Instruction Sheet Electro-Hydraulic Hand Tool Adapter Assembly 2119840-1 for 408-10386 Heavy Head Hand Tool Assemblies 31 AUG 10 Rev A Tool Head Adapter Assembly Electro-Hydraulic Hand Tool Quick-Release Pins Trigger Handle Assembly The Heavy Head Hand Tool Head is a premium- grade tool head and is designed primarily for field installation, repair, maintenance work, or prototyping in Battery (Power Source) industrial, commercial, or institutional applications. A Battery Release wide selection of powered application equipment for extended use production is available. Figure 1 Refer to Customer Manual 409-10095 for information 1. INTRODUCTION concerning Electro-Hydraulic Hand Tool 2031400- . The Tyco Electronics Heavy Head Hand Tool (HHHT) All dimensions on this instruction sheet are in Head Adapter Assembly 2119840-1 is designed to NOTE metric units with inches in brackets . Figures and couple any Tyco Electronics HHHT head assembly illustrations are for identification only, and are not (example: 1-59239-4) to the Electro-Hydraulic Hand i drawn to scale. Tool (2031400- ). Refer to Figure 1 to see the hand tool, adapter, and HHHT head. 2. RECEIVING/INSPECTION The Electro-Hydraulic Hand Tool and specific HHHT head assemblies must be ordered separately. Adapter Assembly 2119840-1 is thoroughly inspected during and after assembly. Prior to packaging and For specific HHHT crimp head information (including shipping a final series of tests and inspections is wire preparation, crimping procedures, maintenance made to ensure proper function of the adapter. The and inspection procedures, as well as repair and following inspections should be performed as a replacement procedures) refer to the appropriate safeguard against potential problems generated in instruction sheet for the associated hand tool and transit. crimping head. 2010 Tyco Electronics Corporation, Berwyn, PA This controlled document is subject to change. TOOLING ASSISTANCE CENTER 1-800-722-1111 1 of 3 All Rights Reserved For latest revision and Regional Customer Service, PRODUCT INFORMATION 1-800-522-6752 TE logo and Tyco Electronics are trademarks. visit our website at www.tycoelectronics.com *Trademark. Other products, logos, and company names might be trademarks of their respective owners. LOC B ORIGINAL INSTRUCTIONS408-10386 1. In a well-lighted area, carefully unpack the These pins must be removed prior to installing the adapter and inspect each component as it is HHHT crimp head. unpacked. 1. Remove the quick-release pins (see Figure 1). 2. Thoroughly inspect each component for 2. Insert the HHHT tool head into the adapter evidence of damage that may have occurred in cavity. transit. If any of the components are damaged, file a claim against the carrier and notify Tyco 3. Insert the two outer quick-release pins Electronics immediately. through the holes in the adapter housing and the holes in the two outer tabs of the HHHT crimp It is IMPORTANT that these instructions, and NOTE head. See Figure 1. other documents shipped with the tooling (e.g., drawings, parts lists, tooling manual, etc.), remain The quick-release pins will snap into position i NOTE with the adapter, head, and hand tool for the when they are properly inserted. benefit of personnel responsible for installation, i operation, and maintenance. The adapter should be inspected at regularly 4. Insert the center quick-release pin into the scheduled intervals, depending on care, degree of adapter ram and through the moveable die of operator skill, the type and size of product being the HHHT crimp head. crimped, and environmental conditions. At a 5. Squeeze the trigger on the handle assembly minimum, the adapter should be inspected on a until the tool completes an advance cycle and weekly basis. retracts to join the handle assembly ram to the adapter ram. 3. INSTALLATION/REMOVAL OF ADAPTER ASSEMBLY B. Removal AND HHHT HEADS 1. Remove the quick-release pins. Do not operate the Electro-Hydraulic Hand Tool CAUTION 2. Remove the HHHT head from the adapter without the HHHT head and adapter installed. cavity. Repeated operation in this manner may result in 4. OPERATION damage to the Electro-Hydraulic Hand Tool. The following procedure provides only general information concerning crimping. Refer to the To avoid personal injury, be sure to exercise DANGER instructions packaged with the HHHT crimp head for extreme caution when handling the Electro- detailed information, including wire stripping STOP Hydraulic Hand Tool. Remove the power source dimensions and instructions for positioning terminals (and release hydraulic pressure, if applicable -- and splices in the crimpers. see 409-10095) before installing or removing the HHHT tool head or adapter assembly. To avoid personal injury, keep fingers clear of the DANGER crimping area. STOP 3.1. Adapter Installation/Removal Refer to the Electro-Hydraulic hand tool manual To operate the HHHT crimp head in the Electro- (409-10095) for instructions on installing and Hydraulic Hand Tool using the Adapter assembly, removing the adapter assembly and the crimping proceed as follows: heads. 1. Insert the contact into the appropriate die Note that adapter 2119840-1 does not have a cavity. terminal grip thumb button. To remove the adapter, unscrew it completely, and then pull the adapter away 2. Pulse the trigger to advance the lower tooling from the cylinder assembly. and hold the contact in place. Do not deform the terminal insulation or wire barrel. 3.2. HHHT Head Installation Removal 3. Place a pre-stripped wire in the barrel of the A. Installation contact. As supplied, the adapter assembly has three quick- 4. Squeeze the tool trigger until the jaws release. release pins installed. Refer to Figure 1. The two When the jaws release, the crimp is complete. outer pins will be used to secure the outer housing tabs of the HHHT crimp head to the adapter It is not necessary to continue to hold the trigger to NOTE assembly. retract the tooling. The tooling will retract automatically. The center pin will be used to secure the movable die i of the HHHT crimp head to the ram of the adapter assembly. 5. Remove the terminated wire. Rev A 2 of 3