TE Connectivity 69069 Manual de usuario
Latch
Thumb Knob
Dust Cap
Hose Assembly
or Handle Control
Collar
Nest Wheel
Lock
©2012 Tyco Electronics Corporation, a TE Connectivity Ltd. company
All Rights Reserved
*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
i
!
!
!
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
i
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
i
NOTE
i
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
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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.
2
13
14
25
12 8
31
30
29
22
23
26
19
15
11 21
10
22
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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