Tyco Electronics STRATO-THERM 1-46673-0 User manual

Instruction Sheet
STRATO- THERM* Crimping Heads
Used with Double Action Battery 408--10033
LOC B
1of 6
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
29 NOV 10 Rev BPowered Hand Tool Kits 1213804- [ ]
-
Figure 1
Battery
Lock
Battery
Cartridge
1725839--1
Battery Powered
Crimp Tool
Retract Button
Crimp Head
Mounting Holes
Typical DAHT
Crimp Head (Ref)
Quick--Release
Pins
DAHT Adapter
Assembly
1. INTRODUCTION
Crimping Heads 1--46673--0, 1--46673--1, and
1--46988--0 are designed to crimp STRATO--THERM
Terminals and Splices onto wire size 26--14 AWG.
Refer to Figure 2. The crimping heads are used with
Double Action Battery Powered Hand Tool Kits
1213804--[ ].
The crimping heads can also be used with the
626 Double Action Pneumatic Tool Adapter
1213563--1.
This instruction sheet provides recommended
procedures for wire preparation, crimping head
installation, crimping, and maintenance and
inspection. For information concerning tool setup and
operation, refer to Customer Manual 409--10056
packaged with the battery tool kit.
Dimensions are in metric units with [inches in
brackets]. Figures and illustrations are for
reference only and are not drawn to scale.
Reasons for reissue are provided in Section 8,
REVISION SUMMARY.
2. DESCRIPTION
The crimping head consists of integral jaws which
close in an arc--like motion. After an operator locates
the terminal or splice between the crimping jaws and
inserts the stripped wire, the tool is activated to crimp
the terminal or splice to the wire.
NOTE
i
NOTE
i

408- 10033
STRATO- THERM Crimping Heads
Rev B2of 6 Tyco Electronics Corporation
T
O
O
L
WIRE
T
O
O
L
SIZE (AWG) STRIP LENGTH
1--46673--0
2
2
1
6
5
1
6
5
9
4
1--46673--1D22--16 5.16--5.94
[
2
0
3
--
2
3
4
]
1--46988--0 16--14
[
.
2
0
3
-- .
2
3
4
]
NOTE: DFor wires with thin--wall insulation.
Figure 2
3. HEAD INSTALLATION AND REMOVAL
3.1. Head Selection
Crimping heads are coated with a preservative to
prevent rust and corrosion. Wipe this preservative
from the head, particularly from the crimping
surfaces.
3.2. Installation
To avoid personal injury, be sure to exercise
extreme caution when handling the crimp tool.
Avoid accidentally depressing the trigger control
when installing or removing crimp heads.
DO NOT operate the battery tool without the
proper crimping head installed. After crimping
head is installed, make sure that the quick pins
are properly inserted to avoid personal injury and
damage to the tool.
1. Remove quick pins from the adapter assembly.
RefertoFigure1.
2. Insert crimping head into the adapter assembly.
3. After the crimping head is properly aligned,
insert the quick pins through the two holes in the
adapter and through the holes in the crimp head.
The quick pins will “snap” into position when they
are properly inserted.
3.3. Removal
To avoid personal injury, ALWAYS disconnect the
battery from the tool before removing crimping
head.
Remove the quick pins from the crimping head; then
remove the crimping head from the tool holder.
4. CRIMPING PROCEDURES
To avoid personal injury, ALWAYS keep fingers
clear of crimping jaws when operating the tool.
Never place anything within the crimping jaws
except Tyco Electronics terminals or splices.
4.1. Crimping Procedure
1. Strip wire to dimensions shown in Figure 2. DO
NOT nick wire strand or use wires with nicked or
missing conductor strands.
2. Push the locator up and, from the FRONT side
of the tool, insert the terminal or splice wire barrel
sleeve into the crimping jaws making sure that the
edge of the wire barrel sleeve rests against the
locator. See Figures 3 and 4.
3. Depress the trigger to advance the moving ram.
This closes the crimp jaws in order to hold the
terminal in place. DO NOT deform the wire barrel.
4. Insert wire conductor through the insulation
barrel sleeve and into the wire barrel sleeve until it
is flush with the outer edge of the wire barrel
sleeve.
The wire barrel sleeve on high--temperature
terminals and splices is color--coded orange.
Heat--resistant terminals and splices are not
color--coded. Refer to Figure 5.
Terminal Tongue
Through Slot in
Locator
Edge of Wire Barrel
Sleeve Resting
Against Locator Insert Wire Conductor
Through Insulation
Barrel Sleeve and into
Wire Barrel Sleeve
Push Locator Up So That Terminal
Tongue Slides Through Slot in Locator
Terminal Crimp
Insulation
Barrel Sleeve
Wire Barrel
Sleeve
Back Side of Tool
Figure 3
NOTE
i
DANGER
DANGER
NOTE
i
DANGER
DANGER
NOTE
i

408- 10033
STRATO- THERM Crimping Heads
3of 6Rev B Tyco Electronics Corporation
Figure 4
Open Section of
Splice in Slot in
Locator
Edge of Wire Barrel
Sleeve Resting
Against Locator
Splice Crimp (First Crimp)
Insulation
Barrel Sleeve
Wire Barrel
Sleeve Insert Wire Conductor
Through Insulation
Barrel Sleeve and into
Wire Barrel Sleeve
Push Locator Up So That Splice
Slides Through Slot in Locator
Back Side
of Tool
Wire Barrel
Sleeve
Insulation
Barrel Sleeve
Insulation
Barrel Sleeve
Wire Barrel
Sleeve
Figure 5
Splice
Terminal
5. Activate the tool to complete the crimp. The
crimp tool automatically returns to the first position
of the cycle when the crimp is complete.
6. Allow tool head to open FULLY. Remove the
crimped terminal or splice from the crimping jaws.
7. To crimp the other half of the splice, reposition
the uncrimped sleeve in the crimping jaws as
described in Step 2. Follow Steps 3 through 6 to
complete the crimp.
8. Refer to Section 5 and Figure 7 for crimp
inspection.
4.2. Insulation Crimp Adjustment
The insulation crimping section of the crimping head
has three positions: 1—Tight; 2—Medium; and
3—Loose.
1. Insert insulation adjustment pins in Position 3.
SeeFigure6.
Always place both adjustment pins in the same
position. See Figure 6.
Figure 6
Insulation
Adjustment
Pin(s) (Ref)
Positions
11
22
33
2. Place terminal or splice in crimping jaws, as
shown in Figures 3 and 4.
3. Insert unstripped wire only into the
insulation barrel of the terminal or splice. See
Figures 3 and 4.
4. Crimp terminal or splice as described in
Paragraph 4.1.
5. Remove terminal or splice. Bend wire forward
and then backward. The terminal or splice should
retain its grip on the wire. If the wire pulls out,
reposition the insulation adjustment pins in the next
tighter position and repeat crimping procedure.
6. Repeat adjustment as necessary until desired
insulation grip is obtained. DO NOT use a tighter
setting than required.
NOTE
i

408- 10033
STRATO- THERM Crimping Heads
Rev B4of 6 Tyco Electronics Corporation
Figure 7
Properly Crimped Terminal and Splice
Crimp Centered on
Wire Barrel Sleeve
No Wire Conductor
Strands Protruding
1 Hashmark on
Bottom of Terminal
2 Hashmarks on
Bottom of Splice
Tool 1--46673--0 and
1--46673--1 (1 Hashmark)
Tool 1--46988--0
(2 Hashmarks)
5. CRIMP INSPECTION
Inspect crimped terminals and splices by checking the
features described in Figure 7. Use only terminals or
splices that meet the conditions shown in the
“ACCEPT” column. “REJECT” terminations can be
avoided through careful use of instructions in
Section 4, and by performing regular head
maintenance, as described in Section 6.
KKKDamaged product should not be used. If a
damaged terminal or splice is evident, it should
be cut from the wire and replaced. Do NOT
re--terminate terminals or splices.
6. MAINTENANCE AND INSPECTION
To avoid personal injury, ALWAYS disconnect the
battery from the tool before performing
maintenance or inspection.
Tyco Electronics recommends that a maintenance
and inspection program be performed periodically to
ensure dependable and uniform terminations. The
crimping head should be inspected once a month.
Frequency of inspection should be adjusted to suit
your requirements through experience. Frequency of
inspection depends on:
1. The care, amount of use, and handling of the
crimping head.
2. The type and size of the product crimped.
3. The degree of operator skill.
4. The presence of abnormal amounts of dust and
dirt.
5. Your own established standards.
Each crimping head is thoroughly inspected before
packaging. Since there is the possibility of crimping
head damage during shipment, new crimping heads
should be inspected immediately upon arrival at your
facility.
6.1. Daily Maintenance
Tyco Electronics recommends that each operator be
responsible for the following steps of daily
maintenance:
1. Remove dust, moisture, and other contaminants
with a clean, soft brush, or a lint--free cloth. Do
NOT use objects that could damage the head.
2. Make sure that all pins, rings, and other
components are in place and secure.
To avoid personal injury and damage to the tool,
make sure quick pins are properly inserted.
3. Make certain all surfaces are protected with a
thin coat of any good SAE 20 motor oil. Do NOT oil
excessively.
4. When the head assembly is not in use, store it
in a clean dry, area.
6.2. Periodic Inspection
Regular inspections should be performed by quality
control personnel. A record of scheduled inspections
should remain with the crimping heads or be supplied
to supervisory personnel responsible for the crimping
heads. Though recommendations call for at least one
inspection a month, the frequency should be based
on amount of use, working conditions, operator
training and skill, and your established company
policies. These inspections should include a visual
inspection (Paragraph 6.3) and a crimping chamber
inspection (Paragraph 6.5).
CAUTION
!
DANGER DANGER

408- 10033
STRATO- THERM Crimping Heads
5of 6Rev B Tyco Electronics Corporation
6.3. Visual Inspection
1. Remove all lubrication and accumulated film by
immersing the crimping head in a suitable
commercial degreaser that will not affect paint or
plastic.
2. Make certain all components are in place. If
replacements are necessary, refer to Figure 10.
3. Check all bearing surfaces for wear. Replace
worn parts.
4. Inspect crimp area for flattened, chipped, or
broken areas. Replace worn or damaged parts.
6.4. Lubrication
Lubricate all pins, pivot points, and bearing surfaces
with a high quality grease. Tyco Electronics
recommends the use of Molykote grease, which is a
commercially available lubricant. Lubricate according
to the following schedule:
Head used in daily production -- lubricate daily
Head used daily (occasional) -- lubricate weekly
Head used weekly -- lubricate monthly
Wipe excess grease from crimping head, particularly
from jaw closure areas. Grease transferred from jaw
closure area onto certain terminations may affect the
electrical characteristics of an application.
6.5. Gaging the Crimping Chamber
This inspection requires the use of plug gages
conforming to the dimensions shown in Figure 8. Tyco
Electronics does not manufacture or market these
gages.
Suggested Plug Gage Design for
Wire Barrel Section of Crimping Chamber
Jaw Closure
Configuration
“R”
6.35 [.250]
Min Typ
GO
Dim.
50.8 [2.00]
Min Typ
“R”
NO--GO
Dim.
H
A
N
D
GAGE ELEMENT DIMENSIONS
H
A
N
D
TOOL GO NO--GO “R”
(Radius)
1--46673--0
1--46673--1
1.499--1.506
[.0590--.0593]
1.648--1.651
[.0649--.0650] 1.57
1--46988--0 1.702--1.709
[.0670--.0673]
1.851--1.854
[.0729--.0730]
1
.
5
7
[.062]
Figure 8 (cont’d)
GO NO
GO
6.35 [.250]
Min Typ
Jaw Closure
Configuration
GO Dim. NO--GO Dim.
“W”
Suggested Plug Gage Design for
Insulation Barrel Section of Crimping Chamber
“W”
H
A
N
D
GAGE ELEMENT DIMENSIONS
H
A
N
D
TOOL GO NO--GO “W” (Width)
(Max)
1--46673--0
1--46673--1
0.762--0.770
[.0300--.0303]
1.267--1.270
[.0499--.0500] 3.05
1--46988--0 1.016--1.024
[.0400--.0403]
1.521--1.524
[.0599--.0600]
3
.
0
5
[.120]
Figure 8 (end)
Disconnect the battery and remove crimping
head from tool before inspecting crimping
chambers.
1. Remove oil and dirt from the jaw bottoming
surfaces and plug gage element surfaces.
2. Close wire barrel crimping jaws until they are
bottomed, but not under pressure.
3. Align GO element with wire barrel crimping
section. Push element straight into crimping
chamber without using force. The GO element
must pass completely through the chamber as
shown in Figure 9.
4. Align the NO--GO element and try to insert it
into the chamber. The element may start entry, but
it must not pass completely through the crimping
chamber.
5. Repeat this procedure for the insulation crimping
section using a plug gage as shown in Figure 8.
If the crimping chamber passes the gage inspection,
the crimping head is considered dimensionally correct
and should be lubricated with a THIN coat of any
good SAE 20 motor oil. If the crimping chamber does
not conform to the plug gage conditions, contact your
local Tyco Electronics Field Representative or refer to
Section 7, REPLACEMENT AND REPAIR.
For additional information about the use of a plug
gage, see Instruction Sheet 408--7424.
DANGER

408- 10033
STRATO- THERM Crimping Heads
Rev B6of 6 Tyco Electronics Corporation
Figure 9
NO--GO Element May Start Entry, But Must Not
Pass Completely Through Crimping Chamber
Jaws Bottomed But
Not Under Pressure
Inspection of
Wire Barrel Section of
Crimping Chamber
Inspection of
Insulation Barrel Section
of Crimping Chamber
GO Element Must Pass Completely
Through Crimping Chamber
7. REPLACEMENT AND REPAIR
Replacement parts and recommended spares are
listed in Figure 10. The recommended spares should
be stocked for immediate replacement.
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
P.O. BOX 3608
HARRISBURG, PA 17105--3608
For further repair and replacement information,
call the Tyco Electronics Tooling Assistance Center at
the number at the bottom of page 1.
1
1
2
3
4
5
REPLACEMENT PARTS
ITEM
NO.
PART
NUMBER DESCRIPTION
QTY
PER
HEAD
139207 PIN, Insulation Crimping
Adjustment 2
2305363 LOCATOR 1
3302994 HOUSING, Locator 1
49--305927--1 SCREW 1
5301201 SPRING 1
Figure 10
8. REVISION SUMMARY
SUpdated document to corporate requirements