Instruction Sheet
408-- 4366
626 Pneumatic Crimping Heads
662546- 1 and 1320369- 1
ORIGINAL INSTRUCTIONS
11 MAR 10 Rev C
Quick
Pin(s)
Rollers
626 Pneumatic
Crimping Head
662546- 1 Shown,
(Ref)
Link
Lower
Crimping Jaw
Tool Holder
Assembly
189767-- 1 or
356302-- 1
Locator
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
1 of 10
LOC B
408- 4366
Pneumatic Crimping Heads 662546- 1 and 1320369- 1
wire, the pneumatic tool is activated to crimp the
product to the wire.
i
4.1. Wire Selection
Select wire for the terminals and splices according to
Application Specification 114--2121.
3. HEAD INSTALLATION AND REMOVAL
NOTE
4. WIRE SELECTION AND PREPARATION
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
3.1. Installation
DANGER
To avoid personal injury, ALWAYS disconnect
pneumatic tool from air supply before installing or
removing the crimping head.
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.
i
Strip Length
Note: Not to Scale
1. Remove quick pins from tool holder. Refer to
Figure 1.
CRIMPING
HEAD
2. Insert crimping head into tool holder as shown in
Figure 1.
662546--1
1320369--1
3. After crimping head is properly aligned, insert
and tighten quick pins provided with the tool holder.
See Figure 1.
NOTE
i
STRANDED COPPER WIRE
SIZE
(AWG)
CIRCULAR
MIL AREA
STRIP LENGTH
(mm [IN.])
8
13,100--20,800
10.31--11.86
[.406--.469]
Figure 2
5. CRIMPING PROCEDURE
DANGER
Tyco Electronics recommends using LOCTITE{
242 removable threadlock, or equivalent, to
prevent the quick pins from loosening.
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.
5.1. Terminal Crimping Procedure
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
Do not strip film--insulated copper or
film--insulated aluminum wire.
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.
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.
{ Trademark of Loctite Corporation
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Tyco Electronics Corporation
Rev C
408- 4366
Pneumatic Crimping Heads 662546- 1 and 1320369- 1
5. Refer to Section 6 for crimp inspection.
NOTE
i
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.
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.
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 wire into splice wire barrel until
the end of the conductor butts against the splice
wire stop.
2. After splice is properly positioned, release rollers
to allow crimping jaws to spring shut, holding splice
in place.
4. Activate the tool to complete the crimp. Open
crimping jaws by squeezing the rollers together
simultaneously; then remove crimped splice.
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. To crimp the other half of the splice, follow the
same procedure for the uncrimped half of the
splice.
5. Refer to Section 6 for crimp inspection.
Detail A — Terminal
Detail B — Butt Splice
Splice Window
Facing Upper Jaw
Wire Barrel
Against Locator
Splice Wire Stop
Sitting on Locator
End of Conductor
Against Locator
Lower
Jaw
Back of Terminal
Facing Upper Jaw
Lower
Jaw
End of Conductor
Against Splice Wire Stop
End of Conductors
Against Locator
End of Splice
Against Locator
Lower
Jaw
Detail C — Parallel Splice
Figure 3
Rev C
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408- 4366
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.
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.
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).
7.3. 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
4 of 10
Flattened
Area
To avoid personal injury and damage to the
crimping head, make sure quick pins are fully
tightened.
Tyco Electronics Corporation
Broken
Corner
Figure 4
Rev C
408- 4366
Pneumatic Crimping Heads 662546- 1 and 1320369- 1
Crimp Inspection
ACCEPT
1
REJECT
4
Wire Range
Stamped
Under Tongue
2
3
4
COPALUM
Terminal
Wire Range
Stamped
Under Tongue 2
7
1
3
1
4
3
COPALUM
Butt Splice
4
3
Wire Range 2
Stamped
On Side
Wire Range 2
Stamped
On Side
1
COPALUM
Parallel Splice
1
5
6
3
1
2
3
4
1
7
1
3
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.
1
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.
3
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.)
4
Excessive flash or extruded insulation. (Wrong crimping head
and terminal combination used, or damaged jaws.)
5
Wire insulation entered wire barrel (applies to stranded copper
wire only). Check for correct wire size or strip length.
6
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.
2
7
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.
Figure 5
Rev C
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Pneumatic Crimping Heads 662546- 1 and 1320369- 1
7.4. Lubrication
Lubricate all pins, pivot points, and bearing surfaces
with a high quality grease. A recommendation is
Molykote} grease, which is a commercially available
lubricant. Lubricate according to the following
schedule:
conforming to the dimensions shown in Figure 6.
Tyco does not manufacture or market these gages.
DANGER
S Head used in daily production -- lubricate daily
S Head used daily (occasional) -- lubricate weekly
S Head used weekly -- lubricate monthly
Disconnect air supply and remove crimping head
from pneumatic tool before inspecting crimping
chamber.
1. Remove oil and dirt from the bottom of the jaw
surfaces and plug gage element surfaces.
2. Close crimping jaws until they are bottomed, but
not under pressure.
Wipe excess grease from crimping head, particularly
from jaw closure areas. Grease transferred from jaw
closure area onto certain terminations may affect the
electrical characteristics of an application.
3. Align the GO element with the inner crimping
section. Push element straight into the crimping
chamber without using force. The GO element
must pass completely through the crimping
chamber and then rotate freely in either direction.
See Figure 7, Detail A.
7.5. Gaging the Crimping Chamber
This inspection requires the use of plug gages
Suggested Plug Gage Design for Inner Crimping Section
GO
NO-- GO
Jaw Closure
Configuration
50.8 mm
[2.00 in.]
A
1/
2A
D
C
B
GAGE ELEMENT DIMENSIONS (mm [IN.])
CRIMPING
HEAD
GO
NO-- GO
“A”
“B”
“C”
“D”
662546--1
1320369--1
2.997--3.005
[.1180--.1183]
3.249--3.251
[.1279--.1280]
1.65
[.065]
7.37
[.290]
7.87
[.310]
.610
[.024]
Suggested Plug Gage Design for Outer Crimping Section
GO
NO-- GO
Jaw Closure
Configuration
50.8 mm
[2.00 in.]
A
1/
2A
D
C
B
GAGE ELEMENT DIMENSIONS (mm [IN.])
CRIMPING
HEAD
GO
NO-- GO
“A”
“B”
“C”
“D”
662546--1
1320369--1
4.445--4.453
[.1750--.1753]
4.798--4.801
[.1889--1890]
2.29
[.090]
3.30
[.130]
7.87
[.310]
1.14
[.045]
Figure 6
} Trademark of Dow Corning Corporation
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Rev C
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Pneumatic Crimping Heads 662546- 1 and 1320369- 1
4. Align the NO--GO element with the inner
crimping section. Push element straight into the
crimping chamber without using force. The
NO--GO element must pass completely through
the crimping chamber and then must not rotate.
See Figure 7, Detail A.
5. Open the crimping jaws. Position the GO
element on the lower jaw in the right outer crimping
section so that the locator is in the notch of the
element. Close the crimping jaws so that the lower
jaw surface of the crimping chamber is seated on
the element. The GO element must pass
completely through the crimping chamber and then
rotate freely in either direction. See Figure 7,
Detail B.
6. Position the NO--GO element on the lower jaw
in the right outer crimping section so that the
locator is in the notch of the element. Close the
crimping jaws so that the lower jaw surface of the
crimping chamber is seated on the element. The
NO--GO element must pass completely through
the crimping chamber and then must not rotate.
See Figure 7, Detail B.
7. Repeat Steps 5 and 6 for the left outer crimping
section.
If the crimping chamber passes the gage inspection,
the crimping head is considered dimensionally correct
and should be lubricated with a THIN coat of any
Rev C
good SAE 20 motor oil. If the crimping chamber does
not conform to the plug gage conditions, contact your
local Field Representative or refer to Section 8.
For additional information about the use of a plug
gage, see instruction sheet 408--7424.
8. REPLACEMENT AND REPAIR
Replacement parts and recommended spares are
listed in Figure 8. The recommended spares should
be stocked for immediate replacement.
Order replacement parts through your 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 (38--35)
TYCO ELECTRONICS CORPORATION
P.O. BOX 3608
HARRISBURG, PA 17105--3608
For repair service, please contact a representative at
1--800--526--5136.
9. REVISION SUMMARY
Since the previous release of this document, the
following changes have been made:
S Added “Original Instructions;”
S Applied the TE logo.
Tyco Electronics Corporation
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408- 4366
Pneumatic Crimping Heads 662546- 1 and 1320369- 1
Detail A
Detail B
Inspection of
Inner Crimping Section
Inspection of
Outer Crimping Section
“GO” Gage Element Must Rotate
Freely in Either Direction
Left Outer
Crimping
Section
Crimping Jaws
Bottomed But Not
Under Pressure
Right Outer
Crimping
Section
Lower Jaw
Locator
“NO- GO” Gage Element
Must Not Rotate
Crimping Jaws
Are Not Bottomed
Lower Jaw
Surfaces of Crimping
Chamber Seated on
Gage Element
Locator Positioned in
Notch of Gage Element
Figure 7
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Rev C
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Pneumatic Crimping Heads 662546- 1 and 1320369- 1
Pneumatic
Crimping Head
662546- 1
3
1
4
12
13
15
7
14
8
9
6
5
2
16 17 18 19
Add Shims to Reduce Gap
Between Item 6 (Retaining Ring)
and Item 11 (Link) to 0.178 mm [.007 in.] (Max)
11
10
3.68-- 3.71 mm
[1.45-- 1.46 in.]
Pneumatic
Crimping Head
1320369- 1
4
20
25
24
8
9
21
30
26 27 28 29
23
22
7
Rev C
Tyco Electronics Corporation
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Pneumatic Crimping Heads 662546- 1 and 1320369- 1
CUSTOMER REPLACEMENT PARTS
ITEM
PART NUMBER
DESCRIPTION
HEAD 662546-- 1
(QTY PER HEAD)
HEAD 1320369-- 1
(QTY PER HEAD)
1
662547--1
INDENTER
1
——
2
662548--1
ANVIL
1
——
3
679942--1
SPRING
1
——
4
23241--2
BALL, Steel
1
1
5
6--23629--0
PIN, Str Grv, .3125 Dia x 1.488
2
——
6
1--21048--0
RING, Retaining
4
——
7
314479--4
ROLLER
4
4
8
3--23620--3
PIN, Str Grv, .2500 Dia
2
2
9
21045--6
RING, Retaining
4
4
10
662549--1
GUARD
1
——
11
768521--6
LINK
2
——
12
189973--2
LOCATOR
1
——
13
21919--4
PIN, Dowel
1
——
14
22353--4
SCREW, Shoulder
1
——
15
2--25022--3
SPRING, Compression
1
——
16
301185--6
SHIM, 0.20 mm [.008 in.]
as required
——
17
301185--7
SHIM, 0.25 mm [.010 in.]
as required
——
18
301185--8
SHIM, 0.31 mm [.012 in.]
as required
——
19
301185--9
SHIM, 0.38 mm [.015 in.]
as required
——
20
1320368--1
ANVIL
——
1
21
1320367--1
INDENTER
——
1
22
1320370--1
GUARD
——
1
23
1320371--1
LINK
——
2
24
5--23630--2
PIN, Str Grv, .378 Dia x 1.508
——
2
25
1--21048--3
RING, Retaining
——
4
26
1--301185--7
SHIM, 0.20 mm [.008 in.]
——
as required
27
1--301185--8
SHIM, 0.25 mm [.010 in.]
——
as required
28
1--301185--9
SHIM, 0.31 mm [.012 in.]
——
as required
29
2--301185--0
SHIM, 0.38 mm [.015 in.]
——
as required
30
679942--2
SPRING
——
1
Figure 8
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