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408-9736
12-10
AWG
Wire
4. CRIMPING TERMINALS AND SPLICES
DANGER
AVOID PERSONAL INJURY! Keep fingers clear of
crimp area. Be careful to keep body parts and other
STOP
objects away from trigger until ready to cycle tool.
1. Pre-strip wires to the dimensions in Figure 2.
2. Place terminal or splice in crimping area of die
head assembly as shown in Figure 4.
3. Insert stripped wire into terminal or splice so that
the wire butts against the wire stop. (If properly
stripped, wire insulation will not enter the product
wire barrel.)
Links
Mounting Lugs
Assembly Pins
8.74 [.344]
9.53 [.375]
Wire Strip
Length (Typ)
Insulation
Barrel
Wire
Barrel
STRATO-THERM
Terminal
NOTE:
Not to Scale
Figure 2
STRATO-THERM
Splice
A wire stop prevents the insulation from entering the
product wire barrel, and also acts as a guard to
prevent injury to fingers. A stop bracket attached to the
stop provides support beneath the product during
crimping. Figure 2 shows typical product and required
wire strip length.
The head assembly can be operated by either tool
listed in Section 1, INTRODUCTION. Although there
are differences in tools, basic operation and
maintenance are similar and are covered in 408-1310.
Be sure to read these (or other) related instructions,
paying special attention to precautions and air
pressure specifications.
Insert Toggle Lever
into Tool
Toggle Arm
Rotated Forward
Assemble Head with
Tool Power Disconnected
Figure 3
3. INSTALLING THE HEAD ASSEMBLY
(Figure 3)
DANGER
AVOID PERSONAL INJURY! Disconnect the
pneumatic tool from its air supply before installing
STOP
the head assembly.
1. Remove assembly pins from mounting lugs.
2. Using your finger, rotate the top end of the toggle
arm toward the front of the tool as far as it will go.
3. Insert toggle lever of head assembly into toggle
arm of tool until it snaps into place. (Links of head
assembly will go to the inside of the tool mounting
lugs.)
4. Insert assembly pins; make sure pins go the
whole way through the entire tool and snap into
place.
To disassemble: remove pins, lower head assembly
away from mounting lugs, rotate head assembly 90_,
and remove from toggle arm.
4. Cycle head assembly. Press tool trigger and hold
it down until crimping stroke is complete, then
release trigger.
5. Remove crimped product; for splices, repeat
steps 2 through 4 for the other end.
6. Inspect crimps for items shown in Figure 5 and
pull lightly on wire to be sure insulation crimp will
hold. Reject all nonconforming crimps.
Rev
B
2
of 4
408-9736
Insert Wire Fully
Wire Barrel
Against Locator
Splice
Crimping
(Ref)
Terminal Ring or
Remainder of Splice
on Stop Bracket
Figure 4
5.1. Daily Maintenance
Wire Barrel
Crimp Centered
(Typ)
Insulation
Held Firmly,
No Insulation
in Wire Barrel
(Typ)
Conductor Flush to, or
Beyond End of,
Wire Barrel
At the close of each shift, the responsible operator
should clean foreign particles from the tool using a
soft, clean, lint-free cloth or brush. Make sure all pins
and rings are in place, and that the crimp components
are undamaged. Lightly lubricate all pins, pivot points,
and bearing surfaces using a good grade SAE 20
motor oil. Do not lubricate excessively.
CAUTION
DO NOT lubricate the surfaces of the crimp
components that contact the product. These areas
must be kept clean to prevent product slippage
!
during crimping.
5.2. Periodic Inspection
We recommend that the following inspections be
conducted at least once a month by quality control
personnel. More frequent inspections should be
conducted if your work environment, company
standards, or amount of tool use indicates the need.
A. Visual Inspection
Conductor Ideally
Against Wire Stop
Figure 5
With the head assembly removed from the tool,
remove all lubrication and accumulated film by
immersing the head in a mild commercial degreaser.
Then:
1. Check for missing or defective pins or retaining
rings. Replace parts as necessary. See Section 6,
REPLACEMENT AND REPAIR.
2. Closely inspect dies for damage, giving special
attention to bearing surfaces and surfaces that
contact the product.
5. MAINTAINING THE HEAD ASSEMBLY
Inspect the head assembly when you receive it and at
regular intervals. When not in use, store it in a clean,
dry area.
Rev
B
3
of 4
408-9736
Suggested Plug Gage Design
(Wire Barrel Crimp Area)
2.31 [.091]
“GO” Dimension
2.46 [.097]
“NO-GO” Dimension
2.36 [.093]
Radius (Typ)
6.35 [.25] Minimum (Typ)
Die Closure
25.4 [1.00]
Minimum (Typ)
Die Opening
(Ref)
Figure 6
Worn, cracked, pitted, or chipped die surfaces, or
other obvious wear or damage to the head
assembly requires removal from service. Return the
entire assembly for evaluation and repair. See
Section 6, REPLACEMENT AND REPAIR.
4. Align the NO-GO element and try to insert it
straight into the die opening. The NO-GO element
may begin entry, but must not pass through the
opening.
If die closure gaging shows that dies conform to
dimensions, lubricate them with a thin coat of any
good SAE 20 motor oil. If not, replace the dies.
For additional information regarding the use of plug
gages, see instruction sheet 408-7424.
B. Gaging the Die Closure
(Figure 6)
The die head assembly is inspected and tested for
correct closure dimensions before being shipped.
However, we recommend periodic die closure
measurement to ensure uniform performance over the
life of the head assembly.
Figure 6 shows dimensions for manufacture of a plug
gage for inspecting the closure of the wire barrel dies.
If the wire barrel dies close properly, and the
adjustment pin is set properly for the size wire
insulation you are using, the insulation barrel dies
should also close properly. So, there is no need for a
plug gage to measure the insulation barrel die closure.
Perform the inspection as follows:
1. Remove head assembly from tool as described
in the disassembly paragraph in Section 3,
INSTALLING THE HEAD ASSEMBLY. Then wipe
oil, film, and debris from the crimping area and
plug gage.
2. Hold the dies in the closed position, but DO NOT
apply pressure beyond initial contact.
3. Align the plug gage GO element with the die
opening. Push the element straight into the
opening, but without forcing it. The GO element
must pass completely through the opening.
6. REPLACEMENT AND REPAIR
Customer-replaceable parts are shown in Figure 1. A
complete inventory should be stocked and controlled
to prevent lost time when replacement of parts is
necessary. Order replacement parts through your field
representative, or call 1-800-526-5142, or send a
facsimile of your purchase order to 717-986-7605 or
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