Tyco Electronics PIDG STRATO-THERM 1-576778-0 Bedienungsanleitung

Instruction Sheet

PIDG* STRATO-THERM* Terminal

Crimping Heads Used with Heavy Head 408-10175

LOC B

of 7

2007 Tyco Electronics Corporation, Harrisburg, PA

All International Rights Reserved

TE logo and Tyco Electronics are trademarks.

*Trademark. Other products, logos, and company names used are the property 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

05 DEC 07 Rev B

Battery Powered Hand Tool Kits 1901235-[

Figure 1

Typical Crimping

Head (Ref)

Heavy Head Hand Tool (HHHT) Adapter

Trigger

Battery Cartridge

1725839-1

Battery Lock

Battery Powered

Crimp Tool

Release Switch

(1901235-1 and -2 Only)

uick-Release Pin 217873-4

(Recommended Spare)

uick-Release Pins 217873-1

(Recommended Spare)

Insulation Crimp Adjusting Pin

1. INTRODUCTION

Crimping Heads 1–576778–0, 1–576779–0,

1–576780–0, 1–576781–0, and 1–576782–0 are

designed to crimp PIDG STRATO–THERM Terminals

onto solid or stranded copper wire size 24–14 AWG.

Refer to Figure 2. The crimping heads are used with

Heavy Head Battery Powered Hand Tool Kits

1901235–[ ].

The crimping heads can a so be used with the

626 Heavy Head Pneumatic Too Adapter

525432-1.

This instruction sheet provides recommended

procedures for wire preparation, crimping head

installation, crimping, and maintenance and

inspection. For information concerning tool setup and

operation, refer to Customer Manual 409–10068

packaged with the battery tool kit.

Dimensions on this instruction sheet are in

mi imeters [with inches in brackets]. Figures and

i ustrations are for identification ony and are not

drawn to sca e.

Reasons for reissue are provided in Section 8,

REVISION SUMMARY.

2. DESCRIPTION

Each crimping head features a head containing two

stationary crimping dies (anvils) and two movable

crimping dies (indenters), a locator, an insulation

crimping adjustment pin, and a battery powered crimp

tool. See Figure 1.

When closed, the crimping dies form one crimping

chamber with two sections: an insulation barrel

section and a wire barrel section. The insulation barrel

section crimps the terminal onto the wire insulation

and, simultaneously, the wire barrel section crimps

the terminal wire barrel onto the stripped wire. The

locator positions the terminal in the crimping chamber.

The insulation crimping adjustment pin is used to

regulate the height of the insulation crimp.

Using Heavy Head Battery Powered Hand Tool Kits

1901235–3 or –4 will ensure full crimping of the

terminal. The rams on tools 1901235–1 and –2 can

be retracted before the terminal is fully crimped.

NOTE

408-10175

Heavy Head PIDG STRATO-THERM Crimping Heads

Rev

of 7 Tyco Electronics Corporation

3. INSTALLATION AND REMO AL OF CRIMPING

HEADS

Do not operate the tool ithout the HHHT

adapter installed. Damage to the ram or seals

can result.

Do not operate the tool ithout a hand tool crimp

head installed. Damage to the adapter can result.

Battery Powered Crimp Tool Kit 1901235–[ ] with

HHHT Adapter comes with the HHHT adapter already

installed on the battery powered hand tool. The only

installation required is the installation of the crimping

heads.

To avoid personal injury, be sure to exercise

extreme caution hen handling the crimp tool.

Remove the battery before installing or removing

the crimping heads.

3.1. Installation of Crimping Heads

As supplied, the adapter has three quick–release pins

installed (Figure 1). The two outer pins will be used to

secure the links of the crimp head (exposed portion of

the crimp head) to the adapter. The center pin will be

used to secure the movable die of the crimp head to

the ram of the adapter.

These pins must be removed prior to installing the

crimping head.

1. Remove the quick–release pins, described

above.

2. Insert the exposed portion of the crimp head

into the adapter cavity. See Figure 1.

3. Insert the two outer quick–release pins

through the holes in the adapter, and through

the holes in the links of the crimping head.

The quick-release pins ill snap" into position

hen they are properly inserted.

4. Insert the center quick–release pin into the

adapter and through the holes in the ram and

the moveable die of the crimp head.

The quick-release pin ill snap" into position

hen it is properly inserted.

3.2. Removal of Crimping Heads

To avoid personal injury, remove the battery

before removing the crimping heads.

To remove the crimping head, it will be necessary to

remove the quick–release pins and the crimp head

from the battery powered crimp tool.

HEAD WIRE

DOT

HANDLE COLOR

TERMINAL COLOR CODE STRIP LENGTH

PART

NUMBER SIZE

(AWG)

DOT

CODE

HANDLE COLOR

CODE HIGH

TEMP. LOW TEMP. Min. Max.

1-576778-0 24-22 2 Dots 1 Han le Black

1 Han le Brown Brown Black 5.56 [.219] 6.35 [.250]

1-576779-0 20 1 Dot 1 Han le Gray

1 Han le Purple Gray Purple

(With Black Stripe) 5.56 [.219] 6.35 [.250]

1-576780-0 18 2 Dots 1 Han le Orange

1 Han le Black Orange Orange

(With Black Stripe) 5.56 [.219] 6.35 [.250]

1-576781-0 16 1 Dot 2 Han les Orange Orange Orange

(With Black Stripe) 5.56 [.219] 6.35 [.250]

1-576782-0 14 2 Dots 1 Han le White

1 Han le Black White White

(With Black Stripe) 5.56 [.219] 6.35 [.250]

Figure 2

CAUTION

DANGER

NOTE

DANGER

408-10175

H avy H ad PIDG STRATO-THERM Crimping H ads

of 7Rev

Tyco Electronics Corporation

4. CRIMPING PROCEDURE

Refer to Section 5 for information on the

insulation crimp adjustment.

Refer to Figure 3 and the following steps for terminal

crimping procedures.

Figure 3

PIDG STRATO-THERM Terminals

Locator

Wire Barrel Butts

Against Locator

End of Conductor

Butts Against

Locator

Insulation Barrel Wire Barrel

1. Strip the wire to the dimension provided in

Figure 2, being careful to avoid nicking or

damaging the conductor(s).

Do NOT use wire with nicked or missing

conductors.

Make sure terminal insulation color code matches

tool handle color.

2. Depress the trigger to advance the moving ram.

This action closes the crimp jaws in order to hold

the terminal in place. DO NOT deform the wire

barrel.

3. Insert stripped wire into terminal until the end of

the conductor butts against the locator as shown in

Figure 3.

Do NOT allow wire insulation to enter the

terminal wire barrel.

4. Activate the tool to complete the crimp. The

crimp tool automatically returns to the first position

of the cycle when the crimp is complete.

5. Observe the dot code on the finished crimp to

ensure that the correct terminal and crimping head

combination was used. See Figure 2.

6. Refer to Section 4 and Figure 4 for terminal

crimp inspection procedure.

5. CRIMP INSPECTION

Inspect crimped terminals by checking the features

described in Figure 4. Terminals, not meeting the

described conditions should NOT Be used.

6. INSULATION CRIMP ADJUSTMENTS

The insulation crimping section of the crimping head

has three positions: 1 (tight), 2 (medium), and 3

(loose). To adjust the section:

1. Insert the insulation crimp adjustment pins into

the No. 3 position. Refer to Figure 1.

2. Place the terminal into the crimping jaws as

shown in Figure 3.

3. Insert the UNSTRIPPED wire into ONLY the

insulation barrel (refer to Figure 3) portion of the

terminal.

4. Close the tool to complete the crimp.

5. Removed the crimped terminal and check the

insulation crimp by bending the wire back and forth

once. The terminal should retain its grip on the wire

insulation. If the wire pulls out, set the insulation

crimp adjustment pins to the next higher position

(No. 2).

6. Perform another crimp and repeat the

adjustment as necessary until the correct insulation

grip is attained. Do not use a tighter setting than

required.

Make sure that both insulation crimp adjustment

pins are in the same position.

NOTE

CAUTION

NOTE

CAUTION

408-10175

Heavy Head PIDG STRATO-THERM Cr mp ng Heads

Rev

of 7 Tyco Electron cs Corporat on

Figure 4

1Insulat on barrel s n f rm contact w th w re nsulat on.

2Correct color code, dot code, and tool comb naton.

3W re s ze s w th n w re range stamped under term nal tongue.

4Cr mp centered on w re barrel.

5End of conductor s flush w th, or extends beyond end of

term nal w re barrel.

6W re nsulat on does not enter w re barrel.

7No n cked or m ss ng conductor strands.

1W re nsulat on extruded. (Insulat on cr mp too t ght on term nals.)

See Paragraph 5.1.

2Wrong dot code and color code comb nat on. See F gure 2.

3W re s ze s not w th n w re range stamped on term nal tongue.

4Cr mp not centered on w re barrel. (Term nal was not butted

aga nst locator.)

5End of conductor s not flush w th or extend ng beyond end of w re

barrel. (Check for correct str p length.)

6W re nsulat on entered w re barrel.

7N cked or m ss ng conductor strands.

W re Range

Stamped Here

W re Range

Stamped Here

124

6 7

1 2

6 7 5

ACCEPT REJECT

7. MAINTENANCE AND INSPECTION PROCEDURE

Tyco Electronics recommends that a maintenance

and inspection program be performed periodically to

ensure dependable and uniform terminations. Though

recommendations call for at least one inspection a

month, frequency of inspection depends on:

1. The care, amount of use, and handling of the

hand tool.

2. The presence of abnormal amounts of dust and

dirt.

3. The degree of operator skill.

4. Your own established standards.

The crimping head 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.

7.1. Da ly Ma ntenance

1. Crimping head should be immersed in a reliable

commercial degreasing compound to remove

accumulated dirt, grease, and foreign matter.

When degreasing compound is not available, head

may be wiped clean with a soft, lint–free cloth. Do

NOT use hard or abrasive objects that could

damage the crimping head.

2. Make certain that the retaining pins are in place

and that they are secured with retaining rings.

3. 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.

408-10175

He vy He d PIDG STRATO-THERM Crimping He ds

of 7Rev

Tyco E ectronics Corporation

7.2. Periodic Inspection

A. Lubric tion

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

area. Oil transferred from the crimping area onto

certain terminations may affect the electrical

characteristics of an application.

B. Visu l Inspection

Inspect head assembly for worn, cracked, or broken

jaws. If damage is evident, return the crimping head

to Tyco Electronics for evaluation and repair. See

Section 7, REPLACEMENT AND REPAIR.

C. Crimping Die Closure Inspections

Each crimping head is inspected for proper die

closure before shipment. However, inspection of die

closure for excessive wear is required periodically.

This inspection requires the use of plug gages

conforming to the dimension shown in Figure 5. Tyco

Electronics does not manufacture or market these

gages.

To gage die closure, refer to Figure 6 and proceed as

follows:

1. Remove traces of oil or dirt from the crimping

chamber and plug gage.

2. Close the tool until the wire barrel dies are

bottomed.

3. With wire barrel dies bottomed, inspect the wire

barrel crimp die closure using the proper plug

gage. Press the spring–loaded locator down and

hold gage in alignment with the die closure.

4. Align the GO element with the wire barrel

section of the crimping chamber. Push element

straight into the crimping chamber without using

force. The GO element must pass completely

through the crimping chamber. See Figure 6.

5. Align the NO–GO element and try to insert it

straight into the same section of the crimping

chamber. The NO–GO element may start entry,

but must not pass completely through the crimping

chamber. See Figure 6.

6. Insert tool insulation crimping adjustment pin

into Position 1.

7. With crimping dies bottomed, check the

insulation barrel section of the crimping chamber

as described in Steps 4 and 5.

If the crimping chamber conforms to the gage

inspection, the crimping head is considered

dimensionally correct, and should be lubricated with a

THIN coat of any good SAE 20 motor oil. If not, the

crimping head must be returned to Tyco Electronics

for further evaluation and repair. Refer to Section 7,

REPLACEMENT AND REPAIR.

For additional information regarding the use of plug

gages, refer to Instruction Sheet 408–7424.

Suggested Plug Gage Design for

Wire Barrel Section of Crimping Chamber

Die Closure

Configuration

GO Dim. NO-GO Dim.

50.8 [2]

Min Typ

GO NO

6.35 [.250]

Min Typ

Die Closure

Configuration

GO Dim. NO-GO Dim.

W"

Suggested Plug Gage Design for

Insulation Barrel Section of Crimping Chamber

W"

HEAD PART WIRE BARREL CRIMP CHAMBER INSULATION BARREL CRIMP CHAMBER

NUMBER GO NO-GO GO NO-GO WIDTH (W)

1-576778-0 2.591-2.598 [.1020-.1023] 2.690-2.692 [.1059-.1060] 0.813-0.820 [.0320-.0323] 1.217-1.219 [.0479-.0480] 4.06 [.160]

1-576779-0 2.591-2.598 [.1020-.1023] 2.690-2.692 [.1059-.1060] 1.067-1.074 [.0420-.0423] 1.471-1.473 [.0579-.0580] 4.39 [.173]

1-576780-0 3.048-3.056 [.1200-.1203] 3.147-3.150 [.1239-.1240] 0.940-0.947 [.0370-.0373] 1.344-1.346 [.0529-.0530] 5.89 [.232]

1-576781-0 3.124-3.132 [.1230-.1233] 3.223-3.226 [.1269-.1270] 0.940-0.947 [.0370-.0373] 1.344-1.346 [.0529-.0530] 5.89 [.232]

1-576782-0 3.327-3.335 [.1310-.1313] 3.426-3.429 [.1349-.1350] 1.067-1.074 [.0420-.0423] 1.471-1.473 [.0579-.0580] 6.63 [.261]

Figure 5

408-10175

Heavy Hea PIDG STRATO-THERM Crimping Hea s

Rev

of 7 Ty o Ele troni s Corporation

Figure 6

(Detail A) Inspection of Wire Barrel Crimping Dies (Detail B) Inspection of Insulation Crimping Dies

GO gage must pass ompletely

through the die losure.

NO-GO gage may enter partially,

but must not pass ompletely

through the die losure.

Wire Barrel Dies

Bottomed But Not

Under Pressure

Gage

Insert 0.025 mm

[.001 In.] Shim Here

When Che king

CERTI-CRIMP Feature

Gage

Adjustment Pin

in No. 1

Position Wire Barrel Dies

Bottomed But

Not Under Pressure

8. REPLACEMENT AND REPAIR

Replaceable parts are listed in Figure 7. Parts other

than those listed in Figure 7 should 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

1–717–986–7605, or write to:

CUSTOMER SERVICE (38–35)

TYCO ELECTRONICS CORPORATION

P.O. BOX 3608

HARRISBURG, PA 17105–3608

For tool repair service, please contact an Tyco

Electronics Representative at 1–800–526–5136.

9. REVISION SUMMARY

Updated document to corporate requirements

Deleted text and changed wire size from 24–10

to 24–14 in Section 1, INTRODUCTION

Deleted 12–10 wire information in tables in

Figures 2, 5, and 7

Changed part numbers in table in Figure 7

408-10175

Heavy Hea PIDG STRATO-THERM Crimping Hea s

of 7Rev

Tyco Electron cs Corporat on

ITEM

DESCRIPTION

QTY PER PIDG STRATO-THERM TERMINAL CRIMPING HEAD REPLACEMENT PARTS

NO.

DESCRIPTION

HEAD 1-576778-0 1-576779-0 1-576780-0 1-576781-0 1-576782-0

1 PIN, Adjustment 1 1752891-1 1752891-1 1752891-1 1752891-1 1752891-1

2 LOCATOR, Stop 1 59580-6

1901238-1 59580-6

1901238-2 59580-6

1901238-2

3 PIN 1 5-21028-7 5-21028-7 5-21028-7 5-21028-7 5-21028-7

4 SPRING 1 7-59683-6 7-59683-6 7-59683-6 7-59683-6 7-59683-6

5 SCREW 2 6-306131-4 6-306131-4 6-306131-4 6-306131-4 6-306131-4

6 PIN 1 21028-4 21028-4 21028-4 21028-4 21028-4

Figure 7

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