crimping head power units 1490191-1 189721-1 189722-1 tool holder assembly 189767-1 quick pin(s) (ref) 354425-1 rollers assembly pins anvil crimping jaws guard indenter crimping jaw crimping head 1490191-1 ? 2012 tyco electronics corporation, a te connectivity ltd. company ? all rights reserved *trademark te connectivity, te connectivit y (logo), and te (logo) are trademarks. other logos, product and/or company names may be tradem arks of their respective owners. 1 of 4 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.te.com 408-8878 626 pneumatic crimping head ? 1490191-1 (used with 626 pneumatic ? tooling assemblies) 07 mar 12 rev a figure 1 1. introduction the 626 pneumatic crimping head, 1490191-1, is designed to crimp wire ferrules on solid or stranded copper wire. the crimping head is used with 626 pneumatic tooling assemblies. figure 1 shows the tool holder assembly, and lists the power units for the crimping head. this instruction sheet provides recommended p rocedures for crimp head installation, crimping, and maintenance and inspection. for information concerning tool setup and operation, refer to the customer manual packaged with the appropriate tool. read these instructions thoroughly before proceeding note i measurements are in metric units [followed by u.s. customary units in brac kets]. figures are for reference only, and are not drawn to scale. ? 2. description the pneumatic crimping head consists of integral jaws which close in an arc-like motion. after an operator locates the ferrule between the crimping jaws and inserts the stripped wire, the tool is activated to crimp the ferrule to the wire. 3. head installation and removal 3.1. installation note i crimping heads are coated wi th a preservative to prevent rust and corrosion. wipe any excess preservative from the head, particularly from the crimping surfaces. danger stop to avoid personal injury, always disconnect tool from air supply before insta lling crimping head. ? ? danger stop do not operate pneumatic tool without proper crimping head installed; make sure that the quick pins a re fully tightened to avoid personal injury and damage to the tool. 1. remove quick pins from tool holder. 2. insert crimping head into tool holder as shown in fig ure 1. 3. after crimping head is properly aligned, insert and tigh ten the quick pins provided with the tool holder assembly.
note i 408-8878 2 of 4 rev a te connectivity recommends using loctite no. 242, removable threadlock or equivalent, to prevent the quick pins from loosening. ? 4. connect tool to an adequate air supply between 620-690 kpa [90-100 psi]. for specific information on air line requirements and air hose installation, refer to the customer manual packaged with the pneumatic power unit. 3.2. removal danger stop always disconnect tool from air supply before removing crimping head. ? ? remove quick pins from the crimping head; then remove crimping head from the tool holder. 4. crimping procedures danger stop to avoid personal injury, always keep fingers clear of crimping jaws when operating the tool. never place anyth ing within the crimping jaws except terminals or splices. note i crimping head shown without guard for clarity. ? ? ? 1. strip wire to required length. do not nick the wire strand or use wires with nicked or missing conductor strands. 2. open crimping jaws by squeezing the rollers tog ether simultaneously; then place the ferrule into the center of the appropriate chamber, as shown in figure 2. use the correct crimp chamber for the specific wire size. center ferrule in dies figure 2 3. after ferrule is properly positioned, release the rollers to allow the jaws to spring shut, holding the ferrule in place. 4. insert stripped wire into ferrule as shown in fig ure 3. figure 3 5. activate the tool to co mplete the crimp. open the crimping jaws by squeezing the rollers together simultaneously; then remove the crimped ferrule. note i damaged ferrules should not be used. if a damaged ferrule is evident, it should be cut from the wire and rep laced. ? 5. maintenance and inspection danger stop to avoid personal injury, disconnect tool from air supply before performing any maintenance, inspe ction, or repairs. ? it is recommended that a maintenance and inspection program be performed periodically to ensure dependable and uniform terminations. heads should be inspected once a month. frequency of inspection should be adjusted to suit your requirements through experience and depends on: 1. the care, amount of use, and handling of ? the head. 2. the type and size of the products crimped. 3. the degree of operator skill. 4. the presence of abnormal amounts of dust ? and dirt. 5. your own established standards. each crimping head is thoroughly inspected before p ackaging. since there is the possibility of crimping head damage in shipment, new crimping heads should be inspected immediately upon arrival at your facility. 5.1. daily maintenance it is recommended that each operator be responsible for the following steps of daily maintenance:
408-8878 3 of 4 rev a 1. remove dust, moisture, and other contaminants with a clean, soft brush, or a lint-free cloth. do not use objects that could damage the heads. 2. make sure pins, rings, and other components are in place and secure. danger stop make sure quick pins, are in place and fully tightened to avoid personal injury and damage to the tool. ? 3. make certain all surfaces are protected with a thin coat of any good sae 20 mo tor oil. do not oil excessively. 4. when the head assembly is not in use, store it in a clean, dry area. 5.2. 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 5.3 and a crimping chamber inspection (paragraph 5.5). 5.3. visual inspection 1. remove all lubrication and accumulated film by immersing the crimping head in a suitable commercial degreaser th at will not affect paint ? or plastic. 2. make certain all components are in place. if re placements are necessary, refer to figure 6. 3. check all bearing surfac es for wear. make sure the rollers turn freely with minimal resistance. replace any worn parts. 4. inspect the crimp area for flattened, chipped, or b roken areas. although the crimping chambers may gage within permissible limits, worn or damaged die closure surfaces are objectionable and will affect the quality of the crimp. 5.4. lubrication lubricate all pins, pivot points, and bearing surfaces with a high quality grease. te 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 (occasi onal) - lubricate weekly ? head used weekly - lubricate monthly wipe excess grease from crimping head, particularly fro m die closure areas. grease transferred from the die closure area onto certain terminations may affect the electrical characteri stics of a termination. 5.5. gaging the crimping chamber this inspection requires the use of plug gages conforming to the dimensions shown in figure 4. te does not manufacture or market these gages. go diameter no-go diameter 50.8 [2.0] min typ jaw closure configuration crimping head wire range, mm2 gage element dimensions go no-go 1490191-1 2.4 1.371 - 1.379 [.0540 - .0543] 1.496 - 1.498 [. 0589 - .0590] 4.0 1.955 - 1.963 [.0770 - .0773] 2.080 - 2.082 [. 0819 - .0820] 6.0 2.362 - 2.369 [.0930 - .0933] 2.486 - 2.489 [. 0979 - .0980] figure 4 danger stop to avoid personal injury , disconnect air supply and remove crimping head from tool before inspection the crimping chambers. ? 1. remove oil and dirt from the bottom of the jaw surfaces, and plug gage element surfaces. 2. close the crimping jaws until they are bottomed, bu t not under pressure. 3. align the go element with the crimping chamber. push the go element straight into the crimping chamber without using force. the go element must pass completely through the crimping chamber. see figure 5. 4. align the no-go elem ent w ith the crimping chamber, and try to insert it straight into the crimping chamber. the no-go element may start entry but must not pass completely through the chamber.
no-go element may enter partially, but must not pass through the crimping jaws go element must pass completely through the crimping jaws jaws bottomed but not under pressure 408-8878 4 of 4 rev a figure 5 if the jaw closure meets the plug gage conditions, the crimping head is considered dimensionally correct and should be lubricated with a thin coat of any good sae 20 motor oil. if the cr imping chambers do not conform to the plug gage conditions, contact your local te field service engineer, or refer to section 6, replacement and repair. for additional information abo ut the use of a plug gage, refer to instruction sheet 408-7424. 6. replacement and repair replacement parts and recommended spares are listed in figure 6. the recommended spares should ? be stocked for immediate replacement. parts should be replaced by te to ensu re quality and reliability of the tool. order replacement parts through your te rep resentative, or call 1-800-526-5142, or send a facsimile of your purchase order to 1-717-986-7605, or write to: customer service (038-035) ? tyco electronics corporation ? po box 3608 ? harrisburg pa 17105-3608 for customer repair service, call 1-800-526-5136. 7. revision summary since the previous version of this document, the following changes were made: ? updated document to corporate requirements. 9 10 11 7 4 5 8 6 3 1 2 item no. part no. description qty pe r head item no. part no. description qty pe r head 1 1725731-1 anvil, wire ferrule 1 7 6-23629-0 pin, retain, grvd, 5/16 x 1.488 2 2 23241-2 ball, steel 1 8 ? 21045-6 ring, retaining 4 3 1725733-1 guard 1 9 1-21048-0 ring, retaining 4 4 768521-2 link 2 10 ? 314479-6 roller 4 5 1725732-1 nest, wire ferrule 2 11 ? 679942-1 spring 1 6 ? 3-23620-3 pin, retain, grvd, 1/4 x .894 2 ? recommended spares figure 6
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