Service Of Machined Terminals And Service of Stamped and Formed Terminals{7553} Caterpillar

Caterpillar Products: All

Introduction

Illustration 1	g01319349
Stamped and formed terminal

Illustration 2	g01319351
Machined terminal

Terminals that are used on common multiway connectors may be Stamped and Formed Terminals as in Illustration 1 or Machined Terminals as in Illustration 2. While the Stamped and Formed Terminals are used extensively in the production of harnesses, service personnel often prefer the Machined Terminals due to the relative ease of extraction. The merits of each type of terminal are outlined in this article, as well as recommendations for servicing.

Stamped and Formed Terminals are manufactured on large reels by taking a copper alloy strip through a progressive stamping die. This process forms the final shape of the terminal. The shape can be a pin or a socket. Typically, the terminals are supplied in strips. Stamped and Formed Terminals can be terminated by using one of the following processes: semi-automatic tooling process and automated tooling process.

A Machined Terminal, sometimes called a solid terminal, is machined from a length of solid copper alloy. The Machined Terminals are supplied as loose pieces. Machined Terminals are terminated onto a wire by using a manual process or a semi-automated process.

The Stamped and Formed Terminals and the Machined Terminal have a hood added to the socket in order to protect the spring contacts from damage if a pin is about to be inserted off-center. The gold plated contacts may be used in order to prevent oxidation. Additionally, gold plated contacts provide better durability under high vibration.

Machined Terminals do not have an insulation crimp. Stamped and Formed Terminals can be supplied with an insulation crimp or without an insulation crimp. An insulation crimp is not essential on 18 AWG cables and larger since there is sufficient cable retention from the wire.

Performance

Automated crimping of Stamped and Formed Terminals terminals can provide consistently high quality crimps. This is especially true if a Crimp Quality Monitor (CQM) is used in harness production. The Crimp Quality Monitor (CQM) is not available for Machined Terminals.

Stamped and Formed Terminals have better temperature performance than Machined Terminals at the end of temperature life testing.

Stamped and Formed Sockets have significantly better wear and vibration performance than Machined Sockets. Stamped and Formed Terminals are preferred for harness production due to the consistent quality of the crimp. In instances of high vibration, gold plated terminals are typically used.

Removal

Extracting the Stamped and Formed Terminals can be difficult. This is caused primarily when the removal tool does not slide over the insulation crimp. Instead, the removal tool snags on the insulation crimp if the insulation crimp is not flush with the surface of the insulation.

Deutsch Stamped and Formed Terminals have an insulation crimp. Machined Terminals and Tyco Stamped and Formed Terminals do not have an insulation crimp. Therefore, the removal of these types of terminals is much easier.

Low quality insulation crimps can result in the cutting of a connector wire seal by a protruding insulation crimp during insertion or withdrawal. Manufacturing a flush insulation crimp has been difficult to achieve for manufacturers of harnesses consistently. Terminals without insulation crimps will not damage the wire seals.

Refer to Step 1 through Step 3 for removing the wire and the terminals. Refer to Table 1 for the part number for the removal tool.

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Illustration 3	g01319536

1. With the rear insert pointing toward you, snap the appropriate size extractor tool over the wire of the contact that is to be removed.

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Illustration 4	g01319539

2. Slide the tool into the insert cavity until the tool engages contact, and resistance is felt.

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Illustration 5	g01319542

3. Pull the contact and the wire assembly out of connector.

Illustration 6	g01319570
Broken connector retention fingers

Illustration 7	g01319577
Broken removal tool

Note: Do not twist the removal tool when Stamped and Formed Terminals are difficult to remove. This can damage the removal tool as well as the retention fingers that are located inside the connector. Refer to Illustration 6 and Illustration 7. This damage is not readily noticeable. Additionally, this damage can severely limit the performance of the connector.

Note: Do not force the removal tool into the connector. Instead remove the tool and rotate the opening 45°. Then, insert the tool again. This process may need to be repeated several times in order to find the best alignment between the service tool and insulation crimp.

Note: Do not use a damaged service tool. It is likely that this will not properly release the contact from the connector. Additionally, a damaged service tool may damage the connector in the process.

Note: Only use the recommended size and the recommended type of service tool. A service tool that is not sized correctly will damage the connector. A service tool that is not designed for this procedure will damage the connector. If the connector is damaged, the tool will not release the terminal from the connector.

Crimping

There is no simple service tool that is available to crimp Stamped and Formed Terminals for servicing that is easy to use. Therefore, solid contacts can be used easily for service, since solid contacts are compatible for use with the standard Caterpillar manual service crimp tool. If a Stamped and Formed Terminals is damaged, a solid contact must be used for repair, in order to ensure a high quality crimp. Nickel terminals may be used for repair only when a nickel terminal has failed. Gold terminals may be used for all repairs. Refer to Table 1 for part numbers.