Tyco Electronics 1213850-1 User manual

©2011 Tyco Electronics Corporation, Berwyn, PA
All Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names might be trademarks of their respective owners.
Instruction Sheet
TOOLING ASSISTANCE CENTER 1-800-722-1111
PRODUCT INFORMATION 1-800-522-6752
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com
1of 9
LOC B
626 Pneumatic Crimping Heads
1213850-[ ] (Used with 626
Pneumatic Tool Holder Assemblies) 408-10004
19 JAN 11 Rev B
Figure 1
1. INTRODUCTION
Pneumatic Crimping Heads 1213850-1 and -2 are
designed to crimp STRATO-THERM non-insulated
terminals and splices with insulation support on wire
sizes 22 to 14 AWG. The crimping heads are used with
626 Pneumatic Tool Holder Assemblies. Figure 1
shows the tool holder assemblies, and lists the
pneumatic tooling assemblies for the crimping heads.
This instruction sheet provides recommended
procedures for insulation crimp adjustments, wire
preparation, crimp head installation, crimping, and
maintenance and inspection. For information
concerning tool setup and operation, refer to customer
manual 409-5862. Product specifications and part
numbers are available in Tyco Electronics Catalogs.
See Figure 1.
Read these instructions thoroughly before proceeding.
Measurements are in metric units [followed by U.S.
customary units in brackets]. Figures are for
reference only and are not drawn to scale.
2. DESCRIPTION (Figure 1)
The pneumatic crimping heads consist of integral jaws
which close in an arc-like motion. After an operator
locates the terminal or splice between the crimping
jaws and inserts the stripped wire, the tool is activated
to crimp the product to the wire.
3. HEAD INSTALLATION AND REMOVAL
3.1. Installation
Crimping heads are coated with a preservative to
prevent rust and corrosion. Wipe any excess
preservative from the head, particularly from
crimping surfaces.
Certain precautions should be taken by the
operator to avoid personal injury or damage to the
pneumatic tool. Refer to the instructions packaged
with the pneumatic tool for operation procedures
and safety precautions.
To avoid personal injury, ALWAYS disconnect tool
from air supply before installing crimping head.
Do NOT operate pneumatic tool without proper
crimping head installed; make sure that the quick
pins are FULLY tightened to avoid personal injury
and damage to the tool.
Quick-Pin(s)
354425-1 (Ref)
Rollers Assembly
Pins
Indenter
Crimping
Jaw
Locator
Anvil Crimping Jaw
Crimping Head
1213850-[ ]
Insulation
Adjustment Pin
Tool Holder Assembly
189766-1 or 356303-1
NOTE
i
NOTE
i
CAUTION
!
DANGER
STOP
DANGER
STOP

408-10004
2of 9
Rev B
Figure 2
Determine the wire size, then refer to Figure 2 to
select the appropriate crimping head. Proceed as
follows:
1. Remove quick pins from tool holder. Refer to
Figure 1.
2. Insert crimping head into the tool holder of the
power unit, as shown in Figure 1.
3. After crimping head is properly aligned, insert and
tighten the quick pins provided with the pneumatic
tooling assembly.
It is recommended using LOCTITE‡ 242
removable thread lock, or equivalent, to prevent the
quick pins from loosening.
4. Connect tool to an adequate air supply between
620 to 690 kPa [90 to 100 psi]. For specific
information on air line requirements and air hose
installation, refer to the instructions packaged with
the tooling assembly.
3.2. Removal
ALWAYS disconnect tool from air supply before
removing crimping head.
1. Remove quick pins from crimping head. See
Figure 1.
2. Remove crimping head from tool holder.
4. CRIMPING PROCEDURES
Refer to Paragraph 4.3 for insulation crimp
adjustments.
To avoid personal injury, exercise caution while
holding terminals or splices near the crimping jaws.
4.1. Terminal Crimping Procedure
1. Strip wire to the dimensions shown in Figure 2.
DO NOT nick the wire or use wires with nicked or
missing conductor strands.
2. Open the crimping jaws by squeezing the rollers
together simultaneously.
3. Then position a terminal between the crimping
jaws as shown in Figure 3. The edge of the terminal
wire barrel must rest against the locator.
4. After the terminal is properly positioned in the
crimping jaws, release the rollers to allow the
crimping jaws to spring shut, holding the terminal in
place.
5. Insert a stripped wire into the terminal; then
activate the tool to complete the crimp. Open the
crimping jaws by squeezing the rollers together
simultaneously.
6. Then remove the crimped terminal.
7. Refer to Section 5 and Figure 6 for crimp
inspections
Wire
Barrel
Insulation
Barrel
Insulation
Barrel
Wire
Barrel
Color Coded Sleeves on High
Temperature Terminals and Splices
Finished Crimp
Splice
(Bottom Shown)
Terminal
(Top Shown)
2 Hashmarks
PNEUMATIC
TOOLING
ASSEMBLIES
CRIMPING
HEADS
WIRE
RANGE
SIZE
HASHMARK CODE┼WIRE STRIP LENGTH
MIN. MAX.
189721-1
189722-1
1213850-1 22 - 16 1 Hashmark 5.16
[.203]
5.94
[.234]
1213850-2 16 - 14 2 Hashmarks
┼A Hashmark code Should Appear on the Bottom (Side Opposite Crimp Indents) for High Temperature and Heat Resistant Terminals and Splices when Crimped with
the Proper Crimp Head.
NOTE
i
DANGER
STOP
‡ Trademark of Loctite Corporation
NOTE
i
DANGER
STOP

408-10004
3of 9
Rev B
Figure 3
4.2. Splice Crimping Procedure
1. Strip wire to the dimensions shown in Figure 2.
Do NOT nick the wire or use wires with nicked or
missing conductor strands.
2. Open the crimping jaws by squeezing the rollers
together simultaneously. Position the splice
between the crimping jaws so that the window
indent of the splice slides under the locator of the
crimping head. See Figure 4, Detail A. For best
results, when brazed seam on the splice is visible,
position the seam toward the “W” shaped jaw.
3. Insert the stripped wire into the wire barrel until
the end of the conductor is positioned against the
splice wire stop. See Figure 4, Detail A.
4. Activate the tool to complete crimp. Remove the
splice from the crimping jaws.
5. To crimp the other half of the splice, reposition
uncrimped half in the crimping jaws. Repeat Steps 1
through 4 to complete the crimp. See Figure 4,
Detail B.
Rotate the crimping head if the splice cannot be
repositioned in the crimping jaws.
6. Refer to Section 5 and Figure 6 for crimping
inspection.
Locator
Edge of Wire Barrel
Rests Against Locator
Crimping Head 1213850-[ ]
Terminal (Ref)
Rollers
Terminal Tongue Positioned Under Locator
NOTE
i

408-10004
4of 9
Rev B
Figure 4
4.3. Insulation Crimp Adjustment
The insulation crimping section of the crimping head
has three positions: 1-tight; 2-medium; and 3-loose.
Adjust the insulation crimp as follows:
1. Insert the insulation adjustment pins in position 3.
See Figure 5.
2. Place the terminal or splice in the crimping jaws.
3. Insert unstripped wire into the insulation grip
portion of the terminal or splice.
4. Crimp the terminal or splice as described in
Paragraph 4.1 or 4.2.
5. Remove the terminal or splice. Bend the wire
forward and then backward. The terminal or splice
should retain its grip on the wire. If the wire pulls
out, set the insulation adjustment pins in the next
tighter position and repeat the crimping procedure.
6. Repeat the adjustment as necessary until the
desired insulation grip is obtained. DO NOT use a
tighter setting than required.
Figure 5
Always place both adjustment pins in the same
position. See Figure 5.
5. CRIMP INSPECTION
Inspect crimped terminals and splices by checking the
features described in Figure 6. Use only the terminals
and splices that meet the conditions in the “ACCEPT”
column.
“REJECT” terminations can be avoided through
careful use of the instructions provided in Section 4,
and by performing regular crimping head maintenance
as described in Section 6.
Detail A
Detail B
Splice (Ref)
“W” Shaped
Jaw (Ref)
Locator
Splice
Positioned
Between
Crimping
Jaws
Locator
Window Indent
Under Locator
Second Crimp
Locator
Locator
Window Indent
Under Locator
Crimping Head
1213850-[ ] (Ref)
Positions
Insulation
Adjustment
Pins
NOTE
i
First Crimp

408-10004
5of 9
Rev B
Figure 6
Crimp Inspection

408-10004
6of 9
Rev B
A hashmark code (see Figure 2) should appear on
the bottom (side opposite the crimp indents) for
high temperature and heat-resistant terminals and
splices when crimped with the proper crimping
head.
6. MAINTENANCE AND INSPECTION
To avoid personal injury, disconnect air supply from
pneumatic tool before performing maintenance,
inspection, or repair procedures.
It is recommended that a maintenance and inspection
program be performed periodically to ensure
dependable and uniform terminations.
6.1. Daily Maintenance
It is recommended that each operator be responsible
for the following four steps of daily maintenance:
1. Remove dust, moisture, and outer contaminants
with a clean, soft brush or a lint-free cloth. Do NOT
use objects that could damage the heads.
2. Make sure that all pins, rings and other
components are in place and secure.
3. Make certain all surfaces are protected with a thin
coat of any good SAE 20 motor oil. Do NOT oil
excessively. Wipe excess grease from head,
particularly die closure areas.
4. When head assembly is not in use, store it in a
clean dry area.
6.2. Periodic Inspection
Regular inspections should be performed by quality-
control personnel. A record of scheduled inspections
should remain with the crimping heads or be supplied
to supervisory personnel responsible for the crimping
heads. 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 6.3) and a crimping chamber inspection
(Paragraph 6.5).
6.3. Visual Inspection
1. Make certain all components are in place. Inspect
for missing pins and retaining rings. If replacements
are necessary, refer to Figure 10.
2. Check all bearing surfaces for wear. Replace
worn parts.
3. Inspect the crimp area for flattened, chipped, or
broken areas. See Figure 7. Replace worn or
damaged parts.
6.4. Lubrication
Lubricate all pins, pivot points, and bearing surfaces
with a high quality grease. Tyco recommends the use
of Molykotepaste, which is a commercially available
lubricant. Lubricate according to the following
schedule:
•Head used in daily production - lubricate daily
•Head used daily (occasional) - lubricate weekly
•Head used weekly - lubricate monthly
Wipe excess grease from crimping head,
particularly jaw closure areas. Grease transferred
from the jaw closure area onto certain terminations
may affect the electrical characteristics of an
application.
Figure 7
6.5. Gaging the Crimping Chamber
This inspection requires the use of plug gages
conforming to the dimensions shown in Figure 8. Tyco
Electronics does not manufacture or sell these gages.
Refer to 408-7424. Proceed as follows:
To avoid personal injury, disconnect air supply from
pneumatic tool and remove head from tool.
1. Remove oil and dirt from jaw bottoming surfaces,
jaw closure surfaces, and plug gage elements.
2. Set insulation adjustment pins in position 3. This
will allow access to the wire barrel crimping jaws
from the insulation crimp side of the head.
3. Close wire barrel crimping jaws until they are
bottomed, but not under pressure.
4. Align GO element with crimping chamber. Push
element straight into crimping chamber without
using force. The GO element must pass completely
through the chamber. See Figure 9, Detail A.
NOTE
i
DANGER
STOP
CAUTION
!
Pitted
Chipped Edge
Broken
Corner
Flattened
Area Crimping Head
1213850-[ ]
DANGER
STOP
.
Trademark of Dow Corning Corporation

408-10004
7of 9
Rev B
5. Align NO-GO element and try to insert it into the
crimp chamber. The element may start entry, but it
must not pass completely through the crimping
chamber.
6. Set insulation adjustment pins to position 1 and
repeat this procedure for insulation crimp chamber.
Refer to Figure 9, Detail B.
If crimping chambers pass plug gage inspection, the
crimping head is considered dimensionally correct. If
crimping chambers do not pass this inspection,
contact your local Tyco Electronics Field
Representative or refer to Section 7, REPLACEMENT
AND REPAIR.
For additional information about the use of a plug
gage, see instruction sheet 408-7424.
7. REPLACEMENT AND REPAIR
Customer-replaceable parts are listed in Figure 10. A
complete inventory should be stocked and controlled
to prevent lost time when replacement of parts is
necessary. Parts other than those listed should be
replaced by Tyco to ensure quality and reliability.
Order replacement parts through your representative,
or call 1-800-526-5142, or send a facsimile of your
purchase order to 717-986-7605, or write to:
CUSTOMER SERVICE (038-035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
For customer repair service, please contact a
representative at 1-800-526-5136.
8. REVISION SUMMARY
Since the previous release of this document, the TE
logo has been applied.
Figure 8
Wire Barrel Crimp Insulation Crimp
NO-GO
Dim.
“G”
“W”
“R”
CRIMPING
HEADS
WIRE BARREL DIMENSIONS “A”
mm [In.} RADIUS
“R”
INSULATION BARREL DIMENSIONS “G”
(Adjustment Pins in Position 1) mm [In.} WIDTH
“W”
(Max.)
GO NO-GO GO NO-GO
1213850-1 1.50 [.059] 1.65 [.065] 1.57 [.062] 0.76 [.030] 1.27 [.050] 3.18 [.125]
1213850-2 1.70 [[.067] 1.85 [.073] 1.57 [.062] 1.02 [.040] 1.52 [.060] 4.78 [.188]
Suggested Plug Gage Design

408-10004
8of 9
Rev B
Figure 9
Inspection of Wire Barrel
Crimping Jaws with Plug Gage
Inspection of Insulation
Crimping Jaws with Plug Gage
Crimping head guard NOT shown for clarity.
NOTE
i

408-10004
9of 9
Rev B
Figure 10

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