adjuster (insertion rod) wire inserter (not shown) shear ball plunger (not shown) ? 2011 tyco electronics corporation, a te connectivity ltd. company ? all rights reserved *trademark te connectivity, te connectivit y (logo), and te (logo) are trademarks. other logos, product and/or company names may be tradem arks of their respective owners. 1 of 5 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.te.com loc b 408-4074 terminating head 122533-1 ? for communications outlet - ? edge connector kit 21 oct 11 rev b 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. re ad 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. 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 in structions supplied with the connector kit. the communications outlet - edge connector kit 5 56524-1 consists of three components: 1. housing 2. terminals 3. stuffer assembly to make the edge connector compatible with the ter minating head, the stuffer assembly (supplied with 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. caution ! failure to use the strain relief may cause the following conditions: 1. the wire insertion will not have the proper ret aining force. 2. the wire may flex at the termination slot and br eak off at that point. 3. during termination in the tool, the product may no t 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 ha ndle assembly and serves as a guide and support for the connector during te rmination. 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. ball plunger - alig ns connector in proper position for wire insertion.
408-4074 2 of 5 rev b shear - positions the connector at the proper depth location and is a shearing surface for the wire. note i the wire inserter and the shear can be rotated 180 to extend the usable life of these parts. 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. 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 pl a ce it in the tool. make a test termination using the procedures described in section 4, terminating procedure. note i the connector may be loaded and indexed (manually) from either side of the tool. figure 2 3. remove terminated connector. 4. inspect the connector for proper termination u sing the inspection requirements in figure 5 . if the wire insertion depth is incorrect, proceed to pa ragraph 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 ad juster 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. ? if wire is not deep enough in contact slot: remove the head and turn the adjuster counter- clockwise. refer to figure 3 . a 1/6-revolution adjustment will increase the w ire 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.] turn counterclockwise 1/6-revolution to increase wire insertion depth approximately 0.41 mm [.016 in.] adjuster (insertion rod) figure 3 4. termination procedure multi-pair copper-conductor cables must be prepared as follows: 1. strip the cable jacket and untwist the individual con ductors to the dimension shown in figure 2 . 2. insert connector into the terminating head (from eith er side) and position the connector so that the two terminals are aligned under the two wire slots. note i 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 visi ble 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 ratche t releases. this will shear the wires and insert the wires into the wire slots of the connector.
wires inserted into wire slot terminating head (ref) connector strain relief 556805-1 (ref) terminals aligned with wire slots 408-4074 3 of 5 rev b figure 4 5. discard the sheared wires from the terminating head. 6. release the cam handle. the inserter will retract. 7. manually reposition the connector in the ter minating head to the next pair of terminals to be terminated. 8. repeat steps 2 through 7 until all the terminals ha ve been terminated. 9. remove connecto r f rom 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 the procedures that follow have been established to ensure the quality an d reliability of te rminating heads. a brief check should be made daily, and a more detailed inspection should be scheduled by your quality control personnel. 6.1. daily maintenance each operator should be aware of the following: 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 pr operly secured. refer to figure 7 . 3. actuate handle assembly to ensure mechanisms in side terminating head move smoothly. figure 5
408-4074 4 of 5 rev b 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. these inspections should be performed in the follo wing sequence: 1. remove any accumulat ed film w ith a suitable cleaning agent that will not affect plastic material. 2. make sure all components are in place and pr operly secured. see figure 7 . 3. make a few test terminations and inspect the ter minations in accordance with section 5, inspection. 4. check for chipped, cracked, worn, or broken a reas. if damage is eviden t, repair if necessary. see section 7, replac ement and repair. 6.3. occasional maintenance because this tool shears wir es 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 r ides 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 i do not lift the inserter off with the cover. 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. 4. replace the inserter, making sure that the sur face (that was in contact with the shear when disassembling the tool) is now rotated 180 away from the shear. socket head cap screws cover shear (rotate 180 to extend life of part) terminating head inserter (rotate 180 to extend life of part) link figure 6 note i make sure that the roll pin going through the inserter is engaged in the slot of the link. 5. replace the cover. align the edges of the ter minating 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 ins erter 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 da mage to the connector or tool.
408-4074 5 of 5 rev b 7. replacement and repair the parts listed in figure 7 are customer- replaceable. a complete inventory may be stocked and controlled to pr event 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. 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 8. revision summary revisions to this instruction sheet include: ? changed company name and logo figure 7
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