Instruction Sheet
Terminating Head 122533-1
for Communications Outlet -
Edge Connector Kit
408-4074
21 OCT 11 Rev B
Adjuster
(Insertion Rod)
Wire Inserter
(Not Shown)
Shear
Ball Plunger
(Not Shown)
Figure 1
1. IINTRODUCTION
This instruction sheet covers the operation and
maintenance of Terminating Head 122533-1 used with
Pistol Grip Manual Handle Assembly 58074-1. Refer
to instruction sheet 408-6790 (packaged with the pistol
grip handle assembly) for details concerning head
installation and removal. Read this instruction sheet
thoroughly before using the terminating head.
NOTE
i
Dimensions on this sheet are in metric units [with
U.S. customary units in brackets]. Figures are for
identification only and are not drawn to scale.
CAUTION Failure to use the strain relief may cause the
following conditions:
!
1. The wire insertion will not have the proper
retaining force.
2. The wire may flex at the termination slot and
break off at that point.
Reasons for reissue of this instruction sheet are
provided in Section 8, REVISION SUMMARY.
2. DESCRIPTION
The terminating head is used to terminate multi-pair,
copper-conductor cables 22 through 26 AWG,
shielded or unshielded, up to 8-pair using
Communications Outlet - Edge Connector Kit
556524-1. To assemble the connector kit, follow the
instructions supplied with the connector kit.
The Communications Outlet - Edge Connector Kit
556524-1 consists of three components:
1. Housing
2. Terminals
3. During termination in the tool, the product may
not be at the proper depth alignment with the
inserters, causing damage to the product and/or
inserter.
The terminating head is inserted into the pistol grip
handle assembly and serves as a guide and support
for the connector during termination. It will shear and
terminate two wires during a normal stroke. Features
of the head (as shown in Figure 1) and their functions
are listed as follows:
Wire Inserter - is one side of the shearing surfaces
that cuts the wire at the proper dimension for insertion
and guides the wire into the IDC (Insulation
Displacement Connector) slot.
Adjuster (Insertion Rod) - is the piston for the wire
inserter and regulates wire insertion travel.
3. Stuffer Assembly
To make the edge connector compatible with the
terminating head, the stuffer assembly (supplied with
© 2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
*Trademark
the Edge Connector Kit) must be replaced with strain
relief 556805-1. One strain relief is required for each
connector and it must be placed onto the connector
before the connector is loaded into the terminating
head.
Ball Plunger - aligns connector in proper position for
wire insertion.
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PRODUCT INFORMATION 1-800-522-6752
This controlled document is subject to change.
For latest revision and Regional Customer Service,
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LOC B
408-4074
Shear - positions the connector at the proper depth
location and is a shearing surface for the wire.
NOTE
The wire inserter and the shear can be rotated
180° to extend the usable life of these parts.
i
3. SETUP ADJUSTMENTS AND TEST
The insertion rod adjuster is preset for wire sizes 22
through 26 AWG. If, after a termination, the wire is
inserted too deeply or not deeply enough inside the
contact, it may be necessary to adjust the depth of the
wire inserter.
• If wire is not deep enough in contact slot: Remove
the head and turn the adjuster COUNTERCLOCKWISE. Refer to Figure 3. A 1/6-revolution
adjustment will increase the wire insertion depth by
approximately 0.41 mm [.016 in.]. Repeat Steps 2,
3, and 4 of Paragraph 3.1 until the desired insertion
depth is attained.
Turn Clockwise
1/6-Revolution
to Reduce Wire
Insertion Depth
Approximately
0.41 mm [.016 In.]
3.1. For Pistol Grip Manual Handle Assembly
1. Select the appropriate cable size and prepare the
cable as shown in Figure 2.
2. Select a connector and place it in the tool. Make
a test termination using the procedures described in
Section 4, TERMINATING PROCEDURE.
NOTE
Adjuster
(Insertion Rod)
Turn Counterclockwise
1/6-Revolution to
Increase Wire Insertion
Depth Approximately
0.41 mm [.016 In.]
The connector may be loaded and indexed
(manually) from either side of the tool.
i
Figure 3
4. TERMINATION PROCEDURE
Multi-pair copper-conductor cables must be prepared
as follows:
1. Strip the cable jacket and untwist the individual
conductors to the dimension shown in Figure 2.
2. Insert connector into the terminating head (from
either side) and position the connector so that the
two terminals are aligned under the two wire slots.
NOTE
i
Figure 2
3. Remove terminated connector.
4. Inspect the connector for proper termination
using the inspection requirements in Figure 5.
If the wire insertion depth is incorrect, proceed to
Paragraph 3.2, Wire Insertion Depth Adjustment.
3.2. Wire Insertion Depth Adjustment.
• If the wire is too deep in the contact slot: Remove
the head and turn the adjuster CLOCKWISE. Refer
to Figure 3. A 1/6-revolution adjustment will reduce
the wire insertion depth by approximately 0.41 mm
[.016 in.]. Repeat steps 2, 3, and 4 of Paragraph 3.1
until the desired insertion depth is attained.
Rev B
The terminating head will terminate two wires at
the same time. Since the connector must be
manually located and advanced, make sure that
the proper terminals are located under the wire
slots of the connector.
3. Select a pair of wires; then insert each wire into
the appropriate wire slot that corresponds with the
proper color code. Insert the wire until the twist of
the wire pair is against the cover. See Figure 4.
NOTE
i
The wire ends must be visible from the back of the
terminating head to ensure there is enough wire to
shear.
4. Squeeze the cam handle of the pistol grip handle
assembly until the ratchet releases. This will shear
the wires and insert the wires into the wire slots of
the connector.
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408-4074
7. Manually reposition the connector in the
terminating head to the next pair of terminals to be
terminated.
Wires Inserted
Into Wire Slot
8. Repeat Steps 2 through 7 until all the terminals
have been terminated.
9. Remove connector from the tool.
10. Inspect each termination using the procedure in
Section 5, INSPECTION.
5. INSPECTION
Inspect each termination to ensure it meets the
inspection criteria shown in Figure 5.
6. TOOL MAINTENANCE
Terminals
Aligned With
Wire Slots
Strain Relief
556805-1 (Ref)
The procedures that follow have been established to
ensure the quality and reliability of terminating heads.
A brief check should be made daily, and a more
detailed inspection should be scheduled by your
quality control personnel.
Connector
Terminating
Head (Ref)
6.1. Daily Maintenance
Each operator should be aware of the following:
Figure 4
5. Discard the sheared wires from the terminating
head.
6. Release the cam handle. The inserter will retract.
1. Remove dust moisture, and other contaminats
with a clean brush, or soft, lint-free cloth. Do NOT
use objects that will damage the tool.
2. Make sure all components are in place and
properly secured. Refer to Figure 7.
3. Actuate handle assembly to ensure mechanisms
inside terminating head move smoothly.
Figure 5
Rev B
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408-4074
6.2. Periodic Maintenance
Regular inspections should be performed by your
quality control personnel with a record of these control
inspections remaining with the personnel responsible
for the tool. TE recommends one inspection a month;
however, operator training and skill, amount of use,
ambient working conditions, and your company's
established standards are all factors in establishing
frequency of inspections.
Socket Head
Cap Screws
Cover
These inspections should be performed in the
following sequence:
1. Remove any accumulated film with a suitable
cleaning agent that will NOT affect plastic material.
2. Make sure all components are in place and
properly secured. See Figure 7.
Inserter
(Rotate 180° to
Extend Life of
Part)
Shear
(Rotate 180° to
Extend Life of
Part)
3. Make a few test terminations and inspect the
terminations in accordance with Section 5,
INSPECTION.
4. Check for chipped, cracked, worn, or broken
areas. If damage is evident, repair if necessary. See
Section 7, REPLACEMENT AND REPAIR.
Link
6.3. Occasional Maintenance
Because this tool shears wires before insertion, wear
of the shearing surfaces can be expected as a normal
operating condition. Since wire size, insulation
diameter and hardness are all variables, a reasonable
life expectancy of the shearing edges cannot be
determined.
Shearing occurs along the edge where the inserter
rides against the shear. When the operator of the tool
starts to notice wire ends that are not cleanly cut, or if
excessive force becomes necessary to shear the
wires, it is time to change or replace the two
components that do the shearing. Refer to Figure 6
and proceed as follows:
1. To change the position of the shear, remove the
cover of the terminating head by loosening the two
4-40 socket head cap screws which hold the head
in place. Carefully, lift off the cover. See Figure 6.
NOTE
DO NOT lift the inserter off with the cover.
i
2. Lift off the inserter. (Make note as to which side is
in contact with the shear.)
3. Lift off the shear. Rotate the shear 180° so that
the surface that was facing down is now facing up.
Place the shear back in place.
Terminating
Head
Figure 6
NOTE
Make sure that the roll pin going through the
inserter is engaged in the slot of the link.
i
5. Replace the cover. Align the edges of the
terminating head, shear, and cover and tighten the
two 4-40 socket head cap screws.
NOTE
i
This procedure can only be done one time for each
set of inserter and shear. When the second
shearing edge becomes dull, replacement of the
inserter and shear will be necessary.
CAUTION Attempts to sharpen the inserter or shear might
cause the inserter to be out of position during wire
insertion and cause damage to the connector or
!
tool.
4. Replace the inserter, making sure that the
surface (that was in contact with the shear when
disassembling the tool) is now rotated 180° away
from the shear.
Rev B
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408-4074
7. REPLACEMENT AND REPAIR
The parts listed in Figure 7are customer- replaceable.
A complete inventory may be stocked and controlled
to prevent lost time when replacement of parts is
necessary. Order replacement parts through your TE
representative, 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 repair service, please contact a representative at
1-800-526-5136.
8. REVISION SUMMARY
Revisions to this instruction sheet include:
• Changed company name and logo
ITEM NUMBER
TE PART NUMBER
DESCRIPTION
QTY PER ASSY
1
189079-1
FRAME
1
2
189086-1
PAD, Friction
1
3
1-21000-6
SCREW, SHC 4-40 x .62
4
4
21019-1
NUT, Hex 1/4-20
1
5
1-22971-8
PLUNGER, Ball 1/4-20
1
6
189081-1
SHEAR
1
7
189082-1
COVER
1
8
189083-1
INSERTER
1
9
1-21028-2
PIN, Slotted Spring .062 Dia x .88
1
10
21028-1
PIN, Slotted Spring .062 Dia x .19
2
11
189084-1
LINK
1
12
189085-1
ROD, Inserter
1
13
22488-5
SPRING, Compression
1
14
312149-1
ADJUSTER, Inserter Rod
1
Figure 7
Rev B
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