Instruction Sheet CrimpingDieAssemblies224027-1and -2 forUsewith626Pneumatic 408--4153 ToolingAssemblies 21 Mar 11 RevB Die Holding Screw Wire and Receptacle Size Identification Marked in This Approximate Area Wire Barrel ~ Moving Die (Indenter) Terminal Loaded This Side Stationary Die (Anvil) NOTE: Not to Scale. Wire Strip Length: 7.94 [.313] NOTE: Use Wire With Stranded Conductors Only. PARTNUMBERS WIRE TERMINAL SIZE HOUSING TERMINALS CRIMPING (AWG) COLOR DIEASSEMBLY STRIP LOOSE--PIECE 224027--1 10 4--520447--2 4--520448--2 Yellow 224027--2 12 4--520447--2 4--520448--2 Yellow Figure 1 packaged with the pneumatic tool, for information 1. INTRODUCTION concerning die assembly installation and general This instruction sheet covers the use of Crimping Die performance of the pneumatic tool. Assemblies 224027--1 and --2 which are designed for Reasons for reissue are provided in Section 7, use in 626 Pneumatic Tooling Assemblies to crimp REVISION SUMMARY. the Ultra--Fast Fully Insulated FASTON* receptacle terminals listed in Figure 1. 2. DESCRIPTION All dimensions on this instruction sheet are in NOTE Each die assembly consists of a stationary die (anvil) metric units [with U.S. customary units in and a moving die indenter. The stationary die features brackets]. i a die holding screw, applicable wire size markings, and the part number of the die assembly. The moving This die assembly requires Adapter Holder NOTE die features a die holding screw, the part number of 189928--1 and Straight Action Crimper 217200--1 the die assembly, and “Ultra--Fast” marking for the to operate in the 626 Pneumatic Tooling System. type of terminal it is designed to crimp. i This sheet also covers terminal and wire A terminal locator/stop (locator) is an integral part of specifications, maintenance and inspection each die assembly. The locator is designed to serve procedures, and general performance of the crimping as a terminal stop, positioning the terminal properly die assemblies. Read customer manual 409--5862, between the dies for crimping. E2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company TOOLING ASSISTANCE CENTER 1--800--722--1111 This controlled document is subject to change. 1 of 4 All Rights Reserved PRODUCT INFORMATION 1--800--522--6752 For latest revision and Regional Customer Service, visit our website at www.te.com TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. LOCB *Trademark. Other logos, product and/or Company names may be trademarks of their respective owners. 408-4153 3. INSTALLATIONANDREMOVALOFSTRAIGHT 5. MAINTENANCEANDINSPECTION ACTIONCRIMPER (Figure 1) To avoid personal injury, ALWAYS disconnect air DANGER supply from pneumatic tool before performing Before installing the straight action crimper, refer to maintenance or inspection. customer manual 409--5862 for instructions on installing the appropriate tool holder assembly (including cam) on the pneumatic tool. After the TE recommends that a maintenance and inspection appropriate tool holder assembly has been installed, program be performed periodically to ensure proceed as follows: dependable and uniform terminations. Frequency of inspection should be adjusted to suit Removal is the reverse of installation. NOTE your requirements through experience. Frequency of inspection depends on: i 1. The care, amount of use, and handling of the crimping head. To prevent personal injury, ALWAYS disconnect DANGER the main air supply and electrical supply (if 2. The type and size of the product crimped. applicable) of the pneumatic tool before installing 3. The degree of operator skill. or removing the straight action crimper. 4. The presence of abnormal amounts of dust and dirt. DO NOT operate pneumatic tool without the DANGER straight action crimper and the proper die 5. Your own established standards. assembly installed. After straight action crimper is Each die assembly is thoroughly inspected before installed, make sure that the quick pins are packaging. Since there is a possibility of damage FULLY tightened to avoid personal injury and during shipment, new die assemblies should be damage to the tool. inspected immediately upon arrival at your facility. 1. Remove quick pins from tool holder assembly. 5.1. DailyMaintenance Refer to Figure 1, a typical instruction sheet It is recommended that each operator of the dies be 408--4105. made aware of — and responsible for — the following 2. Slide the straight action crimper into tool holder three steps of daily maintenance: assembly, aligning the threaded holes on the 1. Remove dust, dirt, and other contaminants with crimper with the threaded quick pin holes on the a clean brush, or a soft, lint--free cloth. Do NOT holder. use objects that could damage the dies. 3. After crimper is properly aligned in the tool 2. Make certain the dies are protected with a THIN holder assembly, insert and tighten the quick pins. coat of any good SAE 20 motor oil. Do NOT oil excessively. TE Connectivity recommends using NOTE 3. When the dies are not in use, mate them and Loctite{ No. 242 removable threadlock, or store in a clean, dry area. equivalent, to prevent the quick pins from i loosening. 5.2. PeriodicInspection Regular inspections should be performed by quality control personnel. A record of scheduled inspections 4. CRIMPING PROCEDURES should remain with the dies and/or be supplied to supervisory personnel responsible for the dies. Refer to the table in Figure 1 and check the selected Though recommendations call for at least one wire, loose--piece terminal, and crimping die assembly inspection a month, the inspection frequency should for compatibility. Strip the wire to the length indicated be based on the amount of use, ambient working — do NOT cut or nick the wire strands. conditions,operator training and skill, and established company standards. These inspections should be Install the die assembly, position terminal and performed in the following sequence: wire,and perform the crimping procedure as instructed in 409--5862, packaged with 626 5.3. VisualInspection Pneumatic Tool. 1. Remove all lubrication and accumulated film by Make certain all surfaces of the dies are protected immersing the dies in a suitable commercial with a THIN coat of any good SAE 20 motor oil. Do degreaser that will not affect paint or plastic NOT oil excessively. material. {Trademark ofLoctiteCorporation 2 of 4 RevB 408-4153 1 3 7 Die Part Number 5 Marked 4 33.32 Here [1.312] 2 6 15.82 23.77 [.623] [.936] REPLACEMENTPARTS WEIG WEIGH HT T (PerAssembly) ITEMNO. PARTNO. DESCRIPTION QTYPERASSY 43g[ g [1.5oz.]] 1 313350--1 ANVIL, For Die Assembly, 224027--1 1 ((A Approximate) i ) 2 2--306131--2 SCREW, Die Holding 1 3 306592--3 SCREW 1 4 313351--1 INDENTER 1 5 313352--1 LOCATOR 1 6 1--21046--3 RING, Retaining 2 7 313350--2 ANVIL, For Die Assembly224027--2 1 Figure 2 2. Make sure all die holding screws, retaining Disconnect air supply and remove adapter holder DANGER rings, and die components are in place. Refer to and straight action crimper, with dies, from the parts listed in Figure 2 if replacements are tooling assembly. necessary. 1. Mate the dies until it is evident that they have 3. Check components for wear. Remove and bottomed. Hold the dies in this position. replace worn components. 2. Align the GO element with the appropriate crimping chamber. Push element straight into the 4. Inspect the crimp area for flattened, chipped, crimping chamber without using force. The GO cracked, worn, or broken areas. If damage is element must pass completely through the evident, the dies must be repaired before returning crimping chamber as shown in Figure 3. them to service (see Section 6, REPLACEMENT AND REPAIR). 3. Now align the NO--GO element and try to insert it straight into the same crimping chamber. The NO--GO element may start entry but must not pass completely through as shown in Figure 3. 5.4. GagingtheCrimpedChamber If the crimping chamber conforms to the gage This inspection requires the use of a plug gage inspection, the dies are considered dimensionally conforming to the diameters shown in Figure 3. TE correct and should be lubricated with a THIN coat of does not manufacture or market these gages. SAE 20 motor oil. If not, the dies must be repaired RevB 3 of 4 408-4153 before returning them to service (see Section 6, 6. REPLACEMENTANDREPAIR REPLACEMENT AND REPAIR). For additional information concerning the use of a Replacement parts are listed in Figure 2. Parts other plug gage, refer to instruction sheet 408--7424. than those listed in Figure 2 should be replaced by TE to ensure quality and reliability of the tool. Order replacement parts through your TE Representative, or Suggested Plug GageDesign GO NO--GO call 1--800--526--5142, or send a facsimile of your Dim. Dim. purchase order to 1--717--986--7605, or write to: CUSTOMER SERVICE (038--035) TYCO ELECTRONICS CORPORATION P.O. BOX 3608 Crimping HARRISBURG, PA 17105--3608 Chamber For tool repair service, please contact a TE Representative at 1--800--526--5136. GO Element NO--GO Element GO element must pass NO--GO element may enter completely through the partially, but must not pass die closure. completely through the die closure. 7. REVISIONSUMMARY ELEMENTDIAMETER DIEASSEMBLY PARTNUMBER GO NO--GO Since the previous release of this sheet, the following 224027--1 2.464 [.0970] 2.616 [.1030] changes were made: 224027--2 2.337 [.0920] 2.489 [.0980] S Updated document to corporate requirements. Figure 3 4 of 4 RevB