This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Selecting the correct Size of Swage terminal:The correct size of swage terminal is selected from the applicabletableforeachtypeofswageterminals.Noteap-plicableropetypesineachtable.Allourswageterminalscomplywiththisqualityspecificationandtoothermate-rialspecificationsstatedintherulingstandards.
Selecting the correct size of swage terminal is based on the following criteria: The rope grade, the diameter of the wirerope,thefillfactorormetalliccross-sectionalareafactor,thewireropecorei.e.fibrecore(FC)orsteelcore(IWRC=independentwireropecore).
8.1 Selection table of Swage terminalS
STTE Terminal STTF Terminal
Example of swage terminal selecting chart
Taluswage terminal with hex shape
STTT Terminal
STTT -R Terminal
WireRopeCapacity
Diameter(mm)
DieIdentification
PartNo. Fill Factor(f=0,62-0,78)
Dies marked
Diameter after
swaging
Keywidthafter swaging
Total length after swaging
approx.
Requiredpressureapprox.
STTE STTF STTTand
STTT-R
STTE STTFSTTTSTTT-R
Min Max STT (mm)/Tol. (mm)/Tol. (mm) (mm) (mm) (kN)
2. Measure the largest diameter of the wire rope and choose terminal in the table. Find the insertion length, H, in the table. Markthewireropewiththeinsertionlength,H.
3.Insertthewireropeintheterminal.Thenloosenthehoseclampslightly.Hammer the terminal into position witharubbermallet.Themarkshowswhenit’sfullyentered.
4. Tighten the hose clamp approximately3-5cmfromtheterminal.Keep the hose clamp on the wire rope during the entire swaging operation. Removeitafterwards.
5. Lubricatetheboreofbothdies.Applyoil on the edge of the lower die, for oil drop test.
1. first step: Usethepressureregulatingvalveandswageuntilthedistance2-3mmbetweenthe dies remains.
2. Second step: Open dies and lubricate. Rotate90°.Closethediesusingthepressureregulatingvalve.Stopswagingwhenappliedoilispressedout,thenthediesarecompletelyclosed(oildroptest).Ifflashmaterialappears,removeitthoroughlywithagrinder. Proceed with third step.
3. third step:Opendiesandrotate90°clockwisefrompositioninsecondstepandclosedies.Repeatprocedureinsecondandthird step until the surface is smooth. Up to 10 swaging operationscanbenecessary.Checkthe diameter after swaging.
4. Swage the terminals in a larger swager or usemulti-stageswaging.(Seenextpage)
8.3 Swaging inStructionS for Swage terminalS - round Shape
multi-Stage Swaging inStructionS:round Shape after Swaging
Always start with the assembly procedure as per page 1. If the machine capac-ity is not enough to close the dies, the multi-stage method with the custom made, shorter dies can be used.
1. first step: Lubricate.Placethefirsthalfoftheterminalinthedie.Swageuntilapprox.1-3mmremainsbetweenthedies,dependingonsize.NOTE!Startswagingprocessontheropeside.
2. Second step: Open the dies. Lubricate and then place the unswaged halfoftheterminalbetweenthedies.Swageuntilapprox.1-3mmre-mains between the dies.
3. third step: Open the dies and rotate the terminal 90 degrees. Lubri-cate.Placetherotatedterminalinthesamepositionasinthefirststep.Applyoilonthelowerdie.Usethepressureregulatingvalvetoclosethedies. Stop when the oil is pressed out.
4. fourth step: Open the dies. Lubricate and place the terminal in the samepositionasinthesecondstep.Applyoilonthelowerdie.Usethepressureregulatingvalvetoclosethedies.Stopwhentheoilispressedout.Ifflashmaterialappears,removeitthoroughlywithagrinder.
6. Sixth step: Open the dies. Lubricate and place the second half of the terminalinthedie.Applyoilonthelowerdie.Usethepressureregulatingvalvetoclosethedies.Stopwhentheoilispressedout.
Swaging inStructionS:hexagonal Shape after Swaging
1. first step: Usethepressureregulatingvalveandswageuntilthedistance2-3mmbetweenthe dies remains.
2. Second step: Open dies and lubricate. Rotate60°clockwise.Closethediesusingthepressureregulatingvalve.Stopswagingwhenappliedoilispressedout,thenthediesarecompletelyclosed(oildroptest).Ifflashmaterialappears,removeitthoroughlywithagrinder,ifnecessary.Proceedwiththirdstep.
3. third step: Opendiesandrotate120°counterclockwisefrompositionin second step and close dies. Then repeat procedure in second and third step until the surface is smooth. Up to 10 swagingoperationscanbenecessary.Checkthediameterafter swaging.
4. Unable to close dies? Swage the terminals in a larger swagerorusemulti-stageswaging.(Seenextpage)
1
Still unable to cloSe dieS?
Dies Oil
Dies
Dies
Dies Oil
Dies
Dies
2-3 mm
8.5 Swaging inStructionS for Swage terminalS- hex Shape
multi Stage Swaging inStructionS: hexagonal Shape after SwagingAlways start with the assembly procedure as per page 1. If the machine capac-ity is not enough to close the dies, the multi-stage method with the shorter dies can be used.
!Alwaysusetheshorterdiesformulti-stageswaging.Iflarger dies for single stage swaging are used, the dies willbesubjectedtounevenloadandthereisariskofseveredamagetothedies/swager.
1. first step:Lubricate.Placethefirsthalfoftheterminalinthedie.Swageuntilapprox.1-3mmremainsbetweenthedies.
2. Second step: Open the dies. Lubricate and then place the unswaged halfoftheterminalbetweenthedies.Swageuntilapprox.1-3mmremainsbetween the dies.
3. third step: Open the dies and rotate the terminal 60 degrees. Lubricate. Placetherotatedterminalinthesamepositionasinthefirststep.Applyoilonthelowerdie.Usethepressureregulatingvalvetoclosethedies.Stopwhen the oil is pressed out.
4. fourth step: Open the dies. Lubricate and place the terminal in the samepositionasinthesecondstep.Applyoilonthelowerdie.Usethepressureregulatingvalvetoclosethedies.Stopwhentheoilispressedout.Ifflashmaterialappears,removeitthoroughlywithagrinder.
5. fifth step:Lubricate.Rotatetheterminal120degreescounterclockwisefrompositioninthethirdstep.Applyoilonthelowerdie.Usethepressureregulatingvalvetoclosethedies.Stopwhentheoil is pressed out.
6. Sixth step: Open the dies. Lubricate and place the second half of the terminalinthedie.Applyoilonthelowerdie.Usethepressureregulatingvalvetoclosethedies.Stopwhentheoilispressedout.
check the condition of the Swaged terminalCheckthattheterminalhasbeenproperlyswagedandthe wire rope is correct in alignment. Each terminal shall bevisuallyexamined,freefromflawsanddefectsandshallnotexhibitanysharpedgesorroughsurfaces.
check the diameter after SwagingAteachset-uptheswagedterminalshallbedimension-allycheckedtoverifythatitiswithinthediameterand,whenapplicable,lengthlimitsspecifiedinthetablesforterminals.Eachswagedterminalaftertheset-upshallbecheckedfordiametertoverifythatitiswithinthediam-eter limits.
marking of terminal after SwagingMarkingofswagedterminalsshouldbecarriedoutac-cording to ruling standards.
non Suitable environmentSTerminals made from stainless steel or carbon steel shall not be exposed to temperatures outside the range:-40°Cto100°C(IWRC).
check for deformation and check diameterTerminationsshallbetakenoutofuseiftheterminalshavebeenexposedtodeformationorwhentheouterdi-ameter has been reduced to less than 95% of the original diameter.