow Steps 3 and 4.

8. Make another test crimp over previously

crimped terminal.

Figure 6

ire fully inserted.

Crimp centered on wire barrel.

Correct color code and die combination. (Terminal insulation

color matches color dots on dies.)

ire size being used is same as wire size embossed on

terminal insulation and stamped on terminal tongue.

End of conductor is flush with or extends beyond end of

wire barrel of terminal.

Insulation barrel is in contact with wire insulation.

(AMPLI-BOND terminals have insulation grip" and

PLASTI-GRIP terminals have insulation support".)

ire not fully inserted.

Crimp not centered on wire barrel. (Terminal was not butted

against stop plate. See Figure 4.)

rong die and terminal color code combination. See Figure 1.

Excessive flash or extruded insulation. ( rong size or damaged

dies.)

End of conductor is not flush with or extending beyond end of

wire barrel of terminal.

ire insulation pinched. (Insulation crimp too tight on

AMPLI-BOND terminals.)

Nicked or missing conductor strands.

Crimp Inspection of

AMPLI-BOND and

PLASTI-GRIP Terminals

Accept Reject

NOTE

408-1724

Crimping Dies 48858-1 t roug 48861-1

Rev

of 6 Tyco Electronics Corporation

9. Remove crimped terminal from dies and visually

inspect insulation crimp.

10. Repeat adjustment as necessary until desired

insulation crimp is obtained. Do NOT use a tighter

setting than required.

11. Refer to Paragraph 3.4 and Figure 6 for crimp

inspection procedure.

3.3. Color Code

Terminals and dies are color coded as listed in

Figure 1 and shown in Figure 5. The dies have the

terminal size stamped in the wire barrel crimp

sections of both the moving and stationary dies.

When crimped, the wire size will appear on both sides

of the terminal wire barrel. The wire size appearing on

the crimped wire barrel should always agree with the

wire size stamped on the terminal tongue.

3.4. Crimp Inspection

Inspect crimped terminals by checking the features

described in Figure 6.

AMPLI-BOND te minals a e shown in Figu e 6.

Inspection p ocedu e is the same fo

PLASTI-GRIP te minals.

Use only the terminals that meet the conditions

shown in the “ACCEPT” column. “REJECT” terminals

can be avoided through careful use of instructions in

Paragraphs 3.1 and 3.2, and by performing regular

die maintenance described in Section 4.

4. MAINTENANCE/INSPECTION

Regular inspections should be performed by quality

control personnel. A record of scheduled inspections

should remain with the dies and/or be supplied to the

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. These inspections should be

performed in the following sequence:

4.1. Cleaning

Do not allow deposits of dirt, grease, or foreign matter

to accumulate in the die closure area, or on the

bottoming surfaces of the dies. These deposits may

prevent the dies from bottoming fully and may also

cause excessive wear in the die closure surfaces,

thereby affecting the quality of the crimp. The dies

should be wiped clean frequently with a clean cloth.

4.2. Visual Inspection

Visually inspect the die closure surfaces for flattened,

broken, pitted, or chipped conditions. Although dies

may gage within permissible limits, worn or damaged

die closure surfaces can affect the quality of the

crimp. Examples of possible damaged die surfaces

are shown in Figure 7.

4.3. Plug Gage Inspection

Every die set is inspected and tested for proper die

closure dimensions before packaging. An inspection

should be performed periodically to check the die

closure for excessive wear.

Figure 7

Broken

Corner

Chipped or

Flattened

Edge

Pitted

The die closure inspection is accomplished using plug

gages. A suggested gage design and the GO and

NO–GO dimensions of the plug gage elements are

shown in Figures 8 and 9. The following procedure is

recommended for inspecting the die closures.

1. Clean oil or dirt from the bottoming surfaces, die

closure surfaces, and plug gage elements.

2. Remove two socket head cap screws and stop

plate from moving die. See Figure 10, Detail A.

This will provide access to the wire barrel dies for

plug gaging.

3. Assemble stationary and moving dies so that

wire barrel dies are bottomed, but not under

pressure. See Figure 10.

4. With wire barrel dies bottomed, inspect the wire

barrel crimp 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 10, Detail A. The GO

element must pass completely through the wire

barrel crimp die closure.

5. Try to insert the NO–GO element. The NO–GO

element may enter partially, but must not pass

completely through the wire barrel die closure.

6. Re–install stop plate and secure with the two

socket head cap screws.

NOTE

408-1724

Crimping Di s 48858-1 through 48861-1

o 6Rev

Tyco Electronics Corporation

50.8 [2.00]

Min Typ

GO Diameter NO-GO Diameter

SUGGESTED PLUG GAGE DESIGN - WIRE BARREL CRIMP

Die Closure

Configuration

TOOL GAGE ELEMENT DIAMETER

NUMBER GO NO-GO

48858-1 5.105-5.113 [.2010-.2013] 5.255-5.258 [.2069-.2070]

48859-1 6.020-6.027 [.2370-.2373] 6.170-6.172 [.2429-.2430]

48860-1 6.833-6.840 [.2690-.2693] 6.982-6.985 [.2749-.2750]

48861-1 8.103-8.110 [.3190-.3193] 8.252-8.255 [.3249-.3250]

Figure 8

SUGGESTED PLUG GAGE DESIGN - INSULATION BARREL CRIMP

GO NO

GO Dimension D"

Dimension F"

Min (Typ)

Die Closure

Configuration

NO-GO Dimension D"

Dimension E" (Typ)

TOOL GAGE ELEMENT DIMENSION D" DIMENSION DIMENSION

NUMBER GO NO-GO E" F"

48858-1 3.861-3.868 [.1520-.1523] 4.366-4.369 [.1719-.1720] 7.14 [.281]

48859-1 4.216-4.224 [.1660-.1663] 4.722-4.724 [.1859-.1860] 7.87 [.310] 4.83 [.190]

48860-1 4.115-4.122 [.1620-.1623] 4.620-4.623 [.1819-.1820] 8.13 [.320]

48861-1 4.623-4.630 [.1820-.1823] 5.128-5.131 [.2019-.2020] 10.29 [.405] 6.35 [.250]

Figure 9

7. Loosen socket head cap screws from both

stationary and moving insulation dies and move

pin–keys all the way out so that insulation crimping

sections of dies are in the tight position.

See Figure 10, Detail B.

8. Press and hold insulation die down against

pin–key, and tighten the socket head cap screws.

9. With wire barrel dies bottomed, inspect the

insulation crimp die closure using the proper plug

gage in the same manner as steps 3 through 5.

See Figure 10, Detail B.

10. If both wire barrel and insulation die closures

meet the plug gage conditions, the dies are

considered to be dimensionally correct.

5. REPLACEMENT AND REPAIR

The parts listed in Figure 11 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 Tyco Electronics 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 (38–35)

TYCO ELECTRONICS CORPORATION

P.O. BOX 3608

HARRISBURG, PA 17105–3608

Dies may be returned for evaluation and repair. For

die repair service, contact a representative at

1–800–526–5136.

6. REVISION SUMMARY

Updated document to corporate requirements

New format

408-1724

Cri ping Dies 48858-1 through 48861-1

Rev

of 6 Tyco Electronics Corporation

Figure 10

Detail A

Inspection of

Wire Barrel

Crimping Dies

Detail B

Inspection of

Insulation Barrel

Crimping Dies

GO element must pass completely through

the die closure.

NO-GO element may enter partially, but must

not pass completely through the die closure.

ire Barrel Dies Bottomed

But Not Under Pressure

Cap Screws and

Stop Plate Removed

Socket Head

Cap Screws

Pin-Keys in Tight Position ire Barrel Dies Bottomed

But Not Under Pressure

Figure 11

ITEM DESCRIPTION QTY PER

DIE SET DIE SET NUMBERS AND COMPONENT PART NUMBERS

48858-1 48859-1 48860-1 48861-1

1 Stationary Die 1 307809-1 307809-2 307809-3 307809-4

2 Screw 4 1-23030-3

3 Moving Die 1 307810-1

4 Insert, Insulation 2 45873-4

5 Key Assembly, Adjustable 2 313291-5

6 Spring 2 1-22279-9

7 Stop Plate 1 307130-1

8 Spring 2 6-59683-8

9 Screw 2 2-21000-8

10 Sleeve 2 306363

11 asher 2 21055-6

12 asher 4 306098-2

1-23030-3

307810-2

45873-1

313291-4

1-22279-9

307130-1

6-59683-8

2-21000-8

306363

21055-6

306098-2

1-23030-3

307810-3

45873-2

313291-3

1-22279-9

307130-2

6-59683-8

2-21000-8

306363

21055-6

306098-2

1-23030-3

307810-4

45873-4

313291-3

1-22279-9

307130-3

6-59683-8

2-21000-8

306363

21055-6

306098-2

810

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