8. splicing instructions - talurit...8. splicing instructions for swage terminals talurit tm...

8. Splicing inStructionSfor Swage terminalS

TALURIT TM

Splicing Instructions

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following Swage terminalS are intended for uSe on Steel wire ropeS made from carbon Steel:

• STTE(Eye)• STTF(Fork)• STTT(Threadedswageterminal)• STTT-R(Reinforcedthreadedswageterminal)• Taluswage(Eye)

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)

1/4 5,8 6,7 1/4 11,2

+0,40

10,7

+0,40

118 127 111 1 000

5/163/8

6,88,4

8,310,0

3/8 17,517,5

16,616,6

149149

169169

162171

2 000

7/161/2

10,111,8

11,713,3

1/2 22,422,4

21,321,3

189189

211211

204222

3 000

9/165/8

13,415,1

15,016,7

5/8 28,428,4

+0,50

27,027,0

+0,50

239239

259259

273286 4 000

3/4 16,8 19,8 3/4 35,1 33,4 283 316 333 5 000

7/8 19,9 23,3 7/8 38,1 36,3 331 369 366 7 000

1 23,4 26,6 1 44,5

+0,70

42,4

+0,70

375 423 426 8 500

11/8 26,7 29,8 11/8 50,8 48,4 417 474 486 10 000

11/4 29,9 33,3 11/4 57,2 54,5 471 526 546 13 000

13/8 33,4 36,5 13/8 63,5 60,5 515 575 615 14 000

11/2 36,6 39,7 11/2 69,9 66,6 556 630 648 15 000

13/4 39,8 46,7 13/4 76,2 72,6 655 734 750 16 000

2 46,8 53,2 2 88,9

+0,90

84,7

+0,90

750 850 852 17 000

21/4 54,0 59,4 21/4 101,2 96,4 814 893 954 20 000

21/2 60,0 66,7 21/2 111,4 106,1 850 939 1014 24 000

3 72,0 80,0 3 134,0 127,6 1031 1117 1188 28 000

TALURIT TM



aSSembly of wire rope in Swage terminalS: type Stte, Sttf

only valid for assembly of rotation resistant wire rope of high grade!

1. Cutthewireropewithadiscbetweentwo narrow tightened hose clamps.

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.

6. Reducethepressurewiththepressureregulatingvalvenottooverloaddies.

8.2 aSSembly of Swage terminalS

4

5

!warning

6

1

H

Dia

met

er 2

3

TALURIT TM



Swaging inStructionS:round Shape after Swaging

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

Still unable to cloSe dieS?

DiesOil

Dies

Dies

Dies

2-3 mm

1

Oil

Dies

2

3

4

2

TALURIT TM



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.

!Alwaysusethecustommadeshorterdiesformulti-stageswaging.Iflargerdiesforsinglestageswagingareused,thedieswillbesubjectedtounevenloadandthereisariskofseveredamagetothedies/swager.

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.

5. fifth step: Lubricate.Rotatetheterminal90degreesfrompositioninthethirdstep.Applyoilonthelowerdie.Usethepressureregulatingvalvetoclosethedies.Stopwhentheoilispressedout.

6. Sixth step: Open the dies. Lubricate and place the second half of the terminalinthedie.Applyoilonthelowerdie.Usethepressureregulatingvalvetoclosethedies.Stopwhentheoilispressedout.

7. Openthedies.Lubricateandrepeatstepthreetosix.Repeatupto10timestoachieveasmoothsurface.

8. Checkthediameter/lengthafterswaging.

1

8.4 multi- Stage Swaging Swage terminalS- round Shape

Dies

Dies

1-3 mm

Dies

Dies

1-3 mm

Dies

Dies

Dies

Dies

Dies

Dies

repeat Step three to Six!

Dies

Dies

check the diameter/length

after Swaging.

2

3 4

4 5

6 7

8

TALURIT TM



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

2

2

3

4

TALURIT TM



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.

7. Openthedies.Lubricateandrepeatstepthreetosix.Repeatupto10timestoachieveasmoothsurface.

8. Checkthediameter/lengthafterswaging.

8.6 multi-Stage Swaging Swage terminalS-hex Shape

Dies

Dies

2-3 MM

Dies

Dies

2-3 MM

Dies

Dies

Dies

Dies

Dies

Dies

repeat Step three to Six!

Dies

Dies

check the diameter/length

after Swaging.

1 2

3 4

4 5

6 7

8

TALURIT TM



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.

Theswagedterminalshallbelegiblyandindeliblymarkedwiththeswagedterminalmanufacturer’sname,symbolormarkandtraceabilitycodeidentifyingtheassemblywithacertificate.

Thecertificateshallincludeatleastthefollowinginforma-tion:

-nameandaddressoftheswagedterminalmanufacturerand,ifappropriate,hisauthorizedrespresentative,includ-ingthedateofissueofthecertificateandauthentication;

-numberandrelevantpartoftheEuropeanStandard

-descriptionoftheassembly;and

-traceablilitycodeaspermarking

8.7 checking and marking after Swaging

TALURIT TM



8.8 uSage and Scrapping

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.

TALURIT TM



8. splicing instructions - talurit...8. splicing instructions for swage terminals talurit tm...

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