Instruction Sheet
626 Pneumatic Crimping Heads
662546- 1 and 1320369- 1
11 MAR 10 Rev C
408-- 4366
ORIGINAL INSTRUCTIONS
Lower
Crimping Jaw
Locator
Quick
Pin(s)
626 Pneumatic
Crimping Head
662546- 1 Shown,
(Ref)
Rollers
Link
Tool Holder
Assembly
189767-- 1 or
356302-- 1
Product:
COPALUM* Terminals and Splices
Wire Size:
8 AWG, Stranded Copper, Film-- Insulated
Copper, or Film-- Insulated Aluminum
Product Catalog:
82020
Tooling Catalog:
124208
Upper
Crimping Jaw
Guard
Figure 1
1. INTRODUCTION
626 Pneumatic Crimping Heads 662546--1 and
1320369--1 (shown in Figure 1) are designed to crimp
COPALUM terminals, butt splices, and parallel splices
onto wire size 8 AWG. The crimping heads are used
with 626 Pneumatic Tooling Assemblies 189721--2 or
189722--2 when fitted with Tool Holder Assembly
189767--1 or 356302--1.
This instruction sheet provides recommended
procedures for wire preparation, crimping head
installation, crimping, and maintenance and
inspection. For setup and operation of the pneumatic
tools, refer to Customer Manual 409--5862 packaged
with the pneumatic tooling assembly. Read these
instructions thoroughly before proceeding.
NOTE
i
Dimensions on this sheet are in metric units
[with U.S. customary units in brackets]. Figures
are not drawn to scale.
Reasons for reissue of this document are provided in
Section 9, REVISION SUMMARY.
2. DESCRIPTION
Each pneumatic crimping head is designed with
integral jaws which close in an arc--like motion.
To ensure proper crimping head selection, each
crimping head link is stamped with a wire size range
which must correspond with the wire size range
stamped on the terminal or splice.
After an operator locates the terminal or splice
between the crimping jaws and inserts the stripped
TOOLING ASSISTANCE CENTER 1-- 800-- 722-- 1111
E2010
Tyco Electronics Corporation, Berwyn, PA
PRODUCT INFORMATION 1-- 800-- 522-- 6752
All Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other product names, logos, or company names might be trademarks of their respective owners.
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
www.tycoelectronics.com
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LOC B
Pneumatic Crimping Heads 662546- 1 and 1320369- 1
wire, the pneumatic tool is activated to crimp the
product to the wire.
408- 4366
4. WIRE SELECTION AND PREPARATION
4.1. Wire Selection
Select wire for the terminals and splices according to
Application Specification 114--2121.
3. HEAD INSTALLATION AND REMOVAL
NOTE
Crimping heads are coated with a preservative to
prevent rust and corrosion. Wipe this preservative
from the crimping head, particularly from the
crimping surfaces.
4.2. Wire Preparation
If using stranded copper wire, strip the wire to
dimensions shown in Figure 2. DO NOT nick wire
strand or use wires with nicked or missing conductor
strands.
NOTE
Do not strip film--insulated copper or
film--insulated aluminum wire.
i
3.1. Installation
DANGER
To avoid personal injury, ALWAYS disconnect
pneumatic tool from air supply before installing or
removing the crimping head.
i
DANGER
DO NOT operate pneumatic tool without the
proper crimping head installed. After crimping
head is installed, make sure that the quick pins
are FULLY tightened to avoid personal injury or
damage to the tool.
CRIMPING
HEAD
662546--1
1320369--1
SIZE
(AWG)
8
Strip Length
Note:
Not to Scale
STRANDED COPPER WIRE
CIRCULAR
MIL AREA
13,100--20,800
Figure 2
STRIP LENGTH
(mm [IN.])
10.31--11.86
[.406--.469]
1. Remove quick pins from tool holder. Refer to
Figure 1.
2. Insert crimping head into tool holder as shown in
Figure 1.
3. After crimping head is properly aligned, insert
and tighten quick pins provided with the tool holder.
See Figure 1.
NOTE
Tyco Electronics recommends using LOCTITE{
242 removable threadlock, or equivalent, to
prevent the quick pins from loosening.
5. CRIMPING PROCEDURE
DANGER
To avoid personal injury, ALWAYS keep fingers
clear of crimping jaws when operating the tool.
Never place anything within the crimping jaws
except terminals and splices.
i
5.1. Terminal Crimping Procedure
1. Open crimping jaws by squeezing rollers
together simultaneously; then position the terminal
in the crimping chamber on the lower jaw, as
shown in Figure 3, Detail A. The terminal is
properly positioned when the back of the terminal
is facing the upper jaw and the wire barrel is
against the locator.
2. After terminal is properly positioned, release
rollers to allow crimping jaws to spring shut,
holding terminal in place.
3. Insert stripped wire into terminal wire barrel until
the end of the conductor butts against the locator.
4. Activate the tool to complete the crimp. Open
crimping jaws by squeezing the rollers together
simultaneously; then remove crimped terminal.
4. Connect pneumatic 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 tooling assembly.
3.2. Removal
DANGER
To avoid personal injury, ALWAYS disconnect
pneumatic tool from air supply before removing
crimping head.
Remove quick pins from crimping head; then remove
crimping head from tool holder.
{
Trademark of Loctite Corporation
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Tyco Electronics Corporation
Rev
C
Pneumatic Crimping Heads 662546- 1 and 1320369- 1
5. Refer to Section 6 for crimp inspection.
NOTE
408- 4366
A slight bend in the splice may result from
crimping the other half of the splice as instructed
in Step 1. If a bend would be objectionable,
position the other half of the splice in the
crimping chamber by rotating the splice 180_
end--over--end; then crimp.
5.2. Butt Splice Crimping Procedure
1. Open crimping jaws by squeezing rollers
together simultaneously; then position the butt
splice in the crimping chamber on the lower jaw, as
shown in Figure 3, Detail B. The butt splice is
properly positioned when the window in the splice
is facing the upper jaw and the splice wire stop is
sitting on the locator.
2. After splice is properly positioned, release rollers
to allow crimping jaws to spring shut, holding splice
in place.
3. Insert stripped wire into splice wire barrel until
the end of the conductor butts against the splice
wire stop.
4. Activate the tool to complete the crimp. Open
crimping jaws by squeezing the rollers together
simultaneously; then remove crimped splice.
5. To crimp the other half of the splice, follow the
same procedure for the uncrimped half of the
splice.
i
6. Refer to Section 6 for crimp inspection.
5.3. Parallel Splice Crimping Procedure
1. Open crimping jaws by squeezing rollers
together simultaneously; then position the parallel
splice in the crimping chamber on the lower jaw, as
shown in Figure 3, Detail C. The parallel splice is
properly positioned when the end of the splice is
against the locator.
2. After splice is properly positioned, release rollers
to allow crimping jaws to spring shut, holding splice
in place.
3. Insert stripped wires into splice until the end of
the conductors butt against the locator.
4. Activate the tool to complete the crimp. Open
crimping jaws by squeezing the rollers together
simultaneously; then remove crimped splice.
5. Refer to Section 6 for crimp inspection.
Detail A — Terminal
Splice Window
Facing Upper Jaw
Detail B — Butt Splice
Wire Barrel
Against Locator
Splice Wire Stop
Sitting on Locator
End of Conductor
Against Locator
Lower
Jaw
Back of Terminal
Facing Upper Jaw
End of Conductors
Against Locator
Lower
Jaw
End of Conductor
Against Splice Wire Stop
End of Splice
Against Locator
Lower
Jaw
Detail C — Parallel Splice
Figure 3
Rev
C
Tyco Electronics Corporation
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Pneumatic Crimping Heads 662546- 1 and 1320369- 1
6. CRIMP INSPECTION
Inspect crimped terminals and splices by checking the
features described in Figure 4. Use only terminals
and splices that meet the conditions shown in the
“ACCEPT” column. “REJECT” terminations can be
avoided through careful use of instructions in
Sections 4 and 5, and by performing regular crimping
head maintenance as described in Section 7.
408- 4366
3. Make certain all surfaces are protected with a
thin coat of any good SAE 20 motor oil. Do NOT oil
excessively.
4. When the crimping head is not in use, store it in
a clean, dry area.
7.2. Periodic Inspection
Regular inspections should be performed by quality
control personnel. A record of scheduled inspections
should remain with the crimping head or be supplied
to supervisory personnel responsible for the crimping
head. 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 7.3) and a crimping chamber
inspection (Paragraph 7.5).
7. MAINTENANCE AND INSPECTION
DANGER
To avoid personal injury, ALWAYS disconnect air
supply from pneumatic tool before performing
maintenance or inspection.
It is recommended that a maintenance and inspection
program be performed periodically to ensure
dependable and uniform terminations. The pneumatic
crimping head should be inspected once a month.
Frequency of inspection should be adjusted to suit
your requirements through experience. Frequency of
inspection depends on:
1. The care, amount of use, and handling of the
crimping head.
2. The type and size of the product 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
packaging. Since there is the possibility of damage
during shipment, new crimping heads should be
inspected immediately upon arrival at your facility.
7.3. Visual Inspection
1. Remove all lubrication and accumulated film by
immersing the crimping head in a suitable
commercial degreaser that will not affect paint or
plastic.
2. Make certain all components are in place. If
replacements are necessary, refer to Section 8,
REPLACEMENT AND REPAIR.
3. Check all bearing surfaces for wear. Make sure
the rollers turn freely with minimal resistance.
Replace worn parts.
4. Inspect crimp area for flattened, chipped, or
broken areas. See Figure 5. Replace worn or
damaged parts.
Chipped Edge
Pitted
7.1. Daily Maintenance
It is recommended that each operator be responsible
for the following steps of daily maintenance:
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 head.
2. Make sure that all pins, rings, and other
components are in place and secure.
DANGER
To avoid personal injury and damage to the
crimping head, make sure quick pins are fully
tightened.
Flattened
Area
Broken
Corner
Figure 4
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Tyco Electronics Corporation
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C
Pneumatic Crimping Heads 662546- 1 and 1320369- 1
Crimp Inspection
1
4
3
408- 4366
ACCEPT
REJECT
4
2
Wire Range
Stamped
Under Tongue
2
COPALUM
Terminal
Wire Range
Stamped
Under Tongue
7
1
3
1
4
3
4
3
COPALUM
Butt Splice
Wire Range
2
Stamped
On Side
7
1
Wire Range
2
Stamped
On Side
1
COPALUM
Parallel Splice
6
1
5
3
1
3
1
2
3
4
Crimp centered on wire barrel. (Crimp may be slightly off
center but not off end of wire barrel.)
Wire size is within wire size range stamped on terminal or
splice and crimping head.
Wire is visible through inspection hole of butt splice.
Wire is flush with or extends slightly beyond end of
terminal wire barrel or parallel splice.
Wire range embossed on crimp matches wire size range
stamped on terminal or splice.
1
2
3
Crimp not centered on wire barrel. (Terminal or splice not
properly seated in crimping chamber.)
Wire size is not within wire size range stamped on terminal or
splice and crimping head.
Wire not fully inserted.
Wire is not visible through inspection hole of butt splice.
Wire is not flush with, or extending beyond, end of terminal wire
barrel or parallel splice. (Check for correct strip length.)
Excessive flash or extruded insulation. (Wrong crimping head
and terminal combination used, or damaged jaws.)
Wire insulation entered wire barrel (applies to stranded copper
wire only). Check for correct wire size or strip length.
Nicked or missing conductor strands (applies to stranded
copper wire only).
Wire range embossed on crimp does not match wire size
range stamped on terminal or splice.
4
5
6
7
Figure 5
Rev
C
Tyco Electronics Corporation
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