instruction sheet pidg* and plasti- grip* terminal 408--10029 loc b 1 of 9 e 2010 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 08 dec 10 rev b and splice crimping heads 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--46121--0, 1--47386--0, 1--47386--4, 1--47387--0, 1--47387--7, 1--525690--0, and 1--525691--0 are designed to crimp pidg terminals and splices, and plasti--grip terminals and splices onto solid or stranded copper 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- 10029 pidg and plasti- grip terminal and splice crimping heads rev b 2 of 9 tyco electronics corporation plasti--grip terminal pidg type terminal pidg butt splice 3 equally spaced stripes on nylon insulation restricting c r i m p i n g d o t w i r e s i z e t e r m i n a l / s p l i c e wire strip length product crimping h e a d dot c o d e w i r e s i z e range t e r m i n a l / s p l i c e insulation terminals splices p r o d u c t h e a d c o d e r a n g e (awg) i n s u l a t i o n color code min. max. min. max. pidg terminals and splices 1--46121--0 1dot 26--22 yellow 3.97 [.156] 4.78 [.188] 4.37 [.172] 5.16 [.203] pidg terminals and splices a n d 1--47386--0 1--47386--4 1--525690--0 1dot 22--16 (commercial) red 5.16 [.203] 5.94 [.234] 6.35 [.250] 7.14 [.281] an d plasti--grip terminals 1--47387--0 1--47387--7 1--525691--0 2dots 16--14 blue 5.16 [.203] 5.94 [.234] 6.35 [.250] 7.14 [.281] product crimping h e a d dot c o d e wire size range insulation d i a m e t e r r a n g e terminal/splice insulation wire strip length p r o d u c t head code r a n g e (awg) diameter range i n s u l a t i o n color code min. max. 2 6 0.66--1.40 y ellow with black 4.75 5.56 1 4 6 1 2 1 0 1 d o t 26 0 . 6 6 1 . 4 0 [.026--.055] y e l l o w w i t h b l a c k stripe 4 . 7 5 [.187] 5 . 5 6 [.219] 1--46121--0 1 d ot 24 0.79--1.40 [.031--.055] yellow with blue stripe 24 0.79--1.40 [.031--.055] yellow with blue stripe pidg nylon i n s u l a t i o n 1--47386--0 1 4 7 3 8 6 4 1 d o t 22 0.97--2.79 [.038--.110] redwithgreen stripe i nsu l at i on restricting terminals 1--47386--4 1--525690--0 1 d ot 20 1.17--2.79 [.046--.110] redwithred stripe 6.35 [.250] 7.14 [.281] 18 1.42--2.79 [.056--.110] redwithwhite stripe [ . 2 5 0 ] [ . 2 8 1 ] 1--47387--0 1 4 7 3 8 7 7 2 d o t s 16 1.60--3.30 [.063--.130] blue with blue stripe 1--47387--7 1--525691--0 2 d ots 14 1.98--3.30 [.078--.130] blue with green stripe note: refer to tyco electronics catalog 82042 for product part numbers. figure 2 3. head installation and removal 3.1. head selection the crimping heads are coded to match the terminal and splice insulation color. observe the embossed dots on the insulation of finished crimps to ensure that the correct combination of terminal or splice and head was used. see figure 2. 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. note i danger danger
408- 10029 pidg and plasti- grip terminal and splice crimping heads 3 of 9 rev b tyco electronics corporation 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. terminal 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. center the terminal or splice wire barrel in the appropriate crimp chamber. see figure 3. 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 stripped wire into terminal until the end of the conductor butts against the locator as shown in figure 3. 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. refer to section 5 and figure 6 for crimp inspection. figure 3 pidg and plasti--grip terminals ?c? ?b? ?c? ?b? ?c? ?b? pidg terminal pidg nylon insulation restricting terminal plasti--grip terminal ?b? equals wire barrel ?c? equals insulation barrel terminal tongue positioned under locator locator locator wire barrel against locator 4.2. butt splice 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. position splice between crimping jaws so that the window indent slides under the locator of crimp head. see figure 4a. 3. depress the trigger to advance the moving ram. this closes the crimp jaws to hold the terminal in place. do not deform the wire barrel. 4. insert stripped wire into wire barrel of splice until the end of the conductor is against the splice wire stop. see figure 4a. 5. activate tool to complete the crimp. 6. to crimp the other half of the butt splice, reposition it in the crimping jaws and repeat steps 1 through 5. if the splice cannot be turned, rotate crimping head. see figure 4b. note i danger danger
408- 10029 pidg and plasti- grip terminal and splice crimping heads rev b 4 of 9 tyco electronics corporation 7. refer to section 5 and figure 6 for crimp inspection. figure 4 pidg butt splice ?c? ?b? window indent splice wire stop locator window indent faces indenter and slides under locator window indent on splice slides under locator locator end of conductor butts against splice wire stop end of conductor butts against splice wire stop ?b? equals wire barrel ?c? equals insulation barrel (a) first crimp (b) second crimp 4a 4b 4.3. insulation crimp adjustment a. pidg terminals and splices pidg terminals and splices contain a wire insulation ?grip.? 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. seefigure5. always place both adjustment pins in the same position. see figure 5. 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 or 4.2. 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. figure 5 insulation adjustment pin(s) (ref) positions 11 22 33 b. plasti- grip terminals plasti--grip terminals contain only a wire insulation ?support?. note i note i note i
408- 10029 pidg and plasti- grip terminal and splice crimping heads 5 of 9 rev b tyco electronics corporation the insulation crimping section of the crimping head has three positions: 1?tight; 2?medium; and 3?loose. position 3 is for wire having a large insulation diameter; position 2 is for wire having a medium insulation diameter; and position 1 is for wire having a small insulation diameter. 1. perform insulation crimp adjustment by placing adjustment pins in position 3 (loose), as shown in figure 5. 2. crimp the terminal as described in paragraph 4.1, terminal crimping procedure. 3. remove crimped terminal from crimping jaws and visually inspect the insulation barrel crimp of the terminal. the insulation barrel crimp should be in contact with and should support the wire insulation. if the insulation barrel crimp does not provide ?support? for wire insulation, place adjustment pins in position 2 (medium) and repeat the crimp procedure. 4. repeat adjustment as necessary until desired insulation support is obtained. do not use a tighter setting than required. 5. crimp inspection inspect crimped terminals and splices by checking the features described in figure 6. 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. 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). 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 9. 3. check all bearing surfaces for wear. 4. inspect crimp area for flattened, chipped, or broken areas. replace worn or damaged parts. danger danger
408- 10029 pidg and plasti- grip terminal and splice crimping heads rev b 6 of 9 tyco electronics corporation figure 6 crimp inspection 1 insulation barrel is in firm contact with wire insulation. 2 correct color code, dot code, and tool combination. 3 wire size is within wire range stamped on terminal tongue or splice. 4 crimp centered on wire barrel. 5 end of conductor is flush with, or extends beyond end of terminal wire barrel. 6 end of conductor against wire stop of splice. note : if conductor is not against wire stop, conductor must at least be flush with, or extend slightly beyond wire barrel of splice. 7 wire insulation does not enter wire barrel. 1 wire insulation extruded. (insulation crimp too tight on pidg terminals.) see paragraph 4.3. 2 wrong dot code and color code combination. see chart, figure 2. 3 wire size is not within wire range stamped on terminal tongue or splice. 4 crimp not centered on wire barrel. (terminal was not butted against locator. see figure 3.) 5 end of conductor is not flush with or extending beyond end of wire barrel. (check for correct strip length.) 6 excessive flash or extruded insulation. (wrong tool, terminal, or splice combination used, or damaged dies.) see figure 2. 7 nicked or missing conductor strands. 8 wire not fully inserted or wrong strip length. 9 wire insulation entered wire barrel. check for correct wire size or strip length. wire range stamped under tongue wire stop wire range stamped here wire range stamped under tongue wire range stamped here 3 1 2 5 4 1 2 5 4 3 7 5 1 4 6 4 1 2 2 1 2 6 2 1 3 7 6 8 7 4 5 3 4 5 1 6 2 6 2 1 9 8 2 5 2 1 7 6 8 2 5 2 1 6 3 6 9 8 accept reject pidg and plasti--grip terminals pidg butt splice pidg insulation restricting terminals
408- 10029 pidg and plasti- grip terminal and splice crimping heads 7 of 9 rev b tyco electronics corporation 6.4. lubrication lubricate all pins, pivot points, and bearing surfaces with a high quality grease. tyco electronics recommends the use of molykote s 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 7. tyco electronics does not manufacture or market these gages. go dia no--go dia 50.8 [2.0] min. typ. jaw closure configuration suggested plug gage design wire barrel crimp crimping h e a d jaw closure gage element diameters h e a d c l o s u r e dimensions go no--go 1--47386--0 1--47386--4 1--525690--0 2.769--2.921 [.1090--.1150] 2.769--2.776 [.1090--.1093] 2.918--2.921 [.1149--.1150] 1--47387--0 1--47387--7 1--525691--0 3.023--3.175 [.1190--.1250] 3.023--3.030 [.1190--.1193] 3.172--3.175 [.1249--.1250] 1--46121--0 1.600--1.752 [.0630--.0690] 1.600--1.608 [.0630--.0633] 1.750--1.752 [.0689--.0690] figure 7 (cont?d) s molykote is a trademark. suggested plug gage design insulation crimp go dim. no--go dim. 6.35 [.250] typ. 3.18 [.125] go no go jaw closure configuration crimping h e a d jaw closure gage element diameters h e a d c l o s u r e dimensions go no--go 1--525690--0 0.889--1.397 [.0350--.0550] 0.889--0.897 [.0350--.0353] 1.394--1.397 [.0549--.0550] 1--47386--0 1--47386--4 0.762--1.270 [.0300--.0500] 0.762--0.770 [.0300--.0303] 1.267--1.270 [.0499--.0500] 1--47387--0 1--47387--7 1.016--1.524 [.0400--.0600] 1.016--1.024 [.0400--.0403] 1.521--1.524 [.0599--.0600] 1--46121--0 0.762--1.270 [.0300--.0500] 0.762--0.770] [.0300--.0303] 1.267--1.270 [.0499--.0500] 1--525691--0 1.143--1.651 [.0450--.0650] 1.143--1.151 [.0450--.0453] 1.648--1.651 [.0649--.0650] figure 7 (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 8a. 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 8b. 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- 10029 pidg and plasti- grip terminal and splice crimping heads rev b 8 of 9 tyco electronics corporation 7. replacement and repair replacement parts and recommended spares are listed in figure 9. 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. 8. revision summary s updated document to corporate requirements figure 8 detail a inspection of wire barrel crimping section detail b inspection of insulation crimping section wire barrel jaws bottomed but not under pressure go element must pass completely through the crimping chamber no--go element may enter partially, but must not pass through the crimping chamber adjustment pins in position 1 (ref) insulation jaws bottomed but not under pressure
408- 10029 pidg and plasti- grip terminal and splice crimping heads 9 of 9 rev b tyco electronics corporation 1 5 2 3 4 customer replacement parts part number for crimping head item no. 1--47387--0 1--47386--0 1--46121--0 1--47386--4 1--47387--7 1--525690--0 1--525691--0 description qty per head 1 45965--6 302993 3--304052--6 525355--8 locator 1 2 9--305927--1 9--305927--1 3--306105--9 9--305927--1 screw, 8--32 x 8.38 [.330] 1 3 302994 302994 302994 302994--1 housing, stop 1 4 301201 301201 301201 301201 spring, compression 1 5 39207 39207 39207 39207 pin, adjustment 2 figure 9
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