Tyco Electronics PIDG STRATO-THERM Manual de usuario

Instruction heet

PIDG* STRATO-THERM* 408-10039

LOC B

of 6

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

408-10039

PIDG STRATO-THERM Terminal Crimping Dies

Rev

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

of 6Rev

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:

The care, amount of use, and handling of the

dies.

The type and size of the products applied.

The degree of operator skill.

The presence of abnormal amounts of dust and

dirt.

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

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

of 6Rev

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

Updated document to corporate requirements

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

of 6 Tyco Electronics Corporation

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

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