Tyco Electronics 1752787-1 User manual

Instruction Sheet
Hydraulic Crimping 408--8914
LOC B
1of 4
E2010 Tyco Electronics Corporation, Berwyn, PA
All Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other product names, logos, or company names might be trademarks 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
18 MAR 10 Rev BHead 1752787- 1
Male
Quick--Disconnect
Coupler
Figure 1
Latch Pin
Dust Cap
Yoke
Pivot
Pin
Cylinder
Piston
(Ram)
This tool is used to crimp: AMPLI--BOND* Terminals,
PLASTI--GRIP* Terminals, TERMINYL* Terminals and Splices,
Pre--Insulated nylon Heavy Duty Terminals, Pre--Insulated
AMPOWER* Terminals, and Sealed COPALUM* Terminals and
Splices.
1. INTRODUCTION
This instruction sheet provides application,
maintenance, and inspection procedures for Crimping
Head 1752787--1 shown in Figure 1. The crimping
head accepts interchangeable die sets for a variety of
heavy--duty terminals and splices for large wire sizes
-- within Size 8 through 4/0 AWG range. Refer to
instructions packaged with specific die sets for
compatible products, wire ranges, strip dimensions,
and application procedures.
The crimping head is designed and recommended
only for use with Foot Hydraulic Pump 1583659--1;
Hand Hydraulic Pump 1583661--1, or Electric
Hydraulic Pump 1583660--1 (115 Vac), or 1583660--2
(230 Vac).
Read these instructions, and all applicable
references, before inserting any die assemblies and
crimping any terminals or splices.
Dimensions on this sheet are in millimeters [with
inches in brackets]. Figures are for reference only
and are not drawn to scale.
2. DESCRIPTION
Main components of the crimping head are: a yoke
which houses the stationary die and retains the
terminal assembly for crimping, a removable latch pin
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 moving die, and a
quick connect/disconnect coupler which mates with
the coupler on the hose to release or supply pressure.
To avoid injury when using hydraulic crimping
equipment, observe the following precautions:
-- Do NOT modify the crimping equipment in any
way.
-- Use only dies, 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.
Make sure that hydraulic pressure to the hose is
released and that power supply is disconnected
to electric power unit, if applicable.
1. Remove protective dust caps from both quick
connect/disconnect couplers.
2. Hold hose vertically to prevent oil spillage.
Attach hose to coupling section on head. Thread
properly and tighten securely.
ORIGINAL INSTRUCTIONS
NOTE
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408- 8914
Hydraulic Crimping Head 1752787- 1
Rev B2 of 4 Tyco Electronics Corporation
Oil flow must be unobstructed between power
unit and crimping head. Make sure that all
couplers are fully mated and tightened.
If crimping head must be removed after being in
production, pressure must be released in the
hydraulic system before head is removed.
-- If using Electric Hydraulic Pump 1583660--[ ],
DISCONNECT POWER UNIT FROM POWER
SUPPLY.
-- If using Foot Hydraulic Pump 1583659--1,
depress pressure release pedal, or if using Hand
Hydraulic Pump 1583661--1, activate the
pressure release knob.
Figure 2
Stationary/Upper Die
Moving/Lower Die
Latch Pin
Removed
Ram
Advanced
Ram
Setscrew
Yoke
Setscrew
4. DIE INSERTION AND REMOVAL (Figure 2)
Avoid personal injury. When using power unit,
exercise caution to avoid accidently depressing
foot pedal or hand control when installing or
changing dies.
Make sure that matched die set, terminal, and wire
size are compatible. With crimping head properly
installed, refer to die set instructions, and
insert/change die set as follows:
1. Remove latch pin and open yoke on crimping
head.
2. Loosen setscrew in yoke. Refer to die set
instructions and insert stationary (upper) die which
includes the nest area into well of yoke. Tighten
setscrew.
3. Activate power unit to advance ram until
setscrew is visible (about 12.7 mm [.50 in.]).
Loosen setscrew.
4. Insert moving (lower) die, which serves as the
indenter, into ram well, making sure that moving
die is properly oriented to mate with stationary die.
Tighten setscrew.
5. Close yoke and secure with latch pin.
6. Slowly close dies to ensure proper alignment.
7. Complete the cycle and return the ram to the
DOWN position.
Always ensure that latch pin is fully inserted or
damage may occur to yoke, dies, or latch pin.
5. CRIMPING PROCEDURE
Avoid personal injury. When operating power unit,
exercise caution while holding terminals, splices,
or wire near crimping area.
The following crimping procedure provides general
information. Refer to instructions packaged with
individual die sets for specific products, wire sizes,
strip dimensions, positioning of terminals and splices
in the dies, and crimping procedures.
Never operate the power unit without having a
crimping head attached to the hose.
1. Insert terminal or splice in the stationary (upper)
die according to instructions packaged with the
dies. Make sure the latch pin is secure before
activating the power unit.
2. Slowly advance moving (lower) die with short,
quick strokes until terminal or splice is secure.
3. Insert the stripped wire.
4. Cycle tool to complete crimp. Remove crimped
terminal or splice.
If the splice or terminal sticks in the die after
crimping, apply a rocking action to remove it from
the die.
6. INSPECTION/MAINTENANCE
Make sure hydraulic pressure is released and
power supply is disconnected before following
inspection and maintenance procedures, unless
otherwise specified in the procedure.
CAUTION
!
NOTE
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DANGER
CAUTION
!
DANGER
NOTE
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408- 8914
Hydraulic Crimping Head 1752787- 1
3of 4Rev BTyco Electronics Corporation
Each crimping head is assembled and inspected
before shipment. Tyco Electronics recommends 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.
6.1. 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.
6.2. Visual Inspection
Refer to Figure 3 and proceed as follows:
1. 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.
2. Inspect pivot pin holes and latch pin holes for
wear. Replace parts, as needed.
Figure 3
Check These Areas
for Cracks
Check Die Areas
for Damage
Check for Excessive Wear
at Pivot Pin and Latch Pin
3. 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.
4. If head shows evidence of galling, cracks, oil
leakage, or rough cycling, return the crimping head
to Tyco Electronics for repairs. (Refer to Section 7,
REPLACEMENT AND REPAIR).
Once a year, or every 7,500 cycles (whichever
comes first), the hydraulic head should be
returned to Tyco Electronics for magnetic particle
inspection. Additionally, inspect and service the
head (as described in Figure 3) every month or
1,000 cycles. Refer to Instruction Sheet
408--8909.
6.3. 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, proceed as follows:
A. Electric Hydraulic Pump 1583660- [ ]
Press the retract/release button on the hand remote
pendant or foot remote, and hold for several seconds.
This will release any pressure in the hydraulic system.
If the ram returns to DOWN position, the trouble is
NOT in the crimping head. If ram does not return,
ensure that the coupler is fully engaged. If coupler is
engaged and ran still does not go DOWN, return the
crimping head to Tyco Electronics for repairs.
B. Foot Hydraulic Pump 1583659- 1
Depress the pressure release pedal.
C. Hand Hydraulic Pump 1583661- 1
Activate the pressure release knob.
7. REPLACEMENT AND REPAIR
Customer--replaceable parts are listed in Figure 4. A
complete inventory can be stocked and controlled to
prevent lost time when replacement of parts is
necessary. 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
PO BOX 3608
HARRISBURG PA 17105--3608
Tools may also be returned to Tyco Electronics for
evaluation and repair. For tool repair service, contact
a Tyco Electronics Representative at
1--800--526--5136.
NOTE
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408- 8914
Hydraulic Crimping Head 1752787- 1
Rev B4 of 4 Tyco Electronics Corporation
8. REVISION SUMMARY
SAddition of “ORIGINAL INSTRUCTIONS”
76.84 [3.025]
123.19 [4.850]
8
5
4
3
2
6
7
1
9
337
[13.27]
A
A
Section A- A
WEIGHT:
13.6 kg [30 lb] (Approx.)
REPLACEMENT PARTS FOR CRIMPING HEAD 1752787--1
ITEM PART NUMBER DESCRIPTION QTY PER HEAD
1311470--1 COUPLER, Quick Connect/Disconnect 1
2306209--8 PIN, Removable Latch 1
38--59558--5 PIN, Pivot 1
41--21045--1 RING, Retaining 1
521061--9 SETSCREW 2
64--23147--7 SPRING, Compression 1
71--21919--6 PIN, Dowel 1
84--21012--0 SETSCREW 1
923150--3 NIPPLE, Hex 1
Figure 4