Instruction Sheet
Pnuematic Platform Adapters
679992- 1 and 679992- 2 (Used with
626 Pneumatic Tooling Assemblies)
408-- 4098
ORIGINAL INSTRUCTIONS
12 MAR 10 Rev D
Quick Pin(s)
Rollers
Link
Locator
Stop
Tool Holder Assembly
189767-- 1 (Ref)
Product:
Ultra-- Fast Fully Insulated FASTON* Terminals
Ultra-- Fast Plus Fully Insulated FASTON Terminals
Wire Size: 26-- 14 AWG
Product Catalog: 82042
Tooling Catalog: 124208
Pneumatic Platform
Adapter 679992-- 1
(Ref)
Top Jaw
Locator
Assembly
Bottom Jaw
Figure 1
1. INTRODUCTION
Pneumatic Platform Adapters 679992--1 (shown in
Figure 1) and 679992--2 are used with 626 Pneumatic
Tooling Assemblies 189721--1, 189722--1, 189723--1,
or 189724--1 when fitted with Tool Holder Assembly
189767--1. The platform adapter accepts the crimping
die assemblies listed in Figure 2 and will crimp
Ultra--Fast FASTON terminals onto wire sizes 26
through 14 AWG.
This instruction sheet provides recommended
procedures for insulation crimp adjustments, wire
preparation, crimp head installation, crimping, and
maintenance and inspection. For information
concerning the setup and operation of the pneumatic
tools, see Customer Manual 409--5862.
Read these instructions thoroughly before
proceeding.
Dimensions in this instruction sheet are in
millimeters [with inches in brackets]. Figures are
not drawn to scale.
NOTE
i
Reasons for reissue are provided in Section 7,
REVISION SUMMARY.
CRIMPING DIE ASSEMBLY
TERMINAL
WIRE SIZE
(AWG)
PART
NUMBER
INSTRUCTION
SHEET
COLOR DOT
CODE
TYPE
CRIMP DOT
CODE
58052--3
408--9277
Violet
Ultra--Fast Fully Insulated FASTON
Terminal
3
26--22
Ultra--Fast Plus Fully Insulated
FASTON Terminal
NA
22--18
NA
16--14
Ultra--Fast
Ultra-Fast Fully Insulated FASTON
Terminal
1
22--18
2
16--14
58079--3
58080--3
90390--3
90391--3
408 9278
408--9278
408 9279
408--9279
Red
Blue
Red
Blue
Figure 2
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 5
LOC B
408- 4098
Pneumatic Platform Adapters 679992- 1 and 679992- 2
2. DESCRIPTION (Figure 1)
NOTE
The platform adapter features a top jaw with a
platform, a bottom jaw, and an adjustable stop. The
top jaw has a mounting hole and the bottom jaw has a
socket head setscrew for securing the crimping die
assembly. The stop adjusts for various terminal series
size. In addition, Adapter --1 has a spring--loaded
locator assembly which aids in positioning the
terminal between the jaws.
i
2. Using hex wrench, turn socket head setscrew
clockwise until secure. Do NOT overtighten.
B. Lower Die
1. Remove die retaining screw from lower die.
The die assembly consists of a lower die and an
upper die, each marked with a color dot code that
must match the color of the terminal insulation.
When closed, the die assembly forms two crimping
chambers, each marked with the wire size range.
2. Squeeze the adapter rollers together to open
jaws. Slide lower die onto bottom jaw of adapter.
Make sure the color dot code on lower die is on the
same side as the color dot code on upper die.
3. Carefully release the rollers to allow the adapter
jaws to close. Make sure that the dies are properly
aligned.
After the operator locates the terminal and inserts the
stripped wire, the tool is activated to complete the
crimp. The crimped terminal will display a crimp dot
code which indicates that the correct crimping die
assembly was used.
4. Insert die retaining screw through the mounting
hole in the platform of the bottom jaw and into the
hole in the lower die.
5. Tighten the die retaining screw until secure.
3. SETUP PROCEDURES
3.1. Die Assembly Installation (Figure 3)
NOTE
i
If upper die will not position properly, use hex
wrench (provided with die assembly) to turn
socket head setscrew either in or out until upper
die is positioned properly.
3.2. Platform Adapter Installation and Removal
The platform adapter must be removed from the
tool holder to install the die assembly. Refer to
Paragraph 3.2, Platform Adapter Installation and
Removal.
A. Installation
NOTE
i
A. Upper Die
1. Slide upper die onto the top jaw of the adapter.
Make sure that the hole on the side of the upper
die aligns with the socket head setscrew in the jaw.
Before installing or removing the adapter,
DISCONNECT THE TOOL FROM THE AIR
SUPPLY. After installation, ALWAYS ensure that
the tool holder quick pins are fully tightened to
avoid personal injury or damage to the tool.
1. Remove quick pins from the tool holder (refer to
Figure 1).
Socket Head
Setscrew
Bottom Jaw
Hole Must Align with
Socket Head Setscrew
Lower Die
Die Retaining
Screw
Color Dot Code
Top Jaw
Hole Must Align with Die
Retaining Screw
2 of 5
Upper Die
Figure 3
Tyco Electronics Corporation
Rev D
408- 4098
Pneumatic Platform Adapters 679992- 1 and 679992- 2
2. Insert platform adapter into tool holder as shown
in Figure 1.
DANGER
3. After platform adapter is properly aligned, insert
and tighten quick pins provided with the tool holder
assembly (refer to Figure 1).
We recommend using LOCTITE{ 242 removable
threadlock, or equivalent, to prevent the quick
pins from loosening..
NOTE
i
4. Connect pneumatic tool to an adequate air
supply between 620 and 690 kPa [90 and100 psi].
For specific information on air line requirements
and air hose installation, refer to the instructions
packaged with the pneumatic tooling assembly.
B. Removal
DANGER
To avoid personal injury, ALWAYS disconnect tool
from air supply before removing platform adapter.
Remove quick pins from platform adapter; then
remove platform adapter from tool holder.
Strip the wire to the appropriate length according to
Application Specification 114--2123. Proceed as
follows:
!
1. The locator stop must be adjusted to
accommodate the terminal series size, which is
marked on the terminal insulation (.110, .187,
or .250). Rotate the blue plastic locator stop until
the series size matches the terminal series size.
NOTE
i
If crimping a flag terminal, the locator stop does
NOT need to be adjusted.
2. Open the dies by squeezing the adapter rollers
together.
3. Center the terminal wire barrel in the appropriate
crimping chamber on the lower die.
a. For straight terminals, insert mating end into
crimping chamber with the flat side facing the
locator assembly (for Adapter --1) as shown in
Figure 4, or the upper die (for Adapter --2). Allow
terminal to butt against the locator stop.
b. For flag terminals, orient the terminal as
shown in Figure 4. The mating end must be
seated on the locator assembly (for Adapter --1),
or the upper die (for Adapter --2).
4. CRIMPING PROCEDURE (Figure 4)
CAUTION
To avoid personal injury or damage to the tool,
always keep fingers clear of jaws, and frequently
check the quick pins to ensure that they are
secure.
4. After terminal is properly positioned, release the
adapter rollers to allow the dies to spring shut,
holding the terminal in place.
Do NOT operate the tool without the platform
adapter or die assembly properly installed.
5. Insert stripped wire into wire barrel until the wire
bottoms.
Lower Die
Strip Length
(Ref)
Ultra-- Fast FASTON
Terminals (Ref)
Series Size Marking
(Must Match Terminal
Series Size)
Locator
Assembly
(Ref)
{ Trademark of Loctite Corporation
Rev D
Upper Die
Locator
Stop
Figure 4
Tyco Electronics Corporation
3 of 5
408- 4098
Pneumatic Platform Adapters 679992- 1 and 679992- 2
6. Activate tool to complete the crimp. Open the
jaws by squeezing the adapter rollers together;
then remove the crimped terminal.
7. Inspect terminal in accordance with 114--2123 to
ensure a proper crimp.
NOTE
i
A properly crimped terminal will display a crimp
dot code on the flat side of the terminal
insulation. For applicable crimp dot codes, refer
to Figure 2. Flag terminals will not have a crimp
dot code.
NOTE
5. MAINTENANCE AND INSPECTION
DANGER
To avoid injury, DISCONNECT TOOL FROM AIR
SUPPLY before performing any maintenance or
inspection procedures.
It is recommended that a maintenance and inspection
program be performed periodically to ensure
dependable and uniform terminations. The platform
adapter should be inspected once a month.
Frequency of inspection should be adjusted to suit
your requirements, and depends on:
1. The care, amount of use, and handling of the
adapter.
B. Lubrication
Lubricate all pins, pivot points, and bearing surfaces
with a high quality grease. The use of MolykoteH
grease, which is a commercially available lubricant, is
recommended. Lubricate according to the following
schedule:
Adapter used in daily production—lubricate daily
Adapter used daily (occasional)—lubricate weekly
Adapter used weekly—lubricate monthly
Wipe excess grease from adapter, particularly from
die closure areas. Grease transferred from the die
closure area onto certain terminations may affect the
electrical characteristics of an application.
5.2. Periodic Inspection
1. Inspect the adapter for missing pins and
retaining rings. If parts are missing or defective,
replace them by referring to Section 6.
2. Check all bearing surfaces for wear. Make sure
the rollers turn freely with minimal resistance.
Replace any worn parts.
3. Inspect the crimping area for flattened, chipped,
or broken areas. Worn or damaged surfaces are
objectionable and will affect the quality of the
crimp.
2. The type and size of the products crimped.
6. REPLACEMENT AND REPAIR
3. The degree of operator skill.
The parts listed in Figure 5 are customer-replaceable. A complete inventory can be stocked
and controlled to prevent lost time when replacement
of parts is necessary. 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:
4. The presence of abnormal amounts of dust and
dirt.
5. Your own established standards.
The platform adapter is thoroughly inspected before
packaging. Since there is the possibility of damage
during shipment, the adapter should be inspected
immediately upon arrival at your facility.
5.1. Maintenance
A. Cleaning
Remove dust, moisture, and other contaminants with
a clean, soft brush, or a soft, lint--free cloth.
Do NOT use objects that could damage the adapter.
Re--lubricate adapter, as instructed in Paragraph
5.1.B. Lubrication, before placing it back into service.
CUSTOMER SERVICE (38--35)
TYCO ELECTRONICS CORPORATION
P.O. BOX 3608
HARRISBURG, PA 17105--3608
Tools may also be returned for evaluation and repair.
For tool repair service, contact a representative at
1--800--526--5136.
7. REVISION SUMMARY
Revisions to this instruction sheet include:
S Added “Original Instructions”
GTrademark of Dow Corning Corporation
4 of 5
Tyco Electronics Corporation
Rev D
408- 4098
Pneumatic Platform Adapters 679992- 1 and 679992- 2
16
15
14
4
11
2
7
10
5
9
17
1
12
13
8
3
6
REPLACEMENT PARTS
ITEM
PART NUMBER
1
217450--1
Jaw, Assembly, Bottom
1
2
217451--1
Jaw, Assembly, Top
1
3
679261--1
Link
2
4
21061--1
Setscrew, Socket Head
2
5
310952--2
Jaw, Platform
1
6
122637--1
Pin, Toggle Link
1
7
122701--1
Spring }
1
8
312388--1
Locator Assembly g
1
9
3--23620--3
Pin, Straight Groove }
2
10
21045--6
Ring, Retaining }
4
11
314479--2
Roller }
4
12
6--23629--1
Pin, Straight Groove
2
13
1--21048--0
Ring, Retaining
4
14
21028--8
Pin, Slotted Spring
1
15
310690--1
Spring, Extension
1
16
679495--2
Pin
1
301185--6
Shim, 0.20 mm [.008 in.] D
At Request
301185--7
Shim, 0.25 mm [.010 in.] D
At Request
301185--8
Shim, 0.30 mm [.012 in.] D
At Request
301185--9
Shim, 0.38 mm [.015 in.] D
At Request
17
DESCRIPTION
QUANTITY PER ADAPTER
D Add Shim to reduce gap by 0.18 mm [.007 in.] (max.) between Link (Item 3) and Retaining Ring (Item 10).
} Recommended Spare Parts
g Locator Assembly (Item 8 ) is not a component of Adapter 679992--2.
Figure 5
Rev D
Tyco Electronics Corporation
5 of 5
