TE Connectivity 2844594-1 User manual

Instruction Sheet

1 of 7

*Trademark

TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners.

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.

408-35007

14 DEC 16 Rev D

Figure 1

1. INTRODUCTION

This instruction sheet covers hand crimping tool PN 2844594-1 used to crimp STRATO-THERM terminals (PN

321897 and PN 321898) to 20 and 18 AWG high temperature wire.

NOTE

Dimensions on this instruction sheet are in millimeters [with inches in brackets]. Figures and illustrations are for identification

only and are not drawn to scale.

2. DESCRIPTION

Each tool features a head containing two stationary crimping dies (anvils) and two movable crimping dies

(indenters), a locator, an insulation crimping adjustment pin, and a CERTI-CRIMP hand crimping tool ratchet

control (see Figure 1).

When closed, the crimping dies form one crimping chamber with two sections: an insulation barrel section and

a wire barrel section. Simultaneously, the insulation barrel section crimps the terminal onto the wire insulation

and the wire barrel section crimps the terminal wire barrel onto the stripped wire. The locator positions the

terminal in the crimping chamber. The insulation crimping adjustment pin is used to regulate the height of the

insulation crimp.

The CERTI-CRIMP hand crimping tool ratchet control ensures full crimping of the terminal. Once engaged, the

ratchet will not release until the tool handles have been FULLY closed.

CAUTION

The crimping dies bottom before the CERTI-CRIMP hand crimping tool ratchet control releases. This design feature ensures

maximum electrical and tensile performance of the crimp. DO NOT re-adjust the ratchet.

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.

Hand Tool; PN 2844594-1, for

Crimping STRATO-THERM* Terminals;

PN 321897 and PN 321898

Restricted to SAFRAN

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Hand Tool

Part Number

Wire Size

(AWG)

Terminal

Part Number

Strip Length

Min.

Max.

2844594-1

20-18

321897

5.16 [0.203]

5.94 [0.234]

321898

Figure 2

3. CRIMPING PROCEDURE

NOTE

Refer to Section 5 for information on the insulation crimp adjustment.

Refer to Figure 3 and the following steps for terminal crimping procedures.

Figure 3

1. Strip the wire to the dimension provided in Figure 2, being careful to avoid nicking or damaging the

conductor(s).

CAUTION

Do NOT use wire with nicked or missing conductors.

2. Open the tool jaws by closing the tool handles until the ratchet releases, then allow the handles to

open fully.

3. Place the terminal in the dies so that the wire barrel butts against the locator.

4. Close the tool handles until the terminal is held firmly in place. Do NOT deform the terminal.

5. Insert properly stripped wire into the terminal until the end of the conductor butts against the locator.

CAUTION

Do NOT allow wire insulation to enter the terminal wire barrel.

6. Complete the crimp by closing the tool handles until the ratchet releases.

7. Release the tool handles, allow the handles to open fully, and remove the crimped terminal.

8. Refer to Section 4 and Figure 4 for terminal crimp inspection procedure.

Hold Down;

PN 2844561-1

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4. CRIMP INSPECTION

Inspect crimped terminals by checking the features described in Figure 4. Terminals, not meeting the

described conditions should NOT be used.

Figure 4

Tooling mark is normal, acceptable and no cause for rejection

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5. INSULATION CRIMP ADJUSTMENTS

The insulation crimping section of the hand tool has three positions: No.1 (tight), No.2 (medium), and No.3

(loose). To adjust the section:

1. Insert the insulation crimp adjustment pins into the No.3 position (refer to Figure 1).

2. Place the terminal into the crimping jaws as shown in Figure 3.

3. Insert the UNSTRIPPED wire into ONLY the insulation barrel (refer to Figure 3) portion of the terminal.

4. Close the tool handles to complete the crimp.

5. Removed the crimped terminal and check the insulation crimp by bending the wire back and forth

once. The terminal should retain its grip on the wire insulation. If the wire pulls out, set the insulation

crimp adjustment pins to the next higher position (No.2).

6. Perform another crimp and repeat the adjustment as necessary until the correct insulation grip is

attained. Do not use a tighter setting than required.

CAUTION

Make sure that both insulation crimp adjustment pins are in the same position.

6. MAINTENANCE AND INSPECTION PROCEDURE

TE Connectivity recommends that a maintenance and inspection program be performed periodically to ensure

dependable and uniform terminations. Though recommendations call for at least one inspection per month,

frequency of inspection depends on:

1. The care, amount of use, and handling of the hand tool.

2. The presence of abnormal amounts of dust and dirt.

3. The degree of operator skill.

4. Your own established standards.

The hand tool is inspected before being shipped; however, TE recommends that the tool be inspected

immediately upon arrival to ensure the tool has not been damaged during shipment.

6.1. Daily Maintenance

1. Hand tool should be immersed (handles partially closed) in a reliable commercial degreasing

compound to remove accumulated dirt, grease, and foreign matter. When degreasing compound is

not available, tool may be wiped clean with a soft, lint-free cloth. Do NOT use hard or abrasive objects

that could damage the tool.

2. Make certain that the retaining pins are in place and that they are secured with retaining rings.

3. All pins, pivot points, and bearing surfaces should be protected with a THIN coat of any good SAE 20

motor oil. Do not oil excessively.

4. When the tool is not in use, keep handles closed to prevent objects from becoming lodged in the

crimping jaws. Store the tool in a clean, dry area.

6.2. Periodic Inspection

Lubrication

1. Lubricate all pins, pivot points, and bearing surfaces with SAE 20 motor oil as follows:

Tool used in daily production: lubricate daily

Tool used daily (occasional): lubricate weekly

Tool used weekly: lubricate monthly

2. Wipe excess oil from tool, particularly from crimping area.

NOTE

Oil transferred from the crimping area onto certain terminations may affect the electrical characteristics of an application.

408-35007

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5 of 7

Visual Inspection

1. Close tool handles until ratchet releases and then allow them to open freely. If they do not open

quickly and fully, the spring is defective and must be replaced. See Section 7, REPLACEMENT AND

REPAIR.

2. Inspect head assembly for worn, cracked, or broken jaws. If damage is evident, return the tool to TE

for evaluation and repair. See Section 7, REPLACEMENT AND REPAIR.

Crimping Die Closure Inspections

1. Each tool is inspected for proper die closure before shipment. However, die closure must be inspected

periodically due to the effects of wear. This inspection requires the use of plug gages conforming to

the dimensions shown in Figure 5.

NOTE

TE Connectivity does not manufacture or sell these gages.

a. To gage die closure, refer to Figure 6 and proceed as follows:

(1) Remove traces of oil or dirt from the crimping chamber and plug gage.

(2) Remove Hold Down.

(3) Close the tool handles until the wire barrel dies are bottomed. Do not apply additional pressure

to the tool handles.

(4) With wire barrel dies bottomed, inspect the wire barrel crimp die closure using the proper plug

gage. Press the spring-loaded locator down and hold gage in alignment with the die closure.

(5) Align the GO element with the wire barrel section of the crimping chamber. Push element

straight into the crimping chamber without using force. The GO element must pass completely

through the crimping chamber (see Figure 6).

(6) Align the NO-GO element and try to insert it straight into the same section of the crimping

chamber. The NO-GO element may start entry, but must not pass completely through the

crimping chamber (see Figure 6).

(7) Insert tool insulation crimping adjustment pin into position No.1.

(8) With crimping dies bottomed, check the insulation barrel section of the crimping chamber as

described in Steps (4) and (5).

(9) Re-install Hold Down.

If the crimping chamber conforms to the gage inspection, the tool is considered dimensionally correct, and

should be lubricated with a THIN coat of any good SAE 20 motor oil. If not, the tool must be returned to TE for

further evaluation and repair. Refer to Section 7, REPLACEMENT AND REPAIR.

For additional information regarding the use of plug gages, refer to Instruction Sheet 408—7424

Figure 5

Wire Barrel Crimp Chamber

Insulation Barrel Crimp Chamber

NO-GO

Width (W)

2.362-2.370

[.0930-.0933]

2.461-2.464

[.0969-.0970]

1.067-1.074

[.0420-.0423]

1.471-1.473

[.0579-.0580]

4.39

[.173]

Suggested Plug Gage Design for Insulation

Barrel Section of Crimping Chamber

Suggested Plug Gage Design for Wire

Barrel Section of Crimping Chamber

GO Dim.

NO-GO Dim.

50.8 [2] Min Typ

Die Closure

Configuration

6.35 [.250] Min Typ

Die Closure

Configuration

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Figure 6

CERTI-CRIMP Hand Crimping Tool Ratchet Control Inspection

1. The CERTI-CRIMP hand crimping tool ratchet control feature on TE hand tools should be checked to

ensure that the ratchet does not release prematurely, allowing the dies to open before they have fully

bottomed. Obtain a 0.025 mm [.001 in.] shim that is suitable for checking the clearance between the

bottoming surfaces of the crimping dies. Proceed as follows:

a. Select the maximum size wire for the tool and a terminal.

b. Position the terminal and wire between the crimping dies as described in Section 3.

c. Hold wire in place and squeeze tool handles until the CERTI-CRIMP hand crimping tool ratchet

control releases. Hold the handles in this position; maintaining just enough tension to keep the dies

closed.

d. Check the clearance between the bottoming surfaces of the crimping dies with the 0.025 mm [.001

in.] shim. If the clearance is 0.025 mm [.001 in.] or less, the ratchet is considered satisfactory. If the

clearance exceeds 0.025 mm [.001 in.], the ratchet is out of adjustment and must be repaired.

NOTE: Remove Hold

Down to gage wire

barrel die.

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Rev D

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7. REPLACEMENT AND REPAIR

Replaceable parts are listed in Figure 7. Parts other than those listed in Figure 7 should be replaced by TE to

ensure 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 (38-35)

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.

Item

No.

Description

Qty

Per Tool

Replacement

Part Number

Item

No.

Description

Qty

Per Tool

Replacement

Part Number

Pin, Retaining

300388

Spring

7-59683-6

Ring, Retaining

525108

Screw

59580-6

Pin, Retaining

300389

Stationary Die, Insulation

576788-1

Ring, Retaining

21045-6

Moving Die, Insulation

576785-1

Pin, Adjustment

1752891-1

21028-4

Locator, Stop

1901238-2

Hold Down

2844561-1

5-21028-7

Screw

18023-2

Figure 7

8. REVISION SUMMARY

Revisions to this Instruction Sheet include:

Revised RESTRICTION on top of page 1.

Added Note 7 and applicable image to Figure 4.

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