125782-1 [TE]

Reasons for reissue of this instruction sheet are provided in Section 7, REVISION SUMMARY.;


型号：	125782-1
厂家：	TE CONNECTIVITY
描述：	Reasons for reissue of this instruction sheet are provided in Section 7, REVISION SUMMARY.
文件：	总4页 (文件大小：111K)
中文：	中文翻译
下载：	下载PDF数据表文档文件

Instruction Sheet

Crimping Die Assemblies

90240-2, 90248-2, and 90280-1

408-7563

14 MAR 11 Rev B

Moving

Die

Holding

Screw

Floating

Crimper

PIDG* FASTON*

Terminal

Wire

Barrel

Wire Strip

Length

(See Table)

Assembly

Screw

Saddle

Insulation

Barrel

AMP -TAPETRONIC*

Machine 69875

Die

Holding

Screw

Conductor

Insulation

Stationary

Die

NOTE: Not to Scale

TERMINAL

WIRE

DIE

ASSEMBLY

PART NUMBER

(TAPE MOUNTED)

INSULATION

COLOR

RANGE

(AWG)

STRIP LENGTH

+0.41 [.016]

INSULATION

DIA (Max)

SERIES

NUMBER

60894--2

61048--2

61060--2

90248--2

.110

.250

Clear

22 -- 18

5.56 [.219]

2.54 [.100]

6.35 [.250]

90240--2

90280--1

42844--3

61198--4

Green

Yellow

14 -- 12

12 -- 10

8.74 [.344]

7.14 [.281]

Figure 1

screw. The moving die has a die holding screw and a

saddle with an assembly screw, and it is marked to

indicate the wire range crimped.

1. INTRODUCTION

This instruction sheet covers die assemblies that are

used to crimp PIDG FASTON Terminals. Refer to

Figure 1 for appropriate die assembly and terminal

combinations. The dies and terminals are color coded

to indicate accepted wire range. The dies fit into the

AMP--TAPETRONIC Machine 69875. Refer to

Customer Manual 409--1993.

3. DIE INSTALLATION

Prepare the machine to receive dies according to the

instructions in 409--1993 under “Die Replacement”,

and proceed as follows:

All dimensions on this sheet are in millimeters

NOTE

[with inch equivalents provided in brackets].

Figures and illustrations are for identification only

and are not drawn to scale.

1. Position the moving die into the upper crimping

area of the machine and finger tighten the holding

screw.

Read these instructions carefully and completely

before crimping any terminals.

2. Position the stationary die into the lower

crimping area of the machine and start the holding

screw, but do not tighten it.

Reasons for reissue of this instruction sheet are

provided in Section 7, REVISION SUMMARY.

3. Hand cycle the machine until the dies bottom

against each other. Tighten both holding screws.

2. DESCRIPTION (Figure 1)

Each die assembly consists of a stationary die and a

moving die. The stationary die has a die holding

Re--assemble and adjust the machine, again following

the instructions provided in 409--1993.

E2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company TOOLING ASSISTANCE CENTER 1--800--722--1111 This controlled document is subject to change.

1 of 4

PRODUCT INFORMATION 1--800--522--6752

For latest revision and Regional Customer Service,

TE logo is a trademark.

visit our website at www.te.com

LOC B

*Trademark. Other product names, logos, or company names might be trademarks of their respective owners.

408-7563

4. PREPARATION AND CRIMPING

Wire Insulation Must

be Inside the

Insulation Barrel

Install a reel of terminals on the machine and align a

terminal with the dies. Refer to customer manual

409--1993.

Bellmouth

Must be

Present at

Wire Barrel

Crimp only terminals specified for the dies you

are using.

CAUTION

Refer to Figure 1 to verify the correct wire size and

insulation diameter for the product you intend to

crimp.

4.1. Insulation Crimp Adjustment

1. With the machine power supply disconnected

and the front guard removed, raise the tape

release lever and turn the insulation crimp

adjustment knob to position No. 4 (loose). Then

lower the tape release lever.

Terminal May Not be

Bent or Twisted

Wire Ends Must

be Flush to or

Beyond End of

Wire Barrel

2. Insert an unstripped wire into the terminal, and

hand cycle the machine one full crimp cycle.

Figure 2

3. Remove the crimped terminal from the machine.

Bend the wire 90_ to both sides. If the wire pulls

out of the terminal, raise the release lever, turn the

adjustment to next lower number, and lower the

release lever. Then repeat steps 2 and 3 until the

crimp is properly adjusted.

— A slight bellmouth must be present in the

terminal plastic insulation at the front of the wire

barrel.

— Terminal may not be bent or twisted in a way

that damages the termination or makes mating

difficult.

The insulation crimp should hold the wire

NOTE

insulation firmly without cutting into it.

For more information on product crimp

specifications, refer to application specification

114 -1002.

NOTE

4.2. Crimping Procedures

Strip the wires to the dimension shown in Figure 1,

being careful not to cut or nick the conductor strands.

Then, proceed as follows:

5. MAINTENANCE AND INSPECTION

5.1. Daily Maintenance

1. Insert the stripped end of a wire into the aligned

terminal until the wire insulation begins to wedge

against the terminal insulation barrel, or until it is

against the end of the terminal wire barrel.

1. Remove dust, moisture, and other contaminants

with a clean, soft brush, or a clean, soft, lint--free

cloth. Do NOT use any objects that could damage

the dies or tool.

2. Hold the wire in place and actuate the machine

through a complete cycle.

2. Make sure all die hardware and parts are

properly secured.

Be sure to allow the crimping dies to open fully

before removing the crimped terminal.

NOTE

3. Coat all surfaces with a thin coat of any good

SAE 20 motor oil. Do not oil excessively.

4.3. Crimp Inspection (Figure 2)

4. When the dies are not in use, store them in a

clean, dry area.

Visually inspect completed crimps, noting the

following:

5.2. Periodic Inspection

— Ends of wire strands must be flush to, or extend

beyond, the front of the wire barrel. However, ends

may not extend far enough to interfere with

insertion of the mating tab.

Regularly scheduled inspections should be conducted

and recorded by quality control personnel. It is

recommended that the inspection procedures that

follow be performed once a month; more often if your

work environment, company standards, or amount of

tool use indicates the need.

— Wire insulation must be inside the insulation

barrel with no conductor showing.

2 of 4

Rev B

408-7563

to ensure quality and reliability of the dies. Order

replacement parts through your TE Representative, or

call 1--800--526--5142, or send a facsimile of your

purchase order to 1--717--986--7605, or write to:

A. Visual Inspection

Remove all lubrication and accumulated film by

immersing the dies in a commercial degreaser. Then:

1. Remove all lubrication and accumulated film

from the dies by immersing the dies in a suitable

commercial degreaser.

Suggested Plug Gage Design

Diameter

NO-GO

Diameter

2. Make sure all die hardware and parts are

properly secured.

3. Carefully inspect die surfaces for wear, cracking,

pitting, or other obvious damage. Replace parts as

necessary before returning dies to service. See

Figure 4.

50.8 [2.00]

Min. Typ.

B. Gaging the Wire Barrel Crimping Chamber (Figure 3)

NO -GO Element Must Not Pass

Through Crimping Chamber

Figure 3 shows dimensions for manufacture of plug

gages needed to inspect the wire barrel crimping

chamber of each die assembly. TE Connectivity (TE)

does not make or market these gages. However,

gages may be purchased from:

Pennoyer--Dodge Company

6643--T San Fernando Road

Glendale, CA 91201

Gage crimping chamber using the following

procedures:

GO Element Must Pass

Through Crimping Chamber

1. Close dies until bottomed, and hold them in this

position.

GAGE ELEMENT DIAMETER

CRIMPING

DIE NUMBER

NO-GO

2. Align the plug gage GO element with the

crimping chamber. Push the element straight into

the chamber, but do not force it. The GO element

must pass through the chamber.

90240--2

90248--2

90280--1

3.52 [.1385]

1.59 [.0625]

3.80 [.1495]

Figure 3

3.64 [.1435]

1.71 [.0675]

3.95 [.1555]

3. Align the NO--GO element and try to insert it

straight into the crimping chamber. The NO--GO

element may begin entry as shown in Figure 3, but

must not pass through the chamber.

CUSTOMER SERVICE (38--35)

TYCO ELECTRONICS CORPORATION

P.O. BOX 3608

HARRISBURG, PA 17105--3608

If dies conform dimensionally, lubricate them with a

thin coat of any good SAE 20 motor oil. If not, replace

the dies.

For repair service, please contact a TE

Representative at 1--800--526--5136.

For additional information on plug gages, refer to

instruction sheet 408--7424.

7. REVISION SUMMARY

6. REPLACEMENT AND REPAIR

S Updated document to corporate requirements

S New logo

Replacement parts are listed in Figure 4. Parts other

than those listed in Figure 4 should be replaced by TE

Rev B

3 of 4

408-7563

DIE SPECIFICATIONS

REPLACEMENT PARTS

QTY

PER

ASSY

DIMENSION (Ref)

DIE

NUMBER

DIE

90240-2

DIE

90248-2

DIE

90280-1

ITEM

DESCRIPTION

59781--1

2--59577--8

2--59781--3

2--59577--9

59781--1

2--59577--8

Die Holding Screw

Saddle Screw

Saddle

56.64

15.85

28.63

90240--2

90248--2

90280--1

[2.230] [.624] [1.127]

1--307275--0 1--307275--2 1--307275--0

56.64

15.85

26.24

[2.230] [.624] [1.033]

1--59781--0

59781--6

59781--5

307276--1

24088--8

Die Holding Screw

Insulation Crimper

Curved Washer

Insulation Anvil

Retaining Ring

Wire Crimper

Wire Anvil

307276--5 2--307285--3

56.64

15.85

28.63

[2.230] [.624] [1.127]

24088--8

3--59619--7

1--21046--3

125719--1

125721--1

24088--8

3--59619--9

1--21046--3

125782--1

125781--1

1--59619--2

1--21046--3

125969--1

125968--1

DIE WEIGHT (Ref)

142 g [5 oz.]

Figure 4

4 of 4

Rev B

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