Tyco Electronics 46121 User manual

Instruction Sheet

408-1559

LOC B

of 10

2007 Tyco Electronics Corporation, Harrisburg, A

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

RODUCT 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

19 JUN 07 Rev

Hand Crimpin Tools

PROPER USE GUIDELINES

CumulativeTraumaDisorderscanresultfromthe prolongeduseofmanually poweredhandtools.Hand toolsareintendedfor occasionaluseandlowvolume

applications. A wide selection of powered application equipment for extended-use, production operations is available.

Figure 1

HAND CRIMPING TOOL PART NUMBERS

46121

47304

47386

47386-5

47387

47907-1

48518-2

69151-1

69454

169485

Wire Size Range

Stamped Here

Insulation Crimp Adjustment

ins in No. 3 osition

Color Code for

Sealed Splices

Color Code for IDG* and

LASTI-GRI * roducts

CERTI-CRIM * Hand

Crimping Tool Ratchet

Control

1. INTRODUCTION

This instruction sheet covers the Hand Crimping Tools

listed in Figure 1, which are used to crimp the

terminal types listed in Figure 2.

Dimensions on this sheet are in millimeters

[with inch-equivalent dimensions in brackets].

Figures and illustrations are for identification only

and are not drawn to scale.

Reasons for reissue are provided in Section 9,

REVISION SUMMARY.

2. DESCRIPTION

(Figure 1)

The handles and label (if applicable) of the crimping

tools are color–coded to match the color coding of the

connectors to be applied, as listed in Figure 3. The

crimping tools may show more than one color code.

Check Figure 3 to be sure that the correct tool/

connector combination is being used.

For example, tool 47386 can be used to apply PIDG

terminals and splices with a yellow color code, as well

as spare wire caps with a red color code.

Figure 3 lists the number of dots (or rib) that appear

embossed on a crimped item when the connector is

crimped in the correct tooling.

The CERTI–CRIMP hand crimping tool ratchet control

ensures full crimping of terminals and splices. Once

engaged, the ratchet will not release until the tool

handles have been FULLY closed.

NOTE

408-1559

Hand Crimping Tools

Rev

of 10 Tyco Electronics Corpor tion

CONNECTOR

TYPE WIRE

TYPE WIRE SIZE

AWG]

PIDG Termin ls nd

Splices Solid or Str nded

Copper 30-14

PIDG Insul tion

Restricting Nylon TermiĆ

n ls Str nded Copper 26-14

PIDG R di tion

Resist nt Termin ls

nd Splices Str nded Copper 27-14

PIDG FASTON*

Recept cles,

P rt Nos 641321-1

(.187 Series) nd

641324-1 (.110 Series)

Str nded Copper 26-24

PLASTI-GRIP

Termin ls Solid or Str nded

Copper 22-14

PLASTI-GRIP

Butt Splices Solid or Str nded

Copper 26-22

Sp re Wire C ps Str nded Copper 22-14

Figure 2

The crimping areas bottom before the crimping

tool ratchet releases. This is a design feature that

assures maximum tensile performance of the

crimp. Do NOT re-adjust the ratchet.

3. CRIMPING PROCEDURE

Refer to Section 5 for information on the

insulation crimp adjustment.

3.1. For PIDG and PLASTI-GRIP Terminals and Splices

1. Strip the wire to the dimension provided in

Figure 3, being careful to avoid nicking or

damaging the conductor(s).

Do NOT use ire ith 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 or splice in the dies as shown

in Figure 4 or Figure 5.

4. Close the tool handles until the terminal or splice

is held firmly in place. Do NOT deform the terminal

or splice wire barrel.

5. Insert properly stripped wire(s) into the terminal

or splice, as shown in Figure 4 or Figure 5.

Do NOT allo ire insulation to enter the

terminal or splice ire 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 or

splice.

8. To crimp the other half of a splice, re–position

the uncrimped half of the splice in the tool as

shown in Figure 5. Follow the procedure used to

crimp the first splice half.

9. Refer to Section 4 and Figure 7 for terminal and

splice crimp inspection procedure.

3.2. For Spare Wire Caps

1. Strip the wire to the dimensions provided in

Figure 3.

Do NOT use ire ith nicked or missing

conductors.

Make sure that the color coding on the spare ire

cap and the tool match.

2. Place the crimping tool’s insulation adjustment

pins in the No. 3 position.

3. Close the tool handles until the crimping jaws

partially close, but leave enough space for the cap

to be inserted between the dies.

4. Raise the locator so that the end of the cap

rests against the recessed surface of the locator,

as shown in Figure 6.

5. Close the tool handles until the cap is held firmly

in place. Do NOT deform the cap wire barrel.

6. Insert the properly stripped wire into the cap

until the wire bottoms.

7. Hold the wire in position and complete the crimp

by closing the tool handles until the ratchet

releases.

8. Release the tool handles, allow the handles to

open fully, and remove the crimped spare wire cap.

9. Refer to Section 4 and Figure 7 for spare wire

cap crimp inspection procedure.

CAUTION

NOTE

CAUTION

NOTE

408-1559

H nd Crimping Tools

1, +8

"9)1 /+)6410.)5 14214(6.10

TOOL NUMBER

AND

DESCRIPTION

WIRE

RANGE

(AWG)

TOOL

COLOR

AND DOT

CODE

PRODUCT PRODUCT

INSULATION COLOR

CODE

WIRE STRIP LENGTH

TERMINALS SPLICES

MIN. MAX. MIN. MAX.

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PLASTI-GRIP

Terminal Spare Wire Cap

PIDG Butt Splice

PLASTI-GRIP

Butt Splice

PIDG Type

Terminals

FASTON

Receptacle

 37(//9 !2()+* 1/14

!64.2+5 10 057/(6.10

+564.)6.0-

1/14 !64.2+ 10

(*.(6.10 +5.56(06

Figure 3 (cont’d)

1/14 !64.2+ 10

(*.(6.10 +5.56(06

408-1559

Hand Crimping Tools

Rev

of 10 Tyco Electronics Corporation

TOOL NUMBER

AND

DESCRIPTION

WIRE

RANGE

(AWG)

TOOL

COLOR

AND DOT

CODE

PRODUCT PRODUCT

INSULATION COLOR

CODE

WIRE STRIP

LENGTH

46121

169485

47304

MIN. MAX.

4.8

[3/16] 5.6

[7/32]

INSUL

DIA.

RANGE

mm [in.

0.66-1.40

[.026-.055]

RED

AND

YELL W

NE D T

PIDG

INSULATI N

RESTRICTING

NYL N

TERMINALS

YELL W W/3

BLACK STRIPES

YELL W W/3

BLUE STRIPES

24 0.79-1.40

[.031-.055]

26 0.66-1.40

[.026-.055]

24 0.79-1.40

[.031-.055]

PIDG INSULATI N

RESTRICTING

NYL N TERMINALS

MS 7928/1-1

THRU -10

YELL W W/3

BLACK STRIPES

YELL W W/3

BLUE STRIPES

69151-1

22 0.97-2.79

[.038-.055]

20 1.17-2.79

[.046-.110]

18 1.42-2.79

[.056-.110]

YELL W AND RED

NE D T (T L N .

69151-1

M D. F IS C DED

RED NLY)

PIDG

INSULATI N

RESTRICTING

NYL N

TERMINALS

RED W/3

GREEN STRIPES

RED W/3

RED STRIPES

RED W/3

WHITE STRIPES

6.4

[1/4] 7.1

9/32

47387 16 1.60-3.30

[.063-.130]

BLUE AND

GREEN

TW D TS

BLUE W/3

BLUE STRIPES

TIGHT INSULATI N SUPP RT F R WIRES WITH THIN WALL INSULATI N

TOOL NUMBER

AND

DESCRIPTION

WIRE

RANGE

(AWG)

TOOL

COLOR

AND DOT

CODE

PRODUCT PRODUCT

INSULATION COLOR

CODE

WIRE STRIP

LENGTH

22-18

MIN. MAX.

[5/16] 8.7

[11/32]

YELL W

AND RED

NE D T

SPARE WIRE CAP

N . 328308 BLUE

47387 16-14 BLUE AND

GREEN

TW D TS

SPARE WIRE CAP

N . 328307 RED

TOOL NUMBER

AND

DESCRIPTION PRODUCT PRODUCT

INSULATION COLOR

CODE

WIRE STRIP

LENGTH

26-24

MIN. MAX.

4.8

[3/16] 5.6

[7/32]

48518-2 PIDG FAST N RECEPTACLES

P/N 641321-1 (187 SERIES) AND P/N

641324-1 (110 SERIES)

YELL W

N TE: Color code is for

reference only. Always order correct

tool by supplying part numbers of

receptacles being crimped.

Figure 3 (end)

B" Equals

Wire Barrel

C" Equals

Insulation

Barrel

Terminal Wire Barrel

Butts Against Locator

End of Wire Conductor

Butts Against Tool Locator

(Note: Wire Butts Against

FAST N Receptacle Wire

Stop)

PIDG and PLASTI-GRIP Terminals

“C” “B”

PIDG

Terminal

“C” “B”

Wire Stop

PIDG FASTON Receptacle PLASTI-GRIP Terminal

“C” “B”

PIDG

Insulation

Restricting

Terminal

WIRE

RANGE

(AWG)

Figure 4

47386

47386-5

47386

47386-5

47386

47386-5

408-1559

Hand Crimping Tools

of 10Rev

Tyco Electronics Cor oration

Figure 5

Butt Splices

C" B"

PIDG Splice

B" Equals Wire Barrel

C" Equals Insulation Barrel

C" B"

PLASTI-GRIP Splice

Window Indent

Wire Sto

Window

Indent

Locator Seats in

Window Indent

of S lice

First

Crimp

End of Wire Conductor Butts

Against S lice Wire Sto

Insulation Crim Adjustment

Pins in No. 3 Position

Second

Crimp

Locator Seats in Window

Indent of S lice

End of Wire Conductor Butts

Against S lice Wire Sto

4. CRIMP INSPECTION

Inspect crimped terminals and splices by checking the

features described in Figure 7. Terminals and splices

not meeting these conditions should NOT be used.

5. INSULATION CRIMP ADJUSTMENTS

5.1. For PIDG Terminals and Spli es

PIDG terminal and plice feature a wire

in ulation grip."

The insulation crimping section of the hand tool has

three positions: 1 (tight), 2 (medium), and 3 (loose).

To adjust the section:

Figure 6

Spare Wire Caps

Wire Barrel Locator

Insulation

Adjustment

Pins in No. 3

Position

Wire Bottoms

in Ca

Raise Locator so

that End of Ca

Rests Against

Recessed Surface

of Locator

1. Insert the insulation crimp adjustment pins into

the No. 3 position. Refer to Figure 1 or Figure 5.

2. Place the terminal or splice into the crimping

jaws as shown in Figure 4 or Figure 5.

3. Insert the UNSTRIPPED wire into ONLY the

insulation barrel (refer to Figure 4 or Figure 5)

portion of the terminal or splice.

4. Close the tool handles to complete the crimp.

5. Remove the crimped terminal or splice and

check the insulation crimp by bending the wire

back and forth once. The terminal or splice 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.

Make ure that both in ulation crimp adju tment

pin are in the ame po ition.

5.2. For PLASTI-GRIP Terminals and Spli es

PLASTI-GRIP terminal and plice feature a

wire in ulation upport" only. The terminal or

plice in ulation hould ideally be in contact with

the wire in ulation.

1. Set adjustment pins in position No. 3 for wire

having a large insulation diameter.

2. Set adjustment pins in position No. 2 for wire

having a medium insulation diameter.

3. Set adjustment pins in position No. 1 for wire

having a small insulation diameter.

Make ure that both in ulation crimp adju tment

pin are in the ame po ition.

NOTE

CAUTION

NOTE

CAUTION

408-1559

Hand Crimping Too s

Rev

of 10 Tyco Electronics Corporation

Figure 7

1Insulation barrel is in firm contact with wire insulation.

2Correct color co e, ot co e, an tool combination (Rib co e

on bottom, ot co e on top when crimpe in tool No. 69454).

3Wire size is within the wire range stampe un er the terminal

tongue or on the center of the splice.

4Crimp is centere on the wire barrel.

5Con uctor en is flush with, or exten s beyon , the en of the

terminal wire barrel.

6Con uctor en is against the wire stop, is at least flush with, or

exten s slightly beyon , the wire barrel.

7Wire insulation oes not enter the wire barrel.

8No nicke or missing con uctor stran s.

1No flash or extru e insulation.

2Correct color co e, ot co e, an tool combination. Dot co ing

isappears from seale splices when they are heat seale .

3Correct wire size is use .

4Wire insulation oes not enter wire barrel of splice.

5En of con uctor is against wire stop, is at least flush with, or

exten s slightly beyon , the splice's wire barrel.

6En of con uctor is bottome in cap.

7Full wi th of crimp is over wire barrel.

8No nicke or missing con uctor stran s.

9Crimp is centere on wire barrel.

10 Splice insulation is in contact with wire insulation.

PIDG AND

PLASTI-GRIP

Terminals

PIDG

Butt Splices

PLASTI-GRIP

Butt Splice

Spare Wire

Caps

1245

7 8

462

A Dot Co e (1 or 2 Dots) Must Appear

on All Crimpe Items

(Rib co e on bottom, ot co e on top when

crimpe in tool No. 69454)

485

Wire Stop

6. INITIAL TOOL INSPECTION

Hand crimping tools are inspected before

shipment. The tool received should be inspected

immediately upon arrival to ensure that the tool has

not been damaged during shipment, and that it

performs according to the criteria described in this

sheet. If a tool is damaged upon arrival, retain the

shipping container, file a claim with the carrier, and

notify Tyco Electronics immediately.

7. MAINTENANCE/INSPECTION

7.1. Dai y Maintenance

1. Remove dust, moisture, and other contaminants

from the tool with a clean brush or a soft, lint–free

cloth. Do NOT use objects that could damage the

tool.

2. Make sure that the proper retaining pins are in

place and are secured with the proper retaining

rings.

3. Make certain that all pins, pivot points, and

bearing surfaces are 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 the handles

closed to prevent objects from becoming lodged in

the crimping areas and store the tool in a clean,

dry area.

408-1559

Hand Crimping Tools

+$ #1

3!+ (#!/-+*&!. +-,+-/&+*

7.2. Periodic Inspection

Regular inspections should be performed by quality

control personnel. A record of scheduled inspections

should remain with the tool and/or be supplied to

supervisory personnel responsible for the tool.

Though recommendations call for at least one

inspection per month, the inspection frequency should

be based on the amount of use, working conditions,

operator training and skill, and established company

standards. These inspections should be performed in

the following sequence:

A. Visual Inspection

1. Remove all lubrication and accumulated film by

immersing the tool (handles partially closed) in a

suitable commercial degreaser that will not affect

paint or plastic material.

2. Make certain that all retaining pins are in place

and are secured with retaining rings. If

replacements are necessary, refer to the parts list

in Figure 11.

3. Inspect crimping areas for pitted or chipped

surfaces.

4. Close the tool handles until the ratchet releases,

then allow handles to open freely. If they do not

open quickly and fully, the spring is defective and

must be replaced. Refer to Section 8,

REPLACEMENT AND REPAIR.

B. Gaging the Crimping Areas

This inspection requires the use of plug gages

conforming to the dimensions listed in Figures 8

and 9. Tyco Electronics does not manufacture or

market these gages.

To gage the crimping area(s), refer to Figure 10 and

proceed as follows:

1. Close the crimping areas by squeezing the tool

handles together until the crimping dies have

bottomed, and then HOLD the tool handles in this

position. Do not force the dies beyond initial

contact.

Figure 8

TOOL NUMBER DIE CLOSURE DIM'S. A"

{

GAGE ELEMENT

{{

DIM'S. B" DIA.

GO NO-GO GO NO-GO

C"

MA . R"

RADIUS

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 

 

 





 

 

 

 



 

 

 

 



 

 

 

 



 

 

 

 



 

 

 

 



 

 

 

 

 

 



77 77

{

&# !(+.0-# "&)#*.&+*. ,,(3 2%#* 2&-# --#( '2. -# +//+)#" 0/ *+/ 0*"#- ,-#..0-#

{{

/#-&(7++( /##(

SUGGESTED PLUG GAGE DESIGN Ċ WIRE BARREL CRIMP



&) 4

4

&)

 

&* 3,

4

3,

 

&* 3,

4

4

3,  &) 4

Tool No. 69454 Only

Die Closu e

Configu ation



&)

4



 &)

Die Closu e

Configu ation

4

&

  &* 3,

4

&

408-1559

Hand Crimping Tools

"0

*#  2 * '" .,*)% - *,+*,.%*)

Figure 9

TOOL NUMBER

DIE CLOSURE DIM'S. F"

{

(Set Insulation

Adjustment Pins at No. 1 Position) GAGE ELEMENT

{{

DIM'S. G"

GO NO-GO GO NO-GO

IDTH

 " (Max.)



 

 

 

 





 

 

 

 











{

%" '*-/," !%(")-%*)- ++'2 1$") 1%," ,,"' &1- ," *..*("! /. )*. /)!", +,"--/,"

{{

.",%'5**' .""'

SUGGESTED PLUG GAGE DESIGN Ċ INSULATION CRIMP

 %(  %(

3 3

3

 



  2+

3 %(

Die Closure

Configuration











 

 

 

 





 

 

 

 





 

 

 

 





 

 

 

 





 

 

 

 





 

 

 

 







2. Align the GO element of the gage with the

appropriate crimping area to be checked. Refer to

Figure 10. Push the element straight into the area

without using force. The GO element must pass

completely through the crimping area.

3. Align the NO–GO element of the gage with the

same crimping area, and try to insert the element.

The NO–GO element may start entry, but it must

not pass completely through the crimping area.

4. Repeat the gage inspection procedure for each

crimping area, making sure to use the correct plug

gage for each inspection.

If the crimping areas conform to the gage inspection,

the tool is considered dimensionally correct. If the

crimping areas do not conform to the inspection, the

tool must be repaired. Refer to Section 8,

REPLACEMENT AND REPAIR.

For additional information concerning the use of the

plug gage, refer to instruction sheet 408–7424.

C. CERTI-CRIMP Hand Crimping Tool Ratchet

Control Inspection

Obtain a .025–mm [.001–in.] shim that is suitable for

checking the clearance between the bottoming

surfaces of the crimping dies. To inspect the ratchet

control:

1. Refer to Figure 3 and select a terminal or splice

and wire (maximum size).

2. Position the terminal or splice in the appropriate

crimping area, according to the method described

in Paragraph 3.1, Steps 1 through 5.

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

handles together until the ratchet releases. Hold

the tool in this position, maintaining just enough

pressure to keep the dies closed.

408-1559

Hand Cri ping Tools

of 10Rev

Tyco Electronics Corporation

Figure 10

GO" ele ent ust pass co pletely

through the die closure.

NO-GO" ele ent ay

enter partially, but ust not pass

co pletely through the die closure.

Detail A

Inspection of Wire Barrel Crimping Dies

Detail B

Inspection of Insulation Crimping Dies

Wire Barrel

Jaws Botto ed

But Not Under

Pressure

Adjust ent

Pins in No. 1

Position

4. Check the clearance between the bottoming

surfaces of the crimping dies. If the clearance is

.025 mm [.001 in.] or less, the ratchet is

satisfactory. If clearance exceeds .025 mm

[.001 in.], the ratchet is out of adjustment, and

must be repaired. Refer to Section 8,

REPLACEMENT AND REPAIR. If the tool

conforms to these inspection procedures, lubricate

it with a THIN coat of any good SAE 20 motor oil

and return it to service.

8. REPLACEMENT AND REPAIR

Replacement parts are listed in Figure 11. Parts other

than those listed in Figure 11 should be replaced by

Tyco Electronics to ensure quality and reliability of the

tool. Order replacement parts through your Tyco

Electronics 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

representative at 1–800–526–5136.

9. REVISION SUMMARY

Since the previous release of this sheet, the following

changes were made:

Updated document to corporate requirements

Added part number 47386–5 to tables in

Figures 1, 3, 8, 9, and 11

408-1559

H nd Crimping Tools

Rev

P10

of 10 Tyco Electronics Corpor tion

Detail

22.22

[.875]

Approx.

279.4 [11.00]

1 2

11 12

Approx.

76.2 [3.00]

ITEM

DESCRIPTION

TOOL NUMBERS, DETAIL REF., AND COMPONENT PART NUMBERS

ITEM

NO.

DESCRIPTION

46121

DETAIL A 47304

DETAIL B 47386, 47386-5

DETAIL A 47387

DETAIL A 47907-1

DETAIL A

1 RING, Ret ining 21045-3 21045-3 21045-3 21045-3 21045-3

2 PIN, Ret ining 1-23619-6 1-23619-6 1-23619-6 1-23619-6 1-23619-6

3 PIN, Adjustment 39207 39207 39207 39207 39207

4 SPRING 39364 39364 39364 39364 39364

6 RING, Ret ining 21045-6 21045-6 21045-6 21045-6 21045-6

7 PIN, Ret ining 2-23620-9 2-23620-9 2-23620-9 2-23620-9 2-23620-9

8 SCREW 3-306105-9 3-21016-4 9-305927-1 9-305927-1 9-305927-1

9 SUPPORT -- 39193 -- -- --

10 STOP -- 302765 -- -- --

11 HOUSING LOCATOR 302994 -- 302994 302994 302994

12 SPRING 301201 -- 301201 301201 301201

13 LOCATOR 3-304052-6 -- 302993 45965-6 303542

ITEM

DESCRIPTION

TOOL NUMBERS, DETAIL REF., AND COMPONENT PART NUMBERS

ITEM

NO.

DESCRIPTION

169485

DETAIL A 48518-2

DETAIL A 69151-1

DETAIL A 69454

DETAIL A

1 RING, Ret ining 21045-3 21045-3 21045-3 21045-3

2 PIN, Ret ining 1-23619-6 1-23619-6 1-23619-6 1-23619-6

3 PIN, Adjustment 39207 39207 39207 39207

4 SPRING 39364 39364 39364 39364

6 RING, Ret ining 21045-6 21045-6 21045-6 21045-6

7 PIN, Ret ining 2-23620-9 2-23620-9 2-23620-9 2-23620-9

8 SCREW 9-305927-1 3-306105-9 9-305927-1 9-305927-1

9 SUPPORT -- -- -- --

10 STOP -- -- -- --

11 HOUSING LOCATOR 302994 302994 302994 302994-1

12 SPRING 301201 301201 301201 2-304668-6

13 LOCATOR 575960-4 125644-7 302993 4-304052-6

Figure 11

This manual suits for next models

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