Tyco Electronics 696675-1 User manual

Instruction Sheet
SOLISTRAND*
Flag Terminal 408-8908
E 2004 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
AMP and Tyco are trade arks. *Trade ark
Other products, logos, and co pany na es used are the property of their respective owners. LOC B
1 of 6
TOOLING ASSISTANCE CENTER 1-800-722-1111
FAX/PRODUCT INFO 1-800-522-6752
For Regional Custo er Service, visit our website at
www.tycoelectronics.com
This controlled docu ent is subject to change.
For latest revision, call the FAX/PRODUCT INFO nu ber.
24 SEP 04 Rev O
rimping Dies
PROPER USE GUIDELINES
Cu ulativeTrau aDisorderscanresultfro theprolongeduseof anuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolu e
applications. A wide selection of powered application equip ent for extended-use, production operations is available.
–
–
–
–
–
–
Hydraulic
Hand Tool
1490749-1
Tools Using Crimping Dies for
SOLISTRAND Flag Terminals
Hydraulic Head
1490746-1
Flag Terminal Die Set (Typical)
Nest
Indenter
PRODU T
DIES NOMINAL WIRE
SIZE MM
2
( MA) TOOLING
PRODU T
NEST INDENTER MM2AWG
()
RANGE HYDRAULI
HEAD HYDRAULI HAND TOOL
696675-1 1752682-1
6 637 10 539
696679-1 1752682-2 1752681-2 7-8 8
6
.
637
-
10
.
539
[13 100
-
20 800]
322727-[ ] 1752680-8
[13
,
100-20
,
800]
321576 1752680-7 13-15 6 10.539-16.771
[20,800-33,100]
321060 1752680-6 1752681-3 21 4 16.771-26.653
[33,100-52,600]
321064 1752680-5 34-35 2 26.653-42.411
[52,600-83,700] 1490746-1 1490749-1
321066 1752680-4 59-60 1/0 42.411-60.511
[83,700-119,500]
321584 1752680-3
1752681 1
67-70 2/0 60.551-72.259
[119,500-150,500]
327887 1752680-2
1752681
-
1
80-95 3/0 72.259-96.274
[150,500-190,000]
321259-[ ] 1752680-1 100-125 4/0 96.274-117.049
[190,000-231,000]
Figure 1
1. INTRODU TION
This instruction sheet provides application
instructions, maintenance, and inspection procedures
for the dies listed in Figure 1. These dies crimp
SOLISTRAND Flag Terminals to solid or stranded
copper wire (also listed in Figure 1).
The dies are used in Hydraulic Head 1490746–1 and
Hydraulic Hand Tool 1490749–1. Refer to Figure 1.

408-8908
SOLISTRAND Flag Terminal Crimping Dies
Rev O2 of 6
All dimensions on this document are in metric
units [with U. S. customary units in brackets].
Figures are for reference only and are not drawn
to scale.
2. DESCRIPTION
Each die assembly consists of a nest and an indenter
(ordered separately) which are retained in the
crimping head by retainer pins. The nest is positioned
in the yoke of the crimping head, and the indenter is
positioned in the ram of the tool.
3. DIE INSTALLATION AND REMO AL
Refer to Figure 1 and determine the correct die
assembly, wire size, product number, and tool head to
use with the die assembly.
Never operate the tool with the dies removed.
3.1. Die Installation (Figure 2)
To avoid personal injury be sure to exercise
extreme caution when using the power unit.
Avoid depressing the footswitch or trigger control
when installing or removing dies.
Figure 2
Nest
Indenter
Die Release Button
Ram (Advanced)
1. Depress the upper release button located in the
“C”–head.
2. Slide the nest into place in “C”–head. See
Figure 2.
3. Release the button and rock the die back and
forth until the nest snaps into position.
4. Activate the power unit until the lower die
release button located in the ram is exposed.
5. Depress the release button.
6. Slide the indenter into position in the ram. See
Figure 2.
7. Release the button and rock the indenter back
and forth until the die snaps into position.
8. Return ram to the down position.
3.2. Die Removal (Figure 2)
1. Depress the upper release button located in the
“C”–head and slide the nest out of the head.
2. Activate the power unit until the lower die
release button (located in the ram) is exposed.
3. Depress the release button and slide the
indenter out of the ram.
4. WIRE STRIPPING AND CRIMPING PROCEDURE
AVOID PERSONAL INJURY. Exercise extreme
caution when operating crimping head and
holding terminals or wire near the crimping dies.
4.1. Wire Stripping
Obtain the correct wire, flag terminal, and crimping
tool (with correct die assembly installed) for your
application. Strip wire insulation to the dimensions
indicated in Figure 3, taking care not to nick or cut
conductor(s), and proceed as follows:
4.2. Crimping Procedure
1. Ensure that wire size stamped on flag terminal
corresponds to wire size being used in the
application and wire size stamped on nest and
indenter.
2. Center flag terminal wire barrel in die nest.
When crimping flag terminals, hold tongue of flag
terminals against nest as shown in Figure 4. If
terminal locator is present, slide terminal into
terminal locator and press the tongue of the flag
terminal against the slope on the nest.
3. Activate power unit so that ram advances and
holds terminal in place but DOES NOT deform wire
barrel.
4. Insert stripped wire into terminal until end of
conductor is flush with or extended slightly beyond
end of wire barrel. See Figure 3.
5. Activate power unit to complete crimp.
If terminal sticks in die after crimping grasp wire
close to crimp and apply a rocking motion to
remove the die.
6. Refer to Paragraph 5.1, Crimp Inspection, for
terminal crimp inspection procedure.
NOTE
CAUTION
DANGER
DANGER
NOTE

408-8908
SOLISTRAND Flag Terminal Crimping Dies
3 of 6Rev O
Wire Barrel
Crimped
Flag Terminal
Die Set
Terminal
Strip Length Hydraulic Head (Typical)
PRODUCT
NOMINAL WIRE SI E STRIP LENGTH
PRODUCT
MM2AWG MINIMUM MAXIMUM
696 5-1
696 9-1 -8 8 9.53 [.3 5] 11.18 [.440]
322 2 -[ ]
3215 6 13-15 6 12. 0 [.500] 14.2 [.562]
321060 21 4 13.82 [.554] 15.48 [.609]
321064 34-35 2 1 .06 [.6 2] 18.65 [. 34]
321066 59-60 1/0 22.23 [.8 5] 23.81 [.93 ]
321584 6 - 0 2/0 23.81 [.93 ] 25.40 [1.000]
32 88 80-95 3/0 26.98 [1.062] 28.58 [1.125]
321259-[ ] 100-125 4/0 28.58 [1.125] 30.16 [1.18 ]
Figure 3
Figure 4
Hydraulic Head (Typical)
Center Terminal
Wire Barrel in Nest
Hold Flag Terminal
Tongue Against
Slope on Nest Until
Crimp is Started
5. MAINTENANCE AND INSPECTION
Disconnect power supply before performing
maintenance, adjustments, inspections, and
repairs.
5.1. Crimp Inspection (Figure 5)
Inspect crimped terminals by checking the features
described in Figure 5. Use only terminals that meet
the conditions shown in the ACCEPT column.
Terminals displaying the features shown in the
REJECT column can be avoided by careful use of
these instructions and by performing the maintenance
and inspection procedures described in Paragraphs
5.2 and 5.3.
5.2. Daily Maintenance
It is recommended that each operator of the dies be
made aware of, and responsible for, the following steps
of daily maintenance.
DANGER

408-8908
SOLISTRAND Flag Terminal Crimping Dies
Rev O4 of 6
Figure 5
ACCEPT REJECT
1. Crimps centered. Crimps may be off center but NOT off
end of wire barrel.
2. Wire size being used matches wire range or size stamped
on flag terminals or dies.
. Insulation does not enter wire barrel.
4. Inserted wire is flush with or extended slightly beyond end
of wire barrel.
1. Crimped off end of terminal.
2. Wire size being used does not match wire size or range
stamped on flag terminal.
. Wire not inserted far enough in terminal.
4. Insulation entered barrel of terminal. CHECK FOR
INCORRECT STRIP LENGTH.
5. Nicked or missing conductor strands.
2
3
1
4
2
5
4
1
3
FLAG TERMINAL
Wire Range
Stamped Here
Wire Range
Stamped Here
1. Remove dust, moisture, and other contaminants
from the dies with a clean brush, or a clean, soft,
lint–free cloth. Do NOT use objects that could
damage the dies.
2. If dies are coated with oil or preservative, wipe
clean – particularly in the crimping areas – before
placing them in use.
3. When dies are not in use, make certain all
surfaces are protected with a THIN coat of any
good SAE No. 20 motor oil, and mate and store
them in a clean, dry area.
5.3. Periodi Inspe tion
Regular inspections should be performed by quality
control personnel. A record of scheduled inspections
should remain with the dies or be made available to
supervisory personnel responsible for the the dies.
Though recommendations call for at least a monthly
inspection, the inspection frequency should be based
upon the amount of use, working conditions, operator
training and skill, and established company
standards. These inspections should be performed in
the following sequence:
A. Visual Inspe tion (Figure 6)
1. Remove all lubrication and accumulated film by
immersing the dies in a suitable degreaser that will
not affect paint or plastic material.
2. Check all surfaces for wear. Inspect the crimp
area for flattened, chipped, cracked, worn, or
broken areas. See Figure 6. If damage is evident,
the die must be replaced.
Figure 6
Broken
Chipped
Pitted

408-8908
SOLISTRAND Flag Terminal Crimping Dies
5 of 6Rev O
B. Gaging the Crimping Cham er (Figures 7 and 8)
This inspection requires the use of a plug gage
conforming to the dimensions in Figure 7. Tyco
Electronics does not manufacture or market these
gages.
Proceed as follows:
1. Mate the dies until it is evident that they have
bottomed. Hold the dies in this position.
2. Align the GO element with the wire barrel
crimping chamber. Push the element straight into
the crimping chamber without using force. The GO
element must pass completely through the
crimping chamber.
3. Align the NO–GO element and try to insert it
straight into the same crimping chamber. The
NO–GO element may start entry but must not pass
completely through. If the crimping chamber
conforms to the gage inspection, the dies are
considered dimensionally correct. If not, they must
be replaced. For additional information regarding
the use of a plug gage, refer to Instruction Sheet
408–7424.
Suggested Plug Gage Design
A" Dim. R"
B" GO Dim. C" Dim. Typ
R"
0.80
[2.000]
Typ
Die Closure
Configuration
B" NO-GO Dim.
DIES DIE CLOSURE
DIMENSION A" GAGE ELEMENT DIMENSION B" C"
DIMENSION
RADIUS

R
"
NEST INDENTER GO NO-GO GO NO-GO
DIMENSION
R"
17 2682-1
17 2682-2 17 2681-2 2. 4 [1.000] 2.692 [.1060] 2. 4-2.
[
.1000-.1003
]
2.689-2.692
[
.10 9-.1060
]
12.70 [. 00] 3. 8 [.141]
17 2680-8
[]
[]
17 2680-7 3. 1 [.1380] 3.708 [.1460] 3. 0 -3. 13
[.1380-.1383] 3.70 -3.708 [.14 9-.1460] 3.96 [.1 6]
17 2680-6 17 2681-3 4.140 [.1630] 4.343 [.1710] 4.140-4.147
[.1630-.1633] 4.340-4.343 [.1709-.1710] 11.099 [.437] 4.76 [.187]
17 2680- 4.9 3 [.19 0] .1 6 [.2030] 4.9 3-4.960
[.19 0-.19 3] .1 3- .1 6 [.2029-.2030] .94 [.234]
17 2680-4 6.172 [.2430] 6.37 [.2 10] 6.172-6.179
[.2430-.2433] 6.372-6.37 [.2 09-.2 10] 7. 2 [.296]
17 2680-3
17 2681 1
6.9 9 [.2740] 7.163 [.2820] 6.9 9-6.967
[.2740-.2743] 7.160-7.163 [.2819-.2820]
14 27 [ 62]
8.33 [.328]
17 2680-2
17 2681
-
1
7.823 [.3080] 8.026 [.3160] 7.823-7.830
[.3080-.3083] 8.023-8.026 [.31 9-.3160]
14
.
27 [
.
62]
9. 3 [.37 ]
17 2680-1 8.788 [.3460] 8.991 [.3 40] 8.788-8.796
[.3460-.3463] 8.989-8.991 [.3 39-.3 40] 10.89 [.421]
Figure 7

408-8908
SOLISTRAND Flag Terminal Crimping Dies
Rev O6 of 6
Figure 8
Terminal Dies (Typical)
Dies Bottomed but
Not Under Pressure
GO" lement Must Pass
Completely Through the
Die Closure
NO-G0" lement May nter
Partially, but Must Not Pass
Completely Through the Die
Closure
6. REPLACEMENT PARTS
Refer to Figure 1 when replacement of a die becomes
necessary, contact your local Tyco Electronics
Representative; call 1–800–526–5142; send a
facsimile of your purchase order to 1–717–986–7605;
or write to:
CUSTOMER SERVICE (38–35)
TYCO ELECTRONICS CORPORATION
P. O. BOX 3608
HARRISBURG, PA 17105–3608
7. RE ISION SUMMARY
Per EC 0990–0402–04:
S Initial release of instruction sheet