Tyco Electronics DYNA-CRIMP 69065 User manual

Instruction Sheet
DYNA- CRIMP* 408--2452
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
24 MAR 10 Rev DHydraulic Crimping Head 69065
Figure 1
Latch
Pin
Dust Cap
Yoke
Pivot Pin
Quick--Disconnect Coupler,
Cylinder Half (Mates with Coupler
on Hose or Handle Control)
1. INTRODUCTION
This instruction sheet provides application,
maintenance, and inspection procedures for
DYNA--CRIMP Crimping Head 69065 (shown
Figure 1). The crimping head is used to crimp:
SAMPOWER* terminals and splices onto solid or
stranded copper wire sizes 2 through 4/0 AWG.
See instruction sheet 408--1565.
SSOLISTRAND* terminals and splices onto solid
or stranded copper wire sizes 8 through
4/0 AWG. See instruction sheet 408--9786.
The crimping head is designed for two DYNA--CRIMP
tools: either Hydraulic Hand Pump 314979--1 covered
in customer manual 409--5860 or Hydraulic Power
Unit 69120--[ ] described in customer manual
409--1950. 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 and illustrations are
not drawn to scale and are for reference only.
Reasons for reissue of this instruction sheet are
provided in Section 8, REVISION SUMMARY.
2. DESCRIPTION
The 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 hydraulic chamber, a piston
(ram) which holds and controls the moving die, and a
quick connect/disconnect coupler (cylinder half) which
mates with the coupler on hose or handle control to
release or supply pressure.
To avoid injury when using DYNA--CRIMP
equipment, observe the following precautions:
-- Do NOT modify the crimping equipment in any
way.
-- Use only dies, terminals, and wire specified for
the crimping 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 the crimping head,
proceed as follows.
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. Remove protective dust caps from both quick
connect/disconnect couplers.
2. Hold hose or handle control vertically to prevent
oil spillage. Attach hose or handle control to
coupling section on head. Thread properly and
tighten securely.
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 Hydraulic Power Unit 69120--[ ],
DISCONNECT POWER UNIT FROM POWER
SUPPLY.
-- If using Hydraulic Hand Pump 314979--1,
activate the pressure release lever.
ORIGINAL INSTRUCTIONS
NOTE
i
DANGER
DANGER
CAUTION
!
DANGER

408- 2452
DYNA- CRIMP Hydraulic Crimping Head 69065
Rev D2 of 4 Tyco Electronics Corporation
Figure 2
Yoke Pu
s
h
S
t
a
t
i
o
n
a
r
y
D
i
e
into Yoke
Latch Pin
Removed
Push Moving Die
into Ram
Place Screwdrivers
Here to Remove Dies
Ram Advanced
4. DIE INSERTION AND REMOVAL (Figure 2)
Avoid personal injury. When using power unit,
exercise caution to avoid accidently depressing
foot pedal or handle control when installing or
changing dies.
4.1. Die Insertion
1. Remove latch pin and open yoke on crimping
head.
2. Insert stationary die (upper) into yoke by
pushing die until it snaps into position.
3. Activate power unit to advance ram slightly as
shown in Figure 2.
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.
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.
4.2. Die Removal
1. Remove latch pin and open yoke.
2. Insert screwdriver under stationary die and pry
die out of yoke. See Figure 2.
3. Raise ram to full UP position.
4. Insert screwdriver under moving die and pry die
out of ram.
Latch Pin Kit 69709--2 is available as an
accessory item. The latch pin is attached to the
pivot pin by a chain to avoid misplacing the
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 handle control or
crimping head coupling.
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. MAINTENANCE AND INSPECTION
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.
DANGER
CAUTION
!
NOTE
i
DANGER
CAUTION
!
NOTE
i
DANGER

408- 2452
DYNA- CRIMP Hydraulic Crimping Head 69065
3of 4Rev DTyco Electronics Corporation
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.
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).
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, release pressure in
the power unit. If the ram retracts, the trouble is not in
the crimping head. If ram does NOT retract, refer to
Paragraph 6.4.
6.4. Crimping Head Disassembly Procedure (Figure 4)
— With Hydraulic Power Unit 69120--[ ],
disconnect power unit from power supply.
— With Hydraulic Hand Pump 314979--1, activate
the pressure release lever.
1. Remove crimping head from handle control or
coupling and place it in a vise. Use a suitable
material to protect the finish on the head.
2. Remove the set screw (item 11) shown in
Figure 4.
3. Turn the head assembly (item 8)
counterclockwise to remove it from the threaded
cylinder (item 2).
4. Remove the ram assembly (item 6) and ram
return spring (item 5).
5. Inspect for deteriorated or torn ram O--ring (item
3) or back--up ring (item 4). Replace with new parts
if damaged.
Figure 3
Check Die Areas
for Damage
Check for
Excessive Wear
at Pivot Pin
Check These
Areas for Cracks
Check for Excessive
Wear at Latch Pin
6. Apply a thin film of hydraulic fluid (same type
used in the power unit reservoir) on the surface of
the O--ring and the back--up ring.
7. Install the ram assembly and ram return spring
in the cylinder.
8. Align the key on ram assembly with the keyway
in head and install the head in threaded cylinder.
Tighten the head by hand.
9. Install set screw (item 11). Be sure it extends
through the cylinder and bottoms on the groove of
the cylinder.
10. Attach crimping head to handle control or
coupling. Refer to Section 3.
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
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
The crimping head may also be returned for
evaluation and repair. For repair service, call
1--800--526--5136.
8. REVISION SUMMARY
Revisions to this instruction sheet include:
SChanged superceded customer manual in
Section 1

408- 2452
DYNA- CRIMP Hydraulic Crimping Head 69065
Rev D4 of 4 Tyco Electronics Corporation
1
2
3
4
6
9
10
7
5
8
11
8A
8B
8C
8
8F
8D
8C
8E
12
REPLACEMENT PARTS
ITEM PART NUMBER DESCRIPTION QTY PER
CRIMPING HEAD
1311471--1 Coupler, Quick--Disconnect, Cylinder Half 1
2311835--1 Cylinder 1
32--21053--9 O--Ring, 2.000 in. OD¢1.625 in. ID¢.188 in. Width 1
42--21107--3 Ring, Back--Up 1
5300680-- 0 Spring, Ram Return 1
6311832--1 Piston (Ram Assembly) 1
7311833--1 Bushing 1
8311837--1 Cylinder Head and Yoke AssemblyH(Contains the Following Hardware Parts) —
8A 306209--3 Pin, Latch 1
8B 302312-- 0 Pin, Pivot 1
8C 21045--9 Ring, Retaining 2
8D 301555-- 0 Spacer 1
8E 301556-- 0 Spring 1
8F 23057--4 Ball Plunger 1
93--21028--4 Pin, Slotted Spring, .094¢.375 in. Long 1
10 311834--1 Key, Piston 1
11 1--22667--4 Set Screw, Socket, Self--Locking, 1/4-- 2 0 ¢.250 in. Long 1
12 23057--4 Ball Plunger 1
Figure 4
HThe head and yoke must be ordered and replaced as a machine fit assembly (part number 311837--1). All other parts of the crimping
head including items 8A through 8F may be ordered and replaced separately.