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