Tyco Electronics 1213850-1 Bedienungsanleitung

TE logo and Tyco Electronics are trademarks.

*Trademark. Other products, logos, and company names might be trademarks of their respective owners.

Instruction Sheet

TOOLING ASSISTANCE CENTER 1-800-722-1111

PRODUCT INFORMATION 1-800-522-6752

This controlled document is subject to change.

For latest revision and Regional Customer Service,

visit our website at www.tycoelectronics.com

1of 9

LOC B

626 Pneumatic Crimping Heads

1213850-[ ] (Used with 626

Pneumatic Tool Holder Assemblies) 408-10004

19 JAN 11 Rev B

Figure 1

1. INTRODUCTION

Pneumatic Crimping Heads 1213850-1 and -2 are

designed to crimp STRATO-THERM non-insulated

terminals and splices with insulation support on wire

sizes 22 to 14 AWG. The crimping heads are used with

626 Pneumatic Tool Holder Assemblies. Figure 1

shows the tool holder assemblies, and lists the

pneumatic tooling assemblies for the crimping heads.

This instruction sheet provides recommended

procedures for insulation crimp adjustments, wire

preparation, crimp head installation, crimping, and

maintenance and inspection. For information

concerning tool setup and operation, refer to customer

manual 409-5862. Product specifications and part

numbers are available in Tyco Electronics Catalogs.

See Figure 1.

Read these instructions thoroughly before proceeding.

Measurements are in metric units [followed by U.S.

customary units in brackets]. Figures are for

reference only and are not drawn to scale.

2. DESCRIPTION (Figure 1)

The pneumatic crimping heads consist of integral jaws

which close in an arc-like motion. After an operator

locates the terminal or splice between the crimping

jaws and inserts the stripped wire, the tool is activated

to crimp the product to the wire.

3. HEAD INSTALLATION AND REMOVAL

3.1. Installation

Crimping heads are coated with a preservative to

prevent rust and corrosion. Wipe any excess

preservative from the head, particularly from

crimping surfaces.

Certain precautions should be taken by the

operator to avoid personal injury or damage to the

pneumatic tool. Refer to the instructions packaged

with the pneumatic tool for operation procedures

and safety precautions.

To avoid personal injury, ALWAYS disconnect tool

from air supply before installing crimping head.

Do NOT operate pneumatic tool without proper

crimping head installed; make sure that the quick

pins are FULLY tightened to avoid personal injury

and damage to the tool.

Quick-Pin(s)

354425-1 (Ref)

Rollers Assembly

Pins

Indenter

Crimping

Jaw

Locator

Anvil Crimping Jaw

Crimping Head

1213850-[ ]

Insulation

Adjustment Pin

Tool Holder Assembly

189766-1 or 356303-1

NOTE

CAUTION

DANGER

STOP

DANGER

STOP

408-10004

2of 9

Rev B

Figure 2

Determine the wire size, then refer to Figure 2 to

select the appropriate crimping head. Proceed as

follows:

1. Remove quick pins from tool holder. Refer to

Figure 1.

2. Insert crimping head into the tool holder of the

power unit, as shown in Figure 1.

3. After crimping head is properly aligned, insert and

tighten the quick pins provided with the pneumatic

tooling assembly.

It is recommended using LOCTITE‡ 242

removable thread lock, or equivalent, to prevent the

quick pins from loosening.

4. Connect tool to an adequate air supply between

620 to 690 kPa [90 to 100 psi]. For specific

information on air line requirements and air hose

installation, refer to the instructions packaged with

the tooling assembly.

3.2. Removal

ALWAYS disconnect tool from air supply before

removing crimping head.

1. Remove quick pins from crimping head. See

Figure 1.

2. Remove crimping head from tool holder.

4. CRIMPING PROCEDURES

Refer to Paragraph 4.3 for insulation crimp

adjustments.

To avoid personal injury, exercise caution while

holding terminals or splices near the crimping jaws.

4.1. Terminal Crimping Procedure

1. Strip wire to the dimensions shown in Figure 2.

DO NOT nick the wire or use wires with nicked or

missing conductor strands.

2. Open the crimping jaws by squeezing the rollers

together simultaneously.

3. Then position a terminal between the crimping

jaws as shown in Figure 3. The edge of the terminal

wire barrel must rest against the locator.

4. After the terminal is properly positioned in the

crimping jaws, release the rollers to allow the

crimping jaws to spring shut, holding the terminal in

place.

5. Insert a stripped wire into the terminal; then

activate the tool to complete the crimp. Open the

crimping jaws by squeezing the rollers together

simultaneously.

6. Then remove the crimped terminal.

7. Refer to Section 5 and Figure 6 for crimp

inspections

Wire

Barrel

Insulation

Barrel

Insulation

Barrel

Wire

Barrel

Color Coded Sleeves on High

Temperature Terminals and Splices

Finished Crimp

Splice

(Bottom Shown)

Terminal

(Top Shown)

2 Hashmarks

PNEUMATIC

TOOLING

ASSEMBLIES

CRIMPING

HEADS

WIRE

RANGE

SIZE

HASHMARK CODE┼WIRE STRIP LENGTH

MIN. MAX.

189721-1

189722-1

1213850-1 22 - 16 1 Hashmark 5.16

[.203]

5.94

[.234]

1213850-2 16 - 14 2 Hashmarks

┼A Hashmark code Should Appear on the Bottom (Side Opposite Crimp Indents) for High Temperature and Heat Resistant Terminals and Splices when Crimped with

the Proper Crimp Head.

NOTE

DANGER

STOP

‡ Trademark of Loctite Corporation

NOTE

DANGER

STOP

408-10004

3of 9

Rev B

Figure 3

4.2. Splice Crimping Procedure

1. Strip wire to the dimensions shown in Figure 2.

Do NOT nick the wire or use wires with nicked or

missing conductor strands.

2. Open the crimping jaws by squeezing the rollers

together simultaneously. Position the splice

between the crimping jaws so that the window

indent of the splice slides under the locator of the

crimping head. See Figure 4, Detail A. For best

results, when brazed seam on the splice is visible,

position the seam toward the “W” shaped jaw.

3. Insert the stripped wire into the wire barrel until

the end of the conductor is positioned against the

splice wire stop. See Figure 4, Detail A.

4. Activate the tool to complete crimp. Remove the

splice from the crimping jaws.

5. To crimp the other half of the splice, reposition

uncrimped half in the crimping jaws. Repeat Steps 1

through 4 to complete the crimp. See Figure 4,

Detail B.

Rotate the crimping head if the splice cannot be

repositioned in the crimping jaws.

6. Refer to Section 5 and Figure 6 for crimping

inspection.

Locator

Edge of Wire Barrel

Rests Against Locator

Crimping Head 1213850-[ ]

Terminal (Ref)

Rollers

Terminal Tongue Positioned Under Locator

NOTE

408-10004

4of 9

Rev B

Figure 4

4.3. Insulation Crimp Adjustment

The insulation crimping section of the crimping head

has three positions: 1-tight; 2-medium; and 3-loose.

Adjust the insulation crimp as follows:

1. Insert the insulation adjustment pins in position 3.

See Figure 5.

2. Place the terminal or splice in the crimping jaws.

3. Insert unstripped wire into the insulation grip

portion of the terminal or splice.

4. Crimp the terminal or splice as described in

Paragraph 4.1 or 4.2.

5. Remove the terminal or splice. Bend the wire

forward and then backward. The terminal or splice

should retain its grip on the wire. If the wire pulls

out, set the insulation adjustment pins in the next

tighter position and repeat the crimping procedure.

6. Repeat the adjustment as necessary until the

desired insulation grip is obtained. DO NOT use a

tighter setting than required.

Figure 5

Always place both adjustment pins in the same

position. See Figure 5.

5. CRIMP INSPECTION

Inspect crimped terminals and splices by checking the

features described in Figure 6. Use only the terminals

and splices that meet the conditions in the “ACCEPT”

column.

“REJECT” terminations can be avoided through

careful use of the instructions provided in Section 4,

and by performing regular crimping head maintenance

as described in Section 6.

Detail A

Detail B

Splice (Ref)

“W” Shaped

Jaw (Ref)

Locator

Splice

Positioned

Between

Crimping

Jaws

Locator

Window Indent

Under Locator

Second Crimp

Locator

Window Indent

Under Locator

Crimping Head

1213850-[ ] (Ref)

Positions

Insulation

Adjustment

Pins

NOTE

First Crimp

408-10004

5of 9

Rev B

Figure 6

Crimp Inspection

408-10004

6of 9

Rev B

A hashmark code (see Figure 2) should appear on

the bottom (side opposite the crimp indents) for

high temperature and heat-resistant terminals and

splices when crimped with the proper crimping

head.

6. MAINTENANCE AND INSPECTION

To avoid personal injury, disconnect air supply from

pneumatic tool before performing maintenance,

inspection, or repair procedures.

It is recommended that a maintenance and inspection

program be performed periodically to ensure

dependable and uniform terminations.

6.1. Daily Maintenance

It is recommended that each operator be responsible

for the following four steps of daily maintenance:

1. Remove dust, moisture, and outer contaminants

with a clean, soft brush or a lint-free cloth. Do NOT

use objects that could damage the heads.

2. Make sure that all pins, rings and other

components are in place and secure.

3. Make certain all surfaces are protected with a thin

coat of any good SAE 20 motor oil. Do NOT oil

excessively. Wipe excess grease from head,

particularly die closure areas.

4. When head assembly is not in use, store it in a

clean dry area.

6.2. Periodic Inspection

Regular inspections should be performed by quality-

control personnel. A record of scheduled inspections

should remain with the crimping heads or be supplied

to supervisory personnel responsible for the crimping

heads. Though recommendations call for at least one

inspection a month, the frequency should be based on

amount of use, working conditions, operator training

and skill, and your established company policies.

These inspections should include a visual inspection

(Paragraph 6.3) and a crimping chamber inspection

(Paragraph 6.5).

6.3. Visual Inspection

1. Make certain all components are in place. Inspect

for missing pins and retaining rings. If replacements

are necessary, refer to Figure 10.

2. Check all bearing surfaces for wear. Replace

worn parts.

3. Inspect the crimp area for flattened, chipped, or

broken areas. See Figure 7. Replace worn or

damaged parts.

6.4. Lubrication

Lubricate all pins, pivot points, and bearing surfaces

with a high quality grease. Tyco recommends the use

of Molykotepaste, which is a commercially available

lubricant. Lubricate according to the following

schedule:

•Head used in daily production - lubricate daily

•Head used daily (occasional) - lubricate weekly

•Head used weekly - lubricate monthly

Wipe excess grease from crimping head,

particularly jaw closure areas. Grease transferred

from the jaw closure area onto certain terminations

may affect the electrical characteristics of an

application.

Figure 7

6.5. Gaging the Crimping Chamber

This inspection requires the use of plug gages

conforming to the dimensions shown in Figure 8. Tyco

Electronics does not manufacture or sell these gages.

Refer to 408-7424. Proceed as follows:

To avoid personal injury, disconnect air supply from

pneumatic tool and remove head from tool.

1. Remove oil and dirt from jaw bottoming surfaces,

jaw closure surfaces, and plug gage elements.

2. Set insulation adjustment pins in position 3. This

will allow access to the wire barrel crimping jaws

from the insulation crimp side of the head.

3. Close wire barrel crimping jaws until they are

bottomed, but not under pressure.

4. Align GO element with crimping chamber. Push

element straight into crimping chamber without

using force. The GO element must pass completely

through the chamber. See Figure 9, Detail A.

NOTE

DANGER

STOP

CAUTION

Pitted

Chipped Edge

Broken

Corner

Flattened

Area Crimping Head

1213850-[ ]

DANGER

STOP

Trademark of Dow Corning Corporation

408-10004

7of 9

Rev B

5. Align NO-GO element and try to insert it into the

crimp chamber. The element may start entry, but it

must not pass completely through the crimping

chamber.

6. Set insulation adjustment pins to position 1 and

repeat this procedure for insulation crimp chamber.

Refer to Figure 9, Detail B.

If crimping chambers pass plug gage inspection, the

crimping head is considered dimensionally correct. If

crimping chambers do not pass this inspection,

contact your local Tyco Electronics Field

Representative or refer to Section 7, REPLACEMENT

AND REPAIR.

For additional information about the use of a plug

gage, see instruction sheet 408-7424.

7. REPLACEMENT AND REPAIR

Customer-replaceable parts are listed in Figure 10. A

complete inventory should be stocked and controlled

to prevent lost time when replacement of parts is

necessary. Parts other than those listed should be

replaced by Tyco to ensure quality and reliability.

Order replacement parts through your representative,

or call 1-800-526-5142, or send a facsimile of your

purchase order to 717-986-7605, or write to:

CUSTOMER SERVICE (038-035)

TYCO ELECTRONICS CORPORATION

PO BOX 3608

HARRISBURG PA 17105-3608

For customer repair service, please contact a

representative at 1-800-526-5136.

8. REVISION SUMMARY

Since the previous release of this document, the TE

logo has been applied.

Figure 8

Wire Barrel Crimp Insulation Crimp

NO-GO

Dim.

“G”

“W”

“R”

CRIMPING

HEADS

WIRE BARREL DIMENSIONS “A”

mm [In.} RADIUS

“R”

INSULATION BARREL DIMENSIONS “G”

(Adjustment Pins in Position 1) mm [In.} WIDTH

“W”

(Max.)

GO NO-GO GO NO-GO

1213850-1 1.50 [.059] 1.65 [.065] 1.57 [.062] 0.76 [.030] 1.27 [.050] 3.18 [.125]

1213850-2 1.70 [[.067] 1.85 [.073] 1.57 [.062] 1.02 [.040] 1.52 [.060] 4.78 [.188]

Suggested Plug Gage Design

408-10004

8of 9

Rev B

Figure 9

Inspection of Wire Barrel

Crimping Jaws with Plug Gage

Inspection of Insulation

Crimping Jaws with Plug Gage

Crimping head guard NOT shown for clarity.

NOTE

408-10004

9of 9

Rev B

Figure 10

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Authorized Distributor

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