Tyco Electronics PIDG STRATO-THERM Bedienungsanleitung
Instruction heet
PIDG* STRATO-THERM* 408-10039
LOC B
1
of 6
E
2009 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 A I TANCE CENTER 1-800-722-1111
PRODUCT INFORMATION 1-800-522-6752 This controlled document is subject to change.
For latest revision and Regional Customer ervice,
visit our website at
www.tycoelectronics.com
22 JAN 09 Rev B
Termin l Crimping Dies
PROPER USE GUIDELINES
CumulativeTraumaDisorderscanresultfromthe prolongeduseofmanually poweredhandtools.Hand toolsareintendedfor occasionaluseandlowvolume
applications. A wide selection of powered application equipment for extended-use, production operations is available.
tationary Die
Die Holding crew
Locator
Moving Die
Color Code
Insulation Adjustment
pacers in No. 3 Position
PIDG STRATO-THERM TERMINAL CRIMPING DIES
576711, 576714, 576715, 576716, 576720, 576723, 576742
Figure 1
1. INTRODUCTION
This instruction sheet provides application
instructions, maintenance, and inspection procedures
for the dies listed in Figure 1. These dies will crimp
PIDG STRATO–THERM Terminals with a wire size
range of 24 thru 10.
Basic instructions on the use of these dies, die
adjustments, wire preparation, etc.; are provided in
Section 2, INSTRUCTIONS.
Section 3, MAINTENANCE and INSPECTION
PROCEDURES, enables you to establish and
maintain a die certification program.
Dies are coated with oil to prevent rust and corrosion.
Wipe this oil from the dies, particularly from the
crimping area. Instructions for Hand Tool 69710–1,
refer to Instruction Sheet 408–2095. For
recommended tooling used with these dies other than
Hand Tool 69710–1, contact Tyco Electronics Tooling
Assistance Center at the number listed at the bottom
of this page.
All dime sio s o this docume t are i metric
u its [with U. S. customary u its i brackets].
Figures a d illustratio s are for refere ce o ly,
a d are ot draw to scale.
2. INSTRUCTIONS
2.1. Die Insertion
Each set of dies consist of a moving die and a
stationary die. See Figure 1.
1. Position the stationary die in the stationary die
holder. Tighten the die holding screw just enough
to hold the die in place. Do not tighten the screw.
2. Position the moving die in the moving die holder.
Tighten the die holding screw just enough to hold
the die in place. Do not tighten the screw.
3. With a terminal in position, insert the wire, then
squeeze the handles until the dies bottom.
Refer to Figure 2 for wire strip le gth.
4. Tighten both the die holding screws while dies
are bottomed. Tool is now ready for operation.
Check the die alig me t a d tighte the die
holdi g screws at least twice daily.
2.2. Die Remov l
Loosen the die holding screws, and remove the dies.
2.3. Wire Stripping nd Crimping Procedures
A. Wire Stripping
Strip the wires to the dimensions provided in Figure 2.
Refer to Paragraph 2.4 for die i sulatio crimp
adjustme t.
B. Crimping with H nd Tool 69710-1
1. Place the terminal in the stationary die as shown
in Figure 3.
Dies will ot accommodate termi als with to gue
width exceedi g 11.91 mm [.469 i .].
NOTE
i
NOTE
i
NOTE
i
NOTE
i
NOTE
i
408-10039
PIDG STRATO-THERM Terminal Crimping Dies
Rev
B2
of 6 Tyco Electronics Corporation
ire Strip
Length
Finished Crimp
Crimp Dot Code
Insulation Barrel ire Barrel
DIE PART WIRE
SI E
COLOR
AND DOT
WIRE STRIP LENGTH
NUMBER
SI E
(AWG)
AND DOT
CODE Min. Max.
576711 24-22 2 Dots
BRO N 5.56 [.219] 6.35 [.250]
576720 20 1 Dot
GRAY 5.56 [.219] 6.35 [.250]
576715 18 2 Dots
ORANGE 5.56 [.219] 6.35 [.250]
576714 16 1 Dot
ORANGE 5.56 [.219] 6.35 [.250]
576716 14 2 Dots
HITE 5.56 [.219] 6.35 [.250]
576742 12 1 Dot
HITE 5.56 [.219] 6.35 [.250]
576723 10 1 Dot
BLACK 7.62 [.300] 8.38 [.330]
Figure 2
2. Close the tool handles until the terminal is held
firmly in place.
3. Insert a stripped wire into the terminal until the
wire butts against the locator.
4. Complete the crimp by closing the handles until
the CERTI–CRIMP* hand crimping tool ratchet
control releases.
5. The handles can now be opened and the
crimped item may be removed.
2.4. Insulation Crimp Adjustment
1. The insulation crimping section of the moving
die has three crimp positions: 1–Tight, 2–Medium,
3–Loose.
2. Turn both insulation crimp adjustment spacers
so that they fit into the notch in the side of the die.
See Figure 1. This is the No. 3 or loose position.
(The moving die must be removed from the die
holder to make this adjustment if the die has
already been installed).
Figure 3
NOTE:
To locate
PIDG STRATO-THERM
Terminals, pull locator
down slightly.
Locator
ire Barrel
Crimping
Section of Die
Terminal Barrel
Rests Against
Locator
Insulation
Crimping
Section
of Die
3. Insert the die into the die holder.
4. Turn the die holding screw enough to hold the
die firmly in place. The die holding screw will be
tightened after completing steps 5 and 6.
5. Insert the UNSTRIPPED wire into ONLY the
insulation barrel position of the terminal.
6. Make a test crimp
(refer to Paragraph 2.3 for
crimping procedure).
Close the die on the terminal
and hold the die in the bottomed position. Tighten
the die holding screw while the dies are bottomed,
then complete the crimping cycle.
7. Remove the terminal from the dies, and check
the insulation grip as follows: Bend the wire back
and forth ONCE. The terminal sleeve should retain
the grip on the wire insulation.
8. If the wire pulls out, use the following procedure
to set the insulation crimp adjustment to the next
tighter position: First, remove the die from the die
holder. Then, turn the lower insulation adjustment
spacer 90°so that it fits between the die and the
die holder. The No. 2 will appear on the corner of
the spacer. Repeat the test crimp, and adjust the
die as necessary until the desired insulation grip is
obtained.
9. With both adjustment spacers placed between
the die and the die holder, the die is set in its
tightest insulation crimping position. The No. 1 will
appear on the corner of the top spacer.
2.5. Color and Dot Code
Note that the dies and terminals are color–coded
according to wire size for easy identification. See
Figure 2. When the terminals are properly crimped in
the correct dies, 1 dot or 2 dots (depending on wire
size), will appear embossed on the top and bottom of
the terminal. See Figure 2.
408-10039
PIDG STRATO-THERM Terminal Crimpin Dies
3
of 6Rev
B
Tyco Electronics Corporation
Damaged product should not be used. If a
damaged product is evident, it should be cut from
the wire and replaced with a new one. Do not
reterminate terminals.
3. MAINTENANCE and INSPECTION PROCEDURE
Tyco Electronics recommends that a
maintenance/inspection program be performed
periodically. This is necessary to ensure that
continued use of the dies will result in the same
dependable and uniform terminations for which the
dies were designed.
We recommend an initial frequency of inspection of
once a month. This frequency may be adjusted to suit
your requirements through experience. The frequency
of an inspection is dependent upon:
S
The care, amount of use, and handling of the
dies.
S
The type and size of the products applied.
S
The degree of operator skill.
S
The presence of abnormal amounts of dust and
dirt.
S
Your own established standards.
With proper maintenance and inspection, these dies
will give years of satisfactory service.
All Tyco Electronics dies are thoroughly inspected
before being shipped from the factory, however, since
there is a possibility of die damage during shipment,
Tyco Electronics recommends that new dies be
inspected in accordance with Section 3 when
received in your plant.
3.1. Cleanin
Do not allow deposits of dirt, grease, and foreign
matter to accumulate in the die closure area and 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, soft cloth.
3.2. Visual Inspection
Visually inspect the die closure surfaces for broken,
chipped, or pitted conditions. Although dies may gage
within permissible limits, worn or damaged die closure
surfaces are objectionable and can affect the quality
of the crimp. Examples of possible damaged die
surfaces are shown in Figure 4.
Figure 4
Pitted
Chipped
Edge
Broken
Corner
3.3. Die Closure Inspection
Every Tyco Electronics die set is inspected and tested
for proper die closure before being shipped from the
factory. An inspection should, however, be performed
periodically to measure the die closure.
The die closure inspection is accomplished using the
GO NO–GO plug gages. A suggested plug gage
design and the GO NO–GO dimensions of the plug
gage members are provided in Figure 5.
The following procedure is recommended for
measuring the die closures:
1. Remove traces of oil or dirt from the die
crimping areas, and plug gage members.
2. Turn both insulation adjustment spacers of the
moving die so that they fit into the notch in the side
of the die. See Figure 1. The die is now set in the
No. 3 or loose position. This will provide access to
the wire barrel dies for plug gaging.
3. Insert both dies in the tool die holders.
4. When using pneumatic tools, reduce air supply
pressure to a range between 103–138 kPa
[15–20 psi]. Actuate the tool to bottom the wire
barrel dies. When using the hand tool, close the
handles of the tool until the wire barrel dies bottom.
Do not apply additional pressure to the tool
handles.
5. Some dies need to be removed from the hand
tool to gage the wire barrel dies. The position of
the locator and the insulation die prevent gaging
the wire barrel die in the tool. Remove the
complete die assembly and rotate the locator 180°.
This will allow access to the wire barrel die. The
complete die can then be placed in a vise with light
pressure for gaging.
CAUTION
!
408-10039
PIDG STRATO-THERM Terminal Crimpin Dies
Rev
B4
of 6 Tyco E ectronics Corporation
Wire Barrel Die
Closure Configurations
Insulation Barrel Die
Closure Configurations
GO Dimension NO-GO Dimension
50.8 [2.000] Min. Typ
GO Dimension NO-GO Dimension
6.35 [.250] Typ
W"
DIE WIRE BARREL CRIMP CHAMBER INSULATION BARREL CRIMP CHAMBER
SET GO NO-GO GO NO-GO WIDTH (W)
576711 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]
576720 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]
576715 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]
576714 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]
576716 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]
576742 3.683-3.691 [.1450-.1453] 3.782-3.785 [.1489-.1490] 1.067-1.074 [.0420-.0423] 1.471-1.473 [.0579-.0580] 6.63 [.261]
576723 4.775-4.783 [.1880-.1883] 4.874-4.877 [.1919-.1920] 1.676-1.684 [.0660-.0663] 2.080-2.083 [.0819-.0820] 8.43 [.332]
Figure 5
6. With the wire barrel dies bottomed, check the
wire barrel crimp die closure using the proper plug
gage. Hold the gage in a straight alignment with
the die closure and carefully try to insert, without
forcing the GO member, and then the NO–GO
member. See Figure 6, Detail A. The GO member
must pass completely through the insulation and
wire barrel crimp die closures.
7. The NO–GO member may enter partially, but
must not pass completely through the wire barrel
crimp die closure. See Figure 6, Detail A.
8. Remove the moving die from the tool die holder.
9. Reposition the insulation adjustment spacers in
the No. 1 position. Refer to Paragraph 2.4 for
insulation crimp position adjustment procedures.
10. Insert the moving die into the tool die holder.
11. With the wire barrel dies bottomed, check the
insulation crimp die closure using the proper plug
gage in the same manner as steps 6 and 7. See
Figure 6, Detail B.
12. If both the wire barrel and insulation die
closures meet the GO NO–GO gage conditions,
the dies may be considered dimensionally correct.
13. If you find that the crimp die closures do not
conform with the GO NO–GO gage conditions,
contact your local Tyco Electronics Representative.
4. REPLACEMENT PARTS
A complete inventory of customer–replaceable parts
for each die set assembly should be stocked and
controlled to prevent lost time when replacement of
parts is necessary. See Figure 7. 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:
408-10039
PIDG STRATO-THERM Term nal Cr mp ng D es
5
of 6Rev
B
Tyco Electronics Corporation
CUSTOMER SERVICE (038–035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105–3608
Tools and dies may also be returned for evaluation
and repair. For repair service, contact a Tyco
Electronics Representative at 1–800–526–5136.
5. REVISION SUMMARY
S
Updated document to corporate requirements
S
Changed wire strip length for wire size 10 in
table in Figure 2
Figure 6
Inspection of Wire Barrel Crimping Dies (Detail A) Inspection of Insulation Crimping Dies (Detail B)
Wire Barrel Dies
Bottomed, but Not
Under Pressure
Adjustment Spacers
in No. 1 Position
Insulation
Dies Wire Barrel Gage Must Pass
T roug t e Insulation Crimp
Die Closure to Enter Wire
Barrel Crimp Die Closure
Wire Barrel Dies
Bottomed, but Not
Under Pressure
Adjustment Spacers
in No. 3 Position
GO" Gage Must Pass Completely T roug Die Closure GO" Gage Must Pass Completely T roug Die Closure
NO-GO" Gage May Enter Partially, but Must
Not Pass Completely T roug t e Die Closure NO-GO" Gage May Enter Partially, but Must
Not Pass Completely T roug t e Die Closure
408-10039
PIDG STRATO-THERM Termin l Crimping Dies
Rev
B6
of 6 Tyco Electronics Corporation
1
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3
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9
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14
ITEM
DESCRIPTION
QTY
PER DIE SET NUMBERS
NO.
DESCRIPTION
DIE
SET 576711 576714 576715 576716 576720 576723 576742
1 RING, Retaining 2 1-21046-3 1-21046-3 1-21046-3 1-21046-3 1-21046-3 1-21046-3 1-21046-3
2 SPACER 1 1-306027-5 306027-6 306027-6 306027-6 1-306027-5 306027-9 306027-6
3 SPACER 1 1-306027-6 306027-7 306027-7 306027-7 1-306027-6 1-306027-0 306027-7
4 SCREW, Special 1 1-306131-6 1-306105-1 1-306105-1 1-306105-1 1-306131-6 2-306131-3 1-306105-1
5 SPACER 1 2-305832-8 2-305832-8 2-305832-8 2-305832-8 2-305832-8 2-305832-8 2-305832-8
6 SPACER, Locator 1 2-305832-9 2-305832-9 2-305832-9 2-305832-9 2-305832-9 2-305832-9 2-305832-9
7 SCREW, Special 1 2-306131-1 1-306131-6 1-306131-6 1-306131-6 2-306131-1 3-306131-4 1-306131-6
8 PIN, Coile 2 21949-1 21949-1 21949-1 21949-1 21949-1 21949-1 21949-1
9 INDENTER, Insulation 1 576712-1 576712-2 2-45931-2 2-45931-3 576712-3 2-45931-4 2-45931-3
10 ANVIL, Insulation 1 576713-1 576713-2 576713-4 1-45932-8 576713-3 1-45932-9 1-45932-8
11 ANVIL 1 576718-7 576718-8 576718-1 576718-2 576718-5 576718-4 576718-6
12 INDENTER, Barrel 1 576719-8 576719-7 576719-1 576719-2 576719-5 576719-4 576719-6
13 LOCATOR 1 576771-1 576771-1 576771-1 576771-1 576771-1 576771-5 576771-1
14 SPRING, Compression 2 7-59683-4 7-59683-4 7-59683-4 7-59683-4 7-59683-4 7-59683-4 7-59683-4
Figure 7
Dieses Handbuch passt für folgende Modelle
7
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