Instruction Sheet Quadrax Ferrule Insertion Tools 408-10191 1976593- 08 MAR 12 Rev D PROPER USE GUIDELINES Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools. Hand tools are intended for occasional use and low volume applications. A wide selection of powered application equipment for extended-use, production operations is available. Reasons for reissue of this instruction sheet are provided in Section 7, REVISION SUMMARY. 2. DESCRIPTION (See Figure 1) Pliers Each insertion tool consists of a pliers and a jaw kit except Tool -5 which includes four jaw kits (1976593-1 through -4). The jaw kit consists of a top jaw, bottom Thumbscrew jaw, and two thumbscrews. The top jaw is designed to (1 Per Jaw) hold the cable and the bottom jaw is designed to hold Jaw Mount the shell during insertion of the ferrule. (2 Places) The jaws are interchangeable between the pliers (of the insertion tools) and the jaw mounts (of the pliers). The jaw kits are also available separately (part Jaw Kit numbers are given in Figure 1). (Refer to Table) 3. JAW INSTALLATION AND REMOVAL To install the jaws, proceed as follows: 1. Slide the top jaw onto either jaw mount of the pliers until it stops. Make sure that the thumbscrew INSERTION faces outward. Tighten the thumbscrew. JAW KIT USED WITH TOOL 2. Slide the bottom jaw onto the other jaw mount Standard Sockets 1445693- until it stops. Make sure that the thumbscrew faces 1976593-1 1976923-1 outward. Tighten the thumbscrew. Boeing BACC47GB1 or BACC47GN1 3. Close the handles of the pliers until the jaws Standard Pin 1445692- 1976593-2 1976923-2 bottom. Check that the jaws align. Boeing BACC47GA1 or BACC47GM1 To remove a jaw, loosen the thumbscrew, and slide the 1976593-3 1976923-3 Short Socket 2000032-1 jaw out of the jaw mount. 1976593-4 1976923-4 Short Pin 2000031-1 4. USING THE TOOL All of the 1976593-5 All of the Above Above These instructions assume that the pin or socket NOTE Standard Socket 1445693- contact is properly installed onto the cable. 1976923-1 Boeing BACC47GB1 or BACC47GN1 i 1976593-6 Standard Pin 1445692- 1976923-2 Refer to Figure 2, and proceed as follows: Boeing BACC47GA1 or BACC47GM1 1. Fully open the handles of the pliers. Long Pin 2000377-1 1976593-7 1976923-5 2. Position the shell of the contact in the bottom jaw Boeing BACC47GM1 so that the shoulder rests on the jaw. Included with Insertion Tool and Available Separately. 3. Position the cable in the top jaw. Make sure that Figure 1 the cable is straight. 1. INTRODUCTION 4. Close the handles until the jaws bottom. Fully open the handles, and pull the contact and cable Quadrax Ferrule Insertion Tools 1976593- are used from the jaws. to insert the ferrule into the shell of Quadrax pin and socket contacts. If used properly, the tool ensures proper insertion depth. Boeing is a trademark. 2012 Tyco Electronics Corporation, a TE Connectivity Ltd. company TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. 1 of 2 All Rights Reserved PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, *Trademark visit our website at www.te.com TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners. 408-10191 To avoid personal injury, DO NOT hold onto the 5.2. Periodic Inspection DANGER cable or shell near the jaws when closing the Regular inspections should be performed by quality handles. Keep fingers and objects clear of the jaws. STOP control personnel. A record of scheduled inspections should remain with the insertion tool or be supplied to personnel responsible for the insertion tool. 6. REPLACEMENT AND REPAIR Pliers Handles The insertion tools are not repairable. Order insertion Fully Open tools and jaw kits 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 Cable 7. REVISION SUMMARY Revisions to this instruction sheet include: Top Jaw Added insertion tool and jaw kit to Figure 1 Added jaw kit part numbers to Section 2 Ferrule (Ref) Removed ORIGINAL INSTRUCTIONS Bottom Jaw Shoulder of Shell Figure 2 5. MAINTENANCE AND INSPECTION 5.1. Daily Maintenance It is recommended that each operator be made aware of, and responsible for, the following steps of daily maintenance. 1. Remove dust, moisture, and contaminants with a clean, soft brush or a lint-free cloth. DO NOT use objects that could damage the insertion tool components. 2. Ensure that all components are in place and properly secured. 3. When the insertion tool is not in use, keep the handles closed to prevent objects from becoming lodged in the jaws. Store it in a clean, dry area. Rev D 2 of 2