TE Connectivity Crimping Die Assemblies 224027-1 and -2

Diagram: Die Assembly Overview

Illustration shows a crimping die assembly. Key components include the stationary die (anvil) and the moving die (indenter). A die holding screw secures each die. The area for loading the terminal is indicated, as is the wire barrel. The diagram notes that the wire and receptacle size identification is marked in an approximate area. The illustration is not to scale. It is noted that only stranded conductors should be used. The recommended wire strip length is 7.94 [.313].

1. INTRODUCTION

This instruction sheet details the use of Crimping Die Assemblies 224027-1 and -2. These assemblies are designed for use with 626 Pneumatic Tooling Assemblies to crimp the Ultra-Fast Fully Insulated FASTON* receptacle terminals listed in Figure 1.

? All dimensions on this instruction sheet are in metric units [with U.S. customary units in brackets].

? This die assembly requires Adapter Holder 189928-1 and Straight Action Crimper 217200-1 to operate within the 626 Pneumatic Tooling System.

This document also covers terminal and wire specifications, maintenance and inspection procedures, and general performance of the crimping die assemblies. For information concerning die assembly installation and general performance of the pneumatic tool, refer to customer manual 409-5862, which is packaged with the pneumatic tool. Reasons for reissue are provided in Section 7, REVISION SUMMARY.

2. DESCRIPTION

Each die assembly comprises a stationary die (anvil) and a moving die (indenter). The stationary die is equipped with a die holding screw, markings for the applicable wire size, and the part number of the die assembly. The moving die features a die holding screw, the part number of the die assembly, and the "Ultra-Fast" marking, indicating the type of terminal it is designed to crimp.

A terminal locator/stop (locator) is an integral part of each die assembly. The locator functions as a terminal stop, ensuring proper positioning of the terminal between the dies for crimping.

3. INSTALLATION AND REMOVAL OF STRAIGHT ACTION CRIMPER

Before installing the straight action crimper, consult customer manual 409-5862 for instructions on installing the appropriate tool holder assembly (including cam) on the pneumatic tool. After the tool holder assembly is installed, proceed as follows:

? Removal is the reverse of installation.

⚠️ To prevent personal injury, ALWAYS disconnect the main air supply and electrical supply (if applicable) of the pneumatic tool before installing or removing the straight action crimper.

⚠️ DO NOT operate the pneumatic tool without the straight action crimper and the proper die assembly installed. After the straight action crimper is installed, ensure that the quick pins are FULLY tightened to avoid personal injury and damage to the tool.

1. Remove quick pins from the tool holder assembly. Refer to Figure 1, a typical instruction sheet 408-4105.
2. Slide the straight action crimper into the tool holder assembly, aligning the threaded holes on the crimper with the threaded quick pin holes on the holder.
3. After the crimper is properly aligned in the tool holder assembly, insert and tighten the quick pins.

? TE Connectivity recommends using Loctite® 242 removable threadlock, or an equivalent, to prevent the quick pins from loosening.

4. CRIMPING PROCEDURES

Refer to the table in Figure 1 and verify the compatibility of the selected wire, loose-piece terminal, and crimping die assembly. Strip the wire to the length indicated – do NOT cut or nick the wire strands.

Install the die assembly, position the terminal and wire, and perform the crimping procedure as instructed in manual 409-5862, packaged with the 626 Pneumatic Tool.

Ensure all surfaces of the dies are protected with a THIN coat of any good SAE 20 motor oil. Do NOT oil excessively.

5. MAINTENANCE AND INSPECTION

⚠️ To avoid personal injury, ALWAYS disconnect the air supply from the pneumatic tool before performing maintenance or inspection.

TE Connectivity recommends a periodic maintenance and inspection program to ensure dependable and uniform terminations. The frequency of inspection should be adjusted to suit your requirements based on experience. Factors influencing inspection frequency include:

1. The care, amount of use, and handling of the crimping head.
2. The type and size of the product being crimped.
3. The degree of operator skill.
4. The presence of abnormal amounts of dust and dirt.
5. Your own established standards.

Each die assembly undergoes thorough inspection before packaging. Due to the possibility of damage during shipment, new die assemblies should be inspected immediately upon arrival at your facility.

5.1. Daily Maintenance

It is recommended that each operator of the dies be aware of and responsible for the following three steps of daily maintenance:

1. Remove dust, dirt, and other contaminants using a clean brush or a soft, lint-free cloth. Do NOT use objects that could damage the dies.
2. Ensure the dies are protected with a THIN coat of any good SAE 20 motor oil. Do NOT oil excessively.
3. When the dies are not in use, mate them and store them in a clean, dry area.

5.2. Periodic Inspection

Regular inspections should be performed by quality control personnel. A record of scheduled inspections should be maintained with the dies and/or supplied to supervisory personnel responsible for the dies. Although recommendations suggest at least one inspection per month, the inspection frequency should be based on the amount of use, ambient working conditions, operator training and skill, and established company standards. These inspections should be performed in the following sequence:

5.3. Visual Inspection

1. Remove all lubrication and accumulated film by immersing the dies in a suitable commercial degreaser that will not affect paint or plastic material.

Diagram: Replacement Parts

Illustration shows the components of a die assembly with numbered callouts. Dimensions are provided in millimeters [inches]. A table lists replacement parts with item numbers, part numbers, descriptions, and quantity per assembly.

2. Ensure all die holding screws, retaining rings, and die components are in place. Refer to the parts listed in Figure 2 if replacements are necessary.

3. Check components for wear. Remove and replace worn components.

4. Inspect the crimp area for flattened, chipped, cracked, worn, or broken areas. If damage is evident, the dies must be repaired before returning them to service (see Section 6, REPLACEMENT AND REPAIR).

5.4. GAGING THE CRIMPED CHAMBER

This inspection requires the use of a plug gage conforming to the diameters shown in Figure 3. TE Connectivity does not manufacture or market these gages. For additional information concerning the use of a plug gage, refer to instruction sheet 408-7424.

Illustration shows a plug gage design with GO and NO-GO elements. It depicts how these elements interact with the crimping chamber. The GO element must pass completely through the die closure, while the NO-GO element may enter partially but must not pass completely through.

Procedure:

1. Mate the dies until it is evident that they have bottomed. Hold the dies in this position.
2. Align the GO element with the appropriate crimping chamber. Push the element straight into the crimping chamber without using force. The GO element must pass completely through the crimping chamber.
3. Now align the NO-GO element and try to insert it straight into the same crimping chamber. The NO-GO element may start entry but must NOT pass completely through.

If the crimping chamber conforms to the gage inspection, the dies are considered dimensionally correct and should be lubricated with a THIN coat of SAE 20 motor oil. If not, the dies must be repaired before returning them to service (see Section 6, REPLACEMENT AND REPAIR).

6. REPLACEMENT AND REPAIR

Replacement parts are listed in Figure 2. Parts other than those listed in Figure 2 should be replaced by TE Connectivity to ensure the quality and reliability of the tool. 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
P.O. BOX 3608
HARRISBURG, PA 17105-3608

For tool repair service, please contact a TE Representative at 1-800-526-5136.

7. REVISION SUMMARY

Since the previous release of this sheet, the following changes were made:

• Updated document to corporate requirements.