Tyco Electronics 1804834-1 User manual

Instruction Sheet

Hand Crimping Tool 1804834- 1 and

Crimping Head 1- 1804834- 1 for Raychem 408--10048

LOC B

1of 5

E2009 Tyco Electronics Corporation, Harrisburg, PA

All International Rights Reserved

TE logo and Tyco Electronics are trademarks.

*Trademark. Other products, logos, and company names used are the property of their respective owners.

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

09 DEC 09 Rev BMiniSeal* Splices

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.

Figure 1

20--26

16--20

12--16

CERTI--CRIMP*

Hand Tool Ratchet

Nest Jaw

Anvil Jaw

Handle(s)

Contact Locator

(On Back of Tool)

1. INTRODUCTION

Double Action Hand Tool (DAHT) 1804834--1 and

Crimping Head 1--1804834--1 (shown in Figure 1) are

used to crimp Raychem MiniSeal Splices listed in

Figure 2 onto stranded wire sizes 26--12 AWG.

Read these instructions thoroughly before using the

tool.

Dimensions in this instruction sheet are in

millimeters [with inch equivalents in brackets].

Figures and illustrations are for reference only

and are not drawn to scale.

Reasons for reissue of this instruction sheet are

provided in Section 7, REVISION SUMMARY.

2. DESCRIPTION

The tool consists of a ratchet, two crimping jaws

(indenter and anvil) containing three crimping

chambers, and a terminal locator. The tool is marked

with the wire size range for each crimping chamber.

SeeFigure1.Fullcrimpingofthespliceisassuredby

the ratchet. Once engaged, the ratchet does not

release until the tool handles have been FULLY

closed.

The crimping jaws bottom before the ratchet

releases. This feature ensures maximum

electrical and tensile performance of the crimp.

Do NOT re--adjust the ratchet.

MiniSeal Splice

Note: Not to Scale

Wire

TE Hand

Tool/

Crimping

Head

Raychem

Splice

No.D

Splice

Color

Code

Crimping

Chamber

Marked

Wire

Size

Range

(AWG)

Wire

Strip

Length

D--436--36 Red 20--26 20--26 7.9--8.6

[.31--.34]

1804834--1

1--1804834--1 D--436--37 Blue 16--20 16--20 7.9--8.6

[.31--.34]

D--436--38 Yellow 12--16 12--16 7.9--8.6

[.31--.34]

DQualified to MIL--S--81824/1

Figure 2

3. CRIMPING PROCEDURE

Strip the wire according to the dimensions listed in

Figure 2. The strip length is determined by the splice

and by the wire size. Do not nick or cut the wire

strands. Proceed as follows:

1. Close the tool handles until the ratchet releases.

Allow the tool handles to open fully.

2. Place the splice against the locator in the

appropriate crimp chamber. See Figure 3.

3. While holding the splice in place, squeeze the

tool handles together just until the jaws begin to

close on the wire barrel. Do NOT deform the wire

barrel.

4. Insert the stripped wire into the wire barrel,

making sure that the wire insulation does not enter

the wire barrel.

5. While holding the wire in place, squeeze the tool

handles together until the ratchet releases, then

allow the tool handles to open fully.

NOTE

CAUTION

408- 10048

Hand Crimping Tool 1804834- 1 and Crimping Head 1- 1804834- 1

Rev B2 of 5 Tyco Electronics Corporation

Figure 3

Splice Placed

Against Locator in

Crimping Chamber

Step 2

Upper Jaw

Lower Jaw

Lower Ja

Wire Being

Crimped

Wire Being

Crimped

1st Wire

Locator

Splice

If the wire is stripped correctly (Figure 2), the

conductor will be exposed slightly more than the

thickness of the locator. This will allow the

conductor to enter the slot in the locator

6. To crimp the other half of a butt splice, position

the crimped wire barrel against the locator. The

crimped wire will go through the slot in the locator.

The uncrimped barrel will line up with the crimping

chamber. Repeat the crimping procedure.

If the splice cannot be turned for crimping other

half, turn the tool around.

4. CRIMP INSPECTION

Inspect crimped terminals and splices by checking the

features described in Figure 4. Poor crimps can be

avoided by carefully following the procedures

provided in Section 3, and by following the tool

maintenance procedures provided in Section 5.

5. MAINTENANCE AND INSPECTION

Tyco Electronics recommends that a maintenance

and inspection program be performed periodically to

ensure dependable and uniform terminations.

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 tool is inspected before being shipped; however,

Tyco Electronics recommends that the tool be

inspected immediately upon arrival at your facility to

ensure that the tool has not been damaged during

shipment.

5.1. Daily Maintenance

1. Remove dust, moisture, and other contaminants

with a clean brush, or a soft, lint--free cloth. Do

NOT use 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.

5.2. Lubrication

Lubricate all pins, pivot points, and bearing surfaces

with SAE 20 motor oil as follows:

Tools used in daily production—lubricate daily

Tools used daily (occasional)—lubricate weekly

Tools used weekly—lubricate monthly

5.3. Periodic Inspection

1. The tool should be immersed (handles partially

closed) in a reliable commercial degreasing

compound to remove accumulated dirt, grease,

and foreign matter.

NOTE

408- 10048

Hand Crimping Tool 1804834- 1 and Crimping Head 1- 1804834- 1

3of 5Rev BTyco Electronics Corporation

Wire Range

Stamped Here

Crimps centered. Crimps may be off center BUT NOT

OFF END OF WIRE BARREL.

Wire size matches wire color range on splice and

tool.

Wire insulation does not enter wire barrel.

Wire is visible through inspection hole of butt splices.

Wire is flush with or extends slightly beyond end of wire

barrel.

On parallel splices, bare wire ends must be flush

with or extended slightly beyond end of wire barrel.

Crimped off end of splice or terminal wire barrel.

Wire size does not match wire size or color range on

splice or tool.

Wire insulation entered wire barrel of terminal or

splice. CHECK FOR INCORRECT STRIP LENGTH.

Wire not inserted far enough in terminal or splice. End

of wire must be visible through inspection hole of butt

splices, and be flush with or extend slightly beyond end

of wire barrel.

Excessive “flash” on terminal or splice indicates damaged

jaws or wrong wire, splice, or tooling combination was

used.

Nicked or missing strands.

MiniSeal Splice

Figure 4

ACCEPT REJECT

2. 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 6, REPLACEMENT AND

REPAIR.

Figure 5

Pitted

Chipped

Edge

Flattened Area

Broken Corner

3. Inspect head assembly for worn, cracked, or

broken jaws. Refer to Figure 5. If damage is

evident, return the tool to Tyco Electronics for

evaluation and repair. See Section 6,

REPLACEMENT AND REPAIR.

5.4. Gaging the Crimping Chambers

This inspection requires the use of a plug gage

conforming to the dimensions provided in Figure 6.

Tyco Electronics does not manufacture or market

these gages. To gage the crimping chambers,

proceed as follows:

1. Remove traces of oil or dirt from the crimping

chambers and plug gage.

2. Close the tool handles until it is evident that the

jaws have bottomed; then hold in this position. Do

NOT force the jaws beyond initial contact.

3. Align the GO element with the crimping

chamber. Push element straight into the crimping

chamber without using force. The GO element

must pass completely through the crimping

chamber.

408- 10048

Hand Crimping Tool 1804834- 1 and Crimping Head 1- 1804834- 1

Rev B4 of 5 Tyco Electronics Corporation

Crimping

Chamber

Element

NO--GO

Element

“GO” element must pass

completely through

crimping chamber.

“NO--GO” element may enter

partially, but must not pass

completely through the

crimping chamber.

DAHT 1804834--1 For Raychem MiniSeal Splices

Tool Die Closure “A” Gage Elements “B”

Cavity GO NO--GO GO NO--GO

20--26 0.64

[.025]

0.81

[.032]

0.635--0.643

[.0250--.0253]

0.836--0.838

[.0329--.0330]

16--20 1.07

[.042]

1.24

[.049]

1.067--1.074

[.0420--.0423]

1.267--1.27

[.0499--.0500]

12--16 1.57

[.062]

1.75

[.069]

1.575--1.582

[.0620--.0623]

1.775--1.778

[.0699--.0700]

Figure 6

NO--GO Dim.

“A” Dim.

GO Dim. Die Closure Configuration

“B”

Dia.

50.8 [2.00]

Min. Typ.

“B”

Dia.

4. Align the NO--GO element and try to insert it

straight into the same crimping chamber. The

NO--GO element may start entry, but must not

pass completely through the crimping chamber.

If the crimping chambers 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 for further evaluation and repair. Refer to

Section 6, REPLACEMENT AND REPAIR.

5.5. CERTI- CRIMP Ratchet Inspection

The CERTI--CRIMP ratchet should be checked to

ensure that the ratchet does not release prematurely,

allowing the jaws to open before they have fully

bottomed. Obtain a 0.025 [.001] shim suitable for

checking the clearance between the bottoming

surfaces of the crimping jaws. Proceed as follows:

1. Select a terminal or splice, and properly stripped

wire with maximum wire load (such as wire size 16

AWG and size 22--16 terminal).

2. Position the terminal or splice and wire between

the crimping jaws, as described in Section 3.

3. Hold the wire in place and squeeze the handles

until the CERTI--CRIMP ratchet releases. Hold the

handles in this position, maintaining just enough

tension to keep the jaws closed.

4. Check the clearance between the bottoming

surfaces of the crimping jaws. If the clearance is

0.025 [.001] or less, the ratchet is satisfactory. If

clearance exceeds 0.025 [.001], the ratchet is out

of adjustment and must be repaired. See Section

6, REPLACEMENT AND REPAIR.

6. REPLACEMENT AND REPAIR

Customer--replaceable parts are listed in Figure 7.

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 Electronics to ensure

quality and reliability. Order replacement parts

through your Tyco Electronics 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

Tools may also be returned to Tyco Electronics for

evaluation and repair. For customer repair service,

please contact a Tyco Electronics Representative at

1--800--526--5136.

7. REVISION SUMMARY

Since the previous release, the following change was

made:

SChanged the strip length in Figure 3

408- 10048

Hand Crimping Tool 1804834- 1 and Crimping Head 1- 1804834- 1

5of 5Rev BTyco Electronics Corporation

76 [3] (Closed)

279 [11]

35 4

Replacement Parts

Item TE Part Number Description Qty Per Tool

121045--3 RING, Retaining 4

21--23619--6 PIN, Straight, Grooved 2

339364 SPRING 1

42--23620--9 PIN, Straight, Grooved 1

521045--6 RING, Retaining 2

Figure 7

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