TE Connectivity 69069 Manual de usuario

Latch

Thumb Knob

Dust Cap

Hose Assembly

or Handle Control

Collar

Nest Wheel

Lock

*Trademark

TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or company names may be trademarks of their respective owners.

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Instruction Sheet

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.te.com

408-1745

Hydraulic Crimping Head 69069 19 DEC 12 Rev D

Figure 1

1. INTRODUCTION

This instruction sheet provides application,

maintenance, and inspection procedures for DYNA-

CRIMP* Crimping Head 69069 (see Figure 1). The

tool is used to crimp SOLISTRAND* Terminals and

splices onto solid or stranded copper wire sizes 8

AWG through 4/0 AWG. See Instruction Sheet

408-9786.

The crimping head is designed for use with Hydraulic

Power Unit 69120-[ ] described in Customer Manual

409-1950. Read these instructions, and all applicable

references, before inserting the nest or indenter and

crimping any terminals or splices.

NOTE

Dimensions on this sheet are in millimeters [with inches

in brackets]. Figures and illustrations are for reference

only and are not drawn to scale.

Reasons for reissue are provided in Section 9,

REVISION SUMMARY.

2. DESCRIPTION

Main components of the crimping head are: a yoke

which houses the indenter and retains the terminal

assembly for crimping, a latch which allows pivoting of

the yoke on the pivot pin (typically required for splice

terminations), a cylinder which contains the head's

hydraulic chamber, a piston (ram) which holds and

controls the indenter, and a quick connect/disconnect

coupler (cylinder half) which mates with the coupler on

hose or handle control to release or supply pressure.

DANGER

To avoid personal injury when using DYNA-CRIMP

equipment:

- Do NOT modify the crimping equipment in any

way.

- Use only the nest and indenter, terminals, and

wire specified for the head.

- Do NOT perform repairs other than those

specified in the instructional material supplied with

the equipment.

3. CRIMPING HEAD INSTALLATION

Each crimping head is shipped with a coating of

lubricating oil to prevent rust and corrosion. Wipe the

oil off before installing the crimping head on the power

unit. Note that the crimping head is shipped without oil

inside the cylinder. To install crimping head, proceed

as follows.

DANGER

Make sure that hydraulic pressure to hose or handle

control is released and that power supply is

disconnected to electric power unit, if applicable.

1. Thoroughly clean the coupling area of the handle

control or hose assembly and crimping head.

2. Remove protective dust caps from both quick

connect/disconnect couplers.

3. Hold hose or handle control vertically to prevent

oil spillage. Attach hose or handle control to

coupling section on head. Thread properly and

tighten the collar.

CAUTION

Oil flow must be unobstructed between power unit and

crimping head. Make sure that all couplers are fully

mated and tightened.

NOTE

408-1745

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Rev D

DANGER

If crimping head must be removed after being in

production, pressure must be released in the hydraulic

system before head is removed.

- If using Hydraulic Power Unit 69120-[ ],

DISCONNECT POWER UNIT FROM POWER

SUPPLY.

4. NEST SELECTION

Nest

Indenterr

Thumb

Knob

Nest Wheel

Lock

To Open Head,

Depress Latch

Pull Back Nest Wheel Lock, Then Turn Thumb

Knob to select Desired Nest.

DANGER

To avoid personal injury, release the hydraulic pressure

to the hose or handle control. Disconnect electric power

unit from power supply.

Figure 2

1. Depress the latch and open the crimping head as

shown in Figure 2.

2. While the head is open, pull back the nest wheel

lock and turn the thumb knob until the desired nest

appears. Wire size numbers appear at each nest.

3. Rotate the thumb knob left or right until the nest

wheel locks into place. If thee nest wheel is not

properly locked, the head cannot be closed.

5. WIRE STRIPPING

Strip wires to the dimensions listed in Figure 3.

CAUTION

Do not use wires with nicked or missing conductor

strands.

6. CRIMPING PROCEDURE

WIRE

SIZE

WIRE STRIP LENGTH

Terminals Butt and Parallel Splices

Min. Max. Min. Max.

88.38

[.33] 9.14

[.36] 10.41

[.41] 11.18

[.44]

69.91

[.39]10.67

[.42} 11.94

[.47] 12.70

[.50]

411.43

[.45]12.19

[.48] 13.46

[.53] 14.22

[.56]

213.21

[.52]14.0

[.55] 14.99

[.59] 15.75

[.62]

DANGER

To avoid personal injury, release the hydraulic pressure

to the hose or handle control. Disconnect electric power

unit from power supply.

Figure 3

1. Center the terminal or splice wire barrel in the

nest as shown in Figure 4. For best results, position

the brazed seam on the terminal or splice toward

the indenter.

NOTE

Wire size stamped on the terminal or splice must

correspond to the wire size stamped in the nest.

2. Activate the power unit to advance the indenter

and hold the terminal or splice in place. Do not

deform the wire barrel of the terminal or splice.

Figure 4

NOTE

Terminal

Parallel

Splice

Butt

Splice

Center Terminal or

Splice Wire Barrel

in Nest

When Brazed Seam on Terminal

orSplice isVisible, PositionSeam

Toward Indenter

“B” Equals Wire Barrel

408-1745

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Rev D

3. Insert the stripped wire into the wire barrel of

terminal or splice. When crimping terminals and

parallel splices, the end of the wire must be flush

with or extend slightly beyond the end of the wire

barrel. When crimping butt splices, wire must be

visible through the inspection hole.Activate the

power unit to complete the crimp.

Figure 5

408-1745

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Rev D

4. Activate the power unit to complete the crimp.

5. To complete the other half of the butt splice,

remove and reposition the uncrimped half of the

splice in the nest. Insert the wire and then activate

the power unit to crimp the splice. The completed

terminal or splice should be as shown in Figure 5.

7. INSPECTION/MAINTENANCE

DANGER

Make sure hydraulic pressure is released and power

supply is disconnected before following inspection and

maintenance procedures, unless otherwise specified in

the procedure.

Each crimping head is assembled and inspected

before shipment. It is recommended that the crimping

head be inspected immediately upon its arrival at your

facility, and at regularly scheduled intervals, to ensure

that the crimping head has not been damaged during

handling. Frequency of inspection depends upon the

following: care, amount of use, and handling of the

head; type and size of products crimped; degree of

operator skill; and environmental conditions.

7.1. Cleaning

Remove accumulations of dirt and grease on the

crimping head, especially in areas where dies are

installed and terminals are crimped. Clean the entire

head frequently with a clean, lint-free cloth.

7.2. Visual Inspection

Refer to Figure 6 and proceed as follows:

Chipped

Area Flattened

Area

Pitted

Area

Check for

Excessive Wear

at all Pivot Points Check These

Areas for Cracks

Check These

Areas for Cracks

1. Visually inspect die closure surfaces for chipped,

pitted, or flattened areas.

2. With hydraulic pressure released, inspect the

assembled head for nicks, scratches, and cracks.

Inspect for cracks especially at the corners of the

yoke and around the top of the cylinder.

3. Inspect pivot pin holes and latch pin holes for

wear. Replace parts, as needed.

4. Activate power unit. Raise ram to UP position.

Inspect flat and round surfaces of ram for galling

(fretting or wear by friction), cracks, or oil leakage.

Release pressure and make sure that ram retracts

smoothly.

5. If head shows evidence of galling, cracks, oil

leakage, or rough cycling, return the crimping head

to for repairs. (Refer to Section 8, REPLACEMENT

AND REPAIR).

NOTEI

t is recommended that the head be returned to TE after

every two years (or every 50,000 cycles) for magnetic

particle inspection. Refer to Instruction Sheet 408-9684.

Figure 6

7.3. Die Closure Inspection

Every crimping head die set is inspected for proper die

closure before shipment. However, the dies should be

inspected for excessive wear periodically. Die closure

is accomplished using GO/NO-GO plug gages.

Suggested plug gage design and GO/NO-GO

dimensions are shown in Figure 7.

NOTE

TE neither manufactures nor sells plug gages. Refer to

408-7424 for gaging information.

1. Clean the oil and dirt from the closure surfaces,

and plug gage members.

2. Lock the desired nest in the crimp position and

raise the indenter to the full UP position, as shown

in Figure 8, Detail A.

3. With the indenter positioned at the full UP

position, inspect the die closure using the

appropriate plug gage. Hold the gage in alignment

with die closure and carefully insert, without forcing,

the GO member. See Figure 8. The GO member

must pass completely through the die closure as

shown in Figure 8, Detail B.

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

member may enter partially, but must NOT pass

completely through the die closure. See Figure 8,

Detail B.

NOTE

Die Closure

Configuration

GO Dimension

Suggested Plug Gage Design NO-GO Dimension

DIE

SIZE

BARREL CRIMP

DIMINSIONS “A” GAGE MEMBER DIMENSIONS “B” RADIUS “R”

GO NO-GO GO NO-GO

82.11[.083] 2.54 [.100] 2.184 - 2.192 [.0860 - .0863] 2.537 - 2.540 [.0999 - .1000] 3.58 [.141]

63.12 [.123] 3.48 [.137] 3.124 - 3.132 [.1230 - .1233] 3.477 - 3.479 [.1369 -.1370] 3.96 [.156]

44.04 [.159] 4.39 [.173] 4.039 - 4.046 [.1590 - 1593] 4.391 -4.394 [.1729 - .1730] 5.56 [.219]

24.83 [.190] 5.18 [.204] 4.826 -4.834 [.1900 - .1903] 5.179 - 5.182 [.2039 - .2040] 6.35 [.250]

408-1745

5of 7

Rev D

Figure 7

Indenter in Full

“Up” Position

Plug Gage

Detail “A” Detail “B”

“GO” Gage Must Pass Completely

Through the Die Closure

“NO-GO”GageMay PartiallyEnter,ButMustNot

Pass Completely Through the Die Closure

5. If the die closure meets the GO/NO-GO gage

conditions, the die closure is considered

dimensionally correct. If the die closure does not

conform with the GO/NO-GO gage conditions,

contact your local TE Representative.

Figure 8

408-1745

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Rev D

7.4. Crimping Head Check-Out Procedure

If the ram fails to return to the DOWN position after

completion of a crimping cycle, the cause may be in

the crimping head. To determine whether or not the

trouble is in the crimping head, release pressure in the

power unit. If the ram retracts, the trouble is not in the

crimping head. If ram does NOT retract, return the

crimping head to Tyco Electronics for repair. See

Section 8, REPLACEMENT AND REPAIR.

8. REPLACEMENT AND REPAIR

Customer-replaceable parts are listed in Figure 9. A

complete inventory can be stocked and controlled to

prevent lost time when replacement of parts is

necessary. Order replacement parts through your TE

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)

TYCO ELECTRONICS CORPORATION

PO BOX 3608

HARRISBURG PA 17105-3608

Tools may also be returned for evaluation and repair.

For tool repair service, contact a TE Representative at

1-800-526-5136.

9. REVISION SUMMARY

Since the previous release of this document, the gage

member dimensions (“B”) were revised.

12 8

11 21

Figure 9 (Cont’d)

ITEM

NUMBER PART NUMBER DESCRIPTION QTY PER

CRIMPING

HEAD

2311471-1 QUICK-COUPLER, Cylinder Half 1

847322 INDENTER 1

10 301707 PIN, Retaining 1

11 301712 SPRING 1

12 304028 STOP, Spring 1

13 2-305927-5 SCREW, Button Head, 10-32 UNF X .31 Inches Long 1

14 304029 SPRING 1

15 3-21028-5 PIN, Roll, .094 Inches, Dia X .438 Inches Long 1

19 1-21045-3 RING, Retaining 2

21 2-21028-4 PIN, Roll, .078 Inches Dia X .812 Inches Long 1

22 21045-8 RING, Retaining 4

23 301710 PIN, Retaining 1

25 21025-4 WASHER, Lock, Internal Tooth No. 8 1

26 4-305927-0 SCREW, Guide Set 8-32 UNC X .350 Inches Long 1

29 7-306105-5 SCREW, Socket Set, 8-32 UNC X .900 Inches Long 1

30 3-23147-2 SPRING 1

31 23241-1 BALL 1

408-1745

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Rev D

Figure 9 (End)

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