Instruction Sheet  Straight Action Die Set Assembly 1490777-2 408-8608 † 18 OCT 11 Rev A for FAKRA Connectors Tool Holder Assembly 189928-1 (Ref) Straight Action Crimp Head Adapter 217201-1 Straight Action Die Set Assembly 1490777-2 Quick Pins (Ref) Quick Release Pins Matched Die Set 1490772-1 Guard 1490778-1 Figure 1 Refer to the appropriate catalog for a wire-to-contact 1. INTRODUCTION selection guide. Contact your TE Connectivity Straight Action Die Set Assembly 1490777-2, shown representative for information concerning wire sizes in Figure 1, consists of Straight Action Crimp Head and contacts not referenced in the catalog. Adapter 217201-1, Matched Die Set 1490772-1, and the Tool Guard 1490778-1. Straight Action Die Set Dimensions on this sheet are in metric units [with NOTE Assembly 1490777-2 was designed to be used with U.S. customary equivalents in brackets], unless 626 Pneumatic Tooling Assemblies to crimp the center otherwise indicated. i contact of FAKRAV connectors to coaxial cable. For information concerning the setup and operation of the 626 pneumatic tools, refer to Customer Manual 409- 2. DESCRIPTION 5862. Information on FAKRA product can be found in Die Set Assembly 1490777-2 consists of the crimp Application Specification 114-13064. head adapter (217201-1), the matched die set For detailed information concerning Straight Action (1490772-1), and the guard (1490778-1) used to cover Crimp Head Adapter 217201-1, refer to Instruction the die set. Sheet 408-4106. Each die set features a head with a crimper (fixed die) This die set assembly was designed for use with and an anvil (movable die). There are two crimp nests NOTE 626 Pneumatic Tooling Assemblies. Note that for two wire sizes. Straight Action Die Set Assembly 1490777-1 is a i straight action hand tool assembly (containing Hand Tool Frame 127038-1) for crimping the center † DIN Standardization Committee of Motor Vehicles (FAKRA) 70010 contacts of FAKRA connectors. © 2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. 1 of 3 All Rights Reserved PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, *Trademark visit our website at www.te.com LOC B TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners. 408-8608 3. INSTALLATION OF STRAIGHT ACTION DIE SET 4. Insert the wire with the end contact into the crimp ASSEMBLY (Figure 1) nest for that size wire until the center contact is in the contact support plate. Before installing the straight action die set assembly, refer to Customer Manual 409-5862 for instructions on 5. Slide the contact down into the support plate until installing the appropriate tool holder assembly it is supported and cannot fall out. (including cam) on the pneumatic tool. After the Do NOT allow the wire center conductor to slip out CAUTION appropriate tool holder assembly has been installed, of the center contact. proceed as follows:  ! To prevent personal injury, ALWAYS disconnect the DANGER main air supply and electrical supply (if applicable) 6. Perform the crimping procedure as described in STOP of the pneumatic tool before installing or removing Customer Manual 409-5862, packaged with 626 the straight action crimper.  Pneumatic Tool. DO NOT operate pneumatic tool without the Make certain all surfaces of the dies are protected  DANGER straight action crimper and the proper die assembly with a THIN coat of any good SAE 20 motor oil. Do STOP installed. After straight action crimper is installed, NOT oil excessively. make sure that the quick pins are FULLY tightened to avoid personal injury and damage to the tool. 5. MAINTENANCE AND INSPECTION To avoid personal injury, ALWAYS disconnect air 1. Remove quick pins from tool holder assembly. DANGER supply from pneumatic tool before performing 2. Slide the straight action crimp head adapter and STOP maintenance or inspection. die set assembly into tool holder assembly. 3. Install the guard over the adapter and die set It is recommended that a maintenance and inspection assembly, aligning the holes on the guard with the program be performed periodically to ensure threaded quick pin holes on the holder. dependable and uniform terminations. 4. After the adapter, die set, and guard are properly Frequency of inspection should be adjusted to suit aligned in the tool holder assembly, insert and your requirements. Frequency of inspection depends tighten the shoulder bolts supplied with the die  on: set assembly. • The care, amount of use, and handling of the Do NOT overtighten the shoulder bolts. CAUTION crimping head.  • The type and size of the product crimped.  ! • The degree of operator skill. It is recommended that Loctite‡ No. 242 removable NOTE • The presence of abnormal amounts of dust  threadlock, or equivalent, be used to prevent the and dirt. guard shoulder bolts from loosening. i • Your own established standards. Removal is the reverse of installation. NOTE Each die set assembly is thoroughly inspected before  packaging. Since there is a possibility of damage  i during shipment, new die assemblies should be inspected immediately upon arrival at your facility. 4. CRIMPING PROCEDURE 5.1. Daily Maintenance Refer to the product catalog to determine the wire It is recommended that each operator of the dies be size, FAKRA connector, and wire size to be used with made aware of - and responsible for - the following the die set. three steps of daily maintenance: 1. Strip the wire to the length indicated in 1. Remove dust, dirt, and other contaminants with  Application Specification 114-13064 - do NOT cut or a clean brush, or a soft, lint-free cloth. Do NOT use nick the wire strands. objects that could damage the dies. 2. Install the die set assembly as described in 2. Make certain the dies are protected with a  Section 3, INSTALLATION OF STRAIGHT ACTION THIN coat of any good SAE 20 motor oil. Do NOT DIE SET ASSEMBLY. oil excessively. 3. Place the appropriate center contact (pin  3. When the dies are not in use, mate them and or socket) on the center conductor of the store in a clean, dry area. prestripped wire. ‡ Trademark of Loctite Corporation Rev A 2 of 3 408-8608 5.2. Periodic Inspection Proceed as follows: Regular inspections should be performed by quality 1. Select a contact and a wire size for the  control personnel. A record of scheduled inspections crimping chamber. should remain with the dies and/or be supplied to Refer to Section 4, CRIMPING PROCEDURE, and supervisory personnel responsible for the dies. crimp the contact accordingly. Though recommendations call for at least one inspection a month, the inspection frequency should Using a crimp height comparator, measure crimp be based on the amount of use, ambient working height as shown in Figure 2. If the crimp height conditions, operator training and skill, and established conforms to that marked on the tool, the tool is company standards. These inspections should be considered dimensionally correct. If not, return the tool performed in the following sequence: to TE for evaluation and repair (refer to Section 6). A. Visual Inspection Refer to Application Specification 114-13064 for NOTE crimp conformity information. 1. Remove all lubrication and accumulated film by  immersing the dies in a suitable commercial i degreaser that will not affect paint or plastic material. Position Point 2. Make sure all die holding screws, retaining rings, on Center of and die components are in place. Refer to the Wire Barrel Wire Barrel drawings shipped with the tool if replacement parts Opposite Seam Crimp Height are required. 3. Check components for wear. Remove and replace worn components. 4. Inspect the crimp area for flattened, chipped, Modified cracked, worn, or broken areas. If damage is Anvil evident, the dies must be repaired before returning them to service (see Section 6, REPLACEMENT Figure 2 AND REPAIR). B. Crimp Height Inspection (Figure 2) 6. REPLACEMENT AND REPAIR This inspection requires the use of micrometer with a Parts should be replaced by TE to ensure quality and modified anvil as shown in Figure 2. reliability of the tool. Order replacement parts through your TE representative, or call 1-800-526-5142, or Crimp height inspection is performed through the send a facsimile of your purchase order to  use of a micrometer with a modified anvil, 1-717-986-7605, or write to: commonly referred to as a crimp height comparator.  TE does not market crimp height comparators. CUSTOMER SERVICE (038-035) Refer to Instruction Sheet 408-7424 for detailed TYCO ELECTRONICS CORPORATION information on obtaining and using a crimp height PO BOX 3608 comparator. HARRISBURG PA 17105-3608 Crimp Height Comparator 3-576692-6 is Tools may also be returned for evaluation. For tool recommended in Great Britain; Crimp Height evaluation/repair service, contact a TE representative Comparator 675836-0 and -1 are recommended  at: 1-800-526-5136, or reference the appropriate in Germany. website below: • toolrepair@tycoelectronics.com Part Number Description Manufacturer Ref Number • asia.tool@tycoelectronics.com Digital Readout 3-576692-6 Imperial/Metric 342-431-30 • jp_tool@tycoelectronics.com 0-1in./0-25.4mm Mitutoyo Corp, • uktoolingservicecentre@tycoelectronics.com 675836-0, -1 Japan Mech Readout 675836-0, -1 112-401 7. REVISION SUMMARY Metric 0-25mm Since the previous version of this document, the following changes were made: • Updated crimp height comparator sourcing information in Paragraph 5.2.B. • Updated document to corporate requirements. Rev A 3 of 3