instruction sheet 1 of 10 ? 2016 te connectivity family of companies all rights reserved *trademark te connectivity, te connectivity (logo), and te (logo) are trademarks. other logos, product, and/or company names may be tra demarks 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 - 1559 11 jan 16 rev u figure 1 1. introduction certi - crimp hand crimping tools listed in figure 1 are used to crimp the products onto the wire listed in figure 2. note dimensions in this instruction sheet are in millimeters [with inches in brackets]. figures and illustrations are for referenc e only and are not drawn to scale. reasons for r eissue of this instruction sheet are provided in section 7, revision summary. 2. description (figure 1) the handles and label (if applicable) of each tool are color - coded to match the color coding of the product to be crimped. the tools may show more than one color code. product copper wire type size range (awg) pidg terminals and splices solid or stranded 30 - 14 pidg radiation resistant terminals and splices stranded 27 - 14 plasti - grip butt splices solid or stranded 26 - 22 pidg insulation restricting nylon terminals stranded 26 - 14 pidg faston* receptacles 641321 - 1 (.187 series) and 641324 - 1 (.110 series) stranded 26 - 24 plasti - grip terminals solid or stranded 22 - 14 spare wire cap stranded 22 - 14 figure 2 these tools are members of the certi - crimp hand crimping tool family. the ratchet ensures full crimping of the product. once engaged, the ratchet will not release until the handles have been fully closed. caution the crimping jaws bottom before the ratchet releases. this design feature ensures maximum 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 occ asional use and low volume applications. a wide selection of p owered application equipment for extended - use, production operations is available. certi - crimp* hand crimping tools handles hand crimping tool part numbers 46121 47304 47386 47386 - 5 47387 47907 - 1 48518 - 2 68343 - 1 69151 - 1 69454 169485 ratchet label (color coded for pidg* and plasti - grip* products) wire size range stamped here locator label (color coded for sealed splices) jaws insulation crimp adjustment pins (shown in position 3) original instructions
408 - 1559 rev u 2 of 10 3. crimping procedure refer to figure 3 to ensure that the correct tool and product combination is being used. figure 3 also lists the number of dots (or dots and rib) tha t appear embossed on a crimped product when it is crimped using the correct tooling. 3.1. pidg and plasti - grip terminal and splice and pidg faston receptacle 1. strip the wire to the dimension provided in figure 3 being careful to avoid nicking or cutting the cond uctor(s). caution do not use wire with nicked or missing conductor(s). 2. open the tool jaws by closing the tool handles until the ratchet releases, then allow the handles to open fully. tool product wire part no. color code dot code description insul color size range (awg) insul dia range strip length terminal splice 46121 169485 red and yellow 1 pidg terminals and splices yellow 26 - 22 --- 4.0 - 4.8 [5/32 - 3/16] 4.4 - 5.2 [11/64 - 13/64] plasti - grip butt splices 47304 yellow --- pidg terminals 47907 - 1 blue and white 2 pidg terminals and splices natural translucent 24 - 20 --- 4.8 - 6.6 [3/16 - 7/32] 5.6 - 6.4 [7/32 - 1/4] pidg radiation resistant terminals and splices natural translucent with white stripe 47386 47386 - 5 red and yellow 1 pidg terminals ms 25036 - 143 through - 147 yellow 26 - 24 --- 5.2 - 6.0 [13/64 - 15/64] --- pidg radiation resistant terminals ms 7928/4 - 143 through - 147 natural with yellow stripe 47386 47386 - 5 red and yellow 1 pidg terminals and splices red 22 - 16 --- 5.2 - 6.0 [13/64 - 15/64] 6 .4 - 7.1 [1/4 - 9/32] plasti - grip terminals pidg radiation resistant terminals and splices natural translucent with white stripe 69151 - 1 red --- pidg terminals and splices red 22 - 16 --- 5.2 - 6.0 [13/64 - 15/64] 6.4 - 7.1 [1/4 - 9/32] plasti - grip terminals pidg radiation resistant terminals and splices natural translucent with white stripe 69454 red 1 dot 1 rib pidg terminals and splices red 22 - 18 --- 5.2 - 6.0 [13/64 - 15/64] 6.4 - 7.1 [1/4 - 9/32] plasti - grip terminals pidg radiation resistant terminals and splices natural translucent with white stripe 47387 blue and green 2 pidg terminals and splices plasti - grip terminals blue 16 - 14 1.04 - 2.62 [.041 - .103] 5.2 - 6.0 [13/64 - 15/64] 6.4 - 7.1 [1/4 - 9/32] green 20 - 16 hd 0.41 - 1.65 [.016 - .065] pidg radiation resistant terminals and splices natural translucent with blue stripe 16 - 14 --- 20 - 16 hd use tight insulation support for wires with thin wall insulation figure 3 (contd)
408 - 1559 rev u 3 of 10 tool product wire part no. color code dot code description insul color size range (awg) insul dia range strip length terminal splice 46121 169485 47304 red and yellow 1 pidg insulation restricting nylon terminals yellow with 3 black stripes 26 0.66 - 1.40 [.026 - .055] 4.8 - 5.6 [3/16 - 7/32] --- yellow with 3 blue stripes 24 0.79 - 1.40 [.031 - .055] 47386 47386 - 5 red and yellow 1 pidg insulation restricting nylon terminals ms 7928/1 - 1 through - 10 yellow with 3 black stripes 26 0.66 - 1.40 [.026 - .055] 6.4 - 7.1 [1/4 - 9/32] --- yellow with 3 blue stripes 24 0.79 - 1.40 [.031 - .055] 47386 47386 - 5 69151 - 1 red and yellow tool 69151 - 1 mod f red only 1 pidg insulation restricting nylon terminals red with 3 green stripes 22 0.97 - 1.40 [.038 - .055] 6.4 - 7.1 [1/4 - 9/32] --- red with 3 red stripes 20 1.17 - 2.79 [.046 - .110] red with 3 white stripes 18 1.42 - 2.79 [.056 - .110] 47387 blue and green 2 pidg insulation restricting nylon terminals blue with 3 blue stripes 16 1.60 - 3.30 [.063 - .130] 6.4 - 7.1 [1/4 - 9/32] --- 47386 47386 - 5 red and yellow 1 spare wire cap 328307 red 22 - 18 --- 8.0 - 8.7 [5/16 - 11/32] 47387 blue and green 2 spare wire cap 328308 blue 16 - 14 --- 48518 - 2 --- --- pidg faston receptacles 641321 - 1 (.187 series) and 641324 - 1 (.110 series) yellow 26 - 24 --- 4.8 - 5.6 [3/16 - 7/32] 68343 - 1 6.35 [.250] exp. blue 2 plasti - grip terminals blue 16 - 14 3.81 - 6.35 [.150 - .250] 5.2 - 6.0 [13/64 - 15/64] --- use tight insulation support for wires with thin wall insulation for reference only C ( check product - to - tool match using part numbers ) figure 3 (end) 3. place the product in the jaws as shown in figure 4 or figure 5. 4. close the tool handles until the product is held firmly in place. do not deform the wire b arrel. 5. insert properly stripped wire(s) into the wire barrel as shown in figure 4 or figure 5. caution do not allow wire insulation to enter the wire barrel. figure 4
408 - 1559 rev u 4 of 10 6. complete the crimp by closing the tool handles until the ratch et releases. 7. release the tool handles, allow the handles to open fully, and remove the crimped product. 8. to crimp the other wire barrel of a splice, re - position the uncrimped wire barrel in the tool as shown in figure 5, and repeat steps 2 through 7. 9. inspect the crimped product according to figure 7. product not meeting these conditions should not be used. if the wire insulation grip is not satisfactory, refer to section 4 to adjust the grip using the insulation crimp adjustment pins. 3.2. spare wire cap 1. st rip the wire to the dimension provided in figure 3, being careful to avoid nicking or cutting the conductor(s). caution do not use wire with nicked or missing conductor(s). figure 5 2. place the tool insulation crimp adjustment pins in position 3. 3. close the tool handles until the jaws partially close, but leave enough space for the spare wire cap to be inserted between the jaws. 4. raise the locator so that the end of the cap rests against the recessed surface of the locator as shown in figure 6. figure 6
408 - 1559 rev u 5 of 10 5. close the tool handles until the spare wire cap is held firmly in place. do not deform the wire barrel. 6. insert a properly stripped wire into the wire barrel until the wire bottoms. 7. hold the wire in position, an d 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. inspect crimped product according to figure 7. product not meeting these conditio ns should not be used. figure 7
408 - 1559 rev u 6 of 10 4. insulation crimp adj ustment the insulation crimp section of the hand tool has three positions: 1 (tight), 2 (medium), and 3 (loose) to adjust the wire insulation crimp grip. to adjust the insulation grip, proceed as follows: 4.1. pidg terminals and splices and pidg faston receptacles note pidg terminals and splices feature a wire insulation grip. 1. insert the insulation crimp adjustment pins into position 3. refer to figure 1. caution make sure that both insulation crimp adjustment pins are in the same position. 2. place a terminal or splice into the tool jaws as shown in figure 4 or figure 5. 3. insert unstripped wire into only the insulation barrel of the terminal or splice. 4. close the tool handles to comp lete 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 both insulation crimp adjustment pins to the next higher position (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. 4.2. plasti - grip terminals and splices note plasti - grip terminals and splices feature a wire insulation support. the terminal or splice insulation should ideally be in contact with the wire insulation. set the insulation crimp adjustment pins into position according to the following: 3 for wire having a large insulation d iameter 2 for wire having a medium insulation diameter 1 for wire having a small insulation diameter caution make sure that both insulation crimp adjustment pins are in the same position. 5. maintenance and insp ection 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 sh ipping container, file a claim with the carrier, and notify te immediately. 5.1. daily 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 t ool 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. 5.2. periodic inspection regular inspections should be performed by quality control personnel. a record of schedule d inspections should remain with the tool or be supplied to supervisory personnel responsible for the tool. though
408 - 1559 rev u 7 of 10 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: 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 10. 3. inspect crimping areas for pit ted 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 6, replacement and repair. gaging crimping chamber this inspection requires the use of plug gages conforming to the dimensions listed in figure 8. to gage the crimping chamber, proceed as follows: 1. close the jaws by squeezing the tool handles together until the jaws have bottomed, and then hold the handles in this position. do not force the jaws beyond initial contact. 2. align the go element of the gage with the wire barrel crimp section of the crimping chamber. refer to figure 9. push the element straight into the crimping chamber without using force. the go element must pass completely through the crimping chamber. 3. align the no - go element of the gage with the same crimp section, and try to insert the element. the no - go element may start entry, but it must not pass completely through the crimping chamb er. refer to figure 9. 4. repeat the gage inspection for the insulation crimp section of the crimping chamber, making sure to use the correct plug gage. if the crimping chamber conforms to the gage inspection, the tool is considered dimensionally correct. if the crimping chamber does not conform to the inspection, the tool must be repaired. refer to section 6, replacement and repair. for additional information concerning the use of the plug gage, refer to instruction sheet 408 - 7424. ratchet inspection obtain a .025 - mm [.001 - in.] shim that is suitable for checking the clearance between the bottoming surfaces of the jaws. to inspect the ratchet control, proceed as follows: 1. refer to figure 3, and select a product and maximum size wire. 2. position the product in the crimping chamber according to paragraph 3.1, steps 1 through 5 or paragraph 3.2, steps 1 through 6. 3. while holding the wire in place, squeeze the tool handles together until the ratchet releases. holding the tool in this position, maintain just enough press ure to keep the jaws closed. 4. check the clearance between the bottoming surfaces of the ja ws. 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 6, replacement and repair. if the tool conforms to this inspection procedure, lubricate it with a thin coat of any good sae 20 motor oil, and return it to service. 6. replacement and repa ir customer - replaceable parts are listed in figure 10. parts other than those listed should be replaced by te to ensure quality and reliability. for customer repair service or to order replacement parts, call 1 - 800 - 522 - 6752, or fax your purchase order to 717 - 986 - 7605, or write to: customer service ( 038 - 035), tyco electronics corporation, po box 3608, harrisburg, pa 17105 - 3608.
408 - 1559 rev u 8 of 10 7. revision summary ? updated document to corporate requirements ? added dimensional callout in figure 8 ? added new note to figure 9 tool jaw closure? diameter a gage element?? diamete r b dimension go no - go go no - go c (width) r (radius) 46121 169485 1.600 [.0630] 1.753 [.0690] 1.600 - 1.608 [.0630 - .0633] 1.750 - 1.753 [.0689 - .0690] --- --- 47304 1.600 [.0630] 1.753 [.0690] 1.600 - 1.608 [.0630 - .0633] 1.750 - 1.753 [.0689 - .0690] 47386 47386 - 5 2.768 [.1090] 2.921 [.1150] 2.768 - 2.776 [.1090 - .1093] 2.918 - 2.921 [.1149 - .1150] 47387 68343 - 1 3.022 [.1190] 3.175 [.1250] 3.022 - 3.030 [.1190 - .1193] 3.172 - 3.175 [.1249 - .1250] 47907 - 1 2.260 [.0890] 2.413 [.0950] 2.260 - 2.268 [.0890 - .0893] 2.410 - 2.413 [.0949 - .0950] 48518 - 2 1.600 [.0630] 1.753 [.0690] 1.600 - 1.608 [.0630 - .0633] 1.750 - 1.753 [.0689 - .0690] 69151 - 1 2.768 [.1090] 2.921 [.1150] 2.768 - 2.776 [.1090 - .1093] 2.918 - 2.921 [.1149 - .1150] 69454 2.616 [.1030] 2.718 [.1070] 2.616 - 2.624 [.1030 - .1033] 2.715 - 2.718 [.1069 - .1070] 3.962 [.156] 3.454 [.136] ? jaw closure dimensions apply when wire barrel jaws are bottomed, but not under pressure . ?? material: tool steel figure 8 (contd)
408 - 1559 rev u 9 of 10 tool jaw closure? dimension f gage element?? dimension g dimension w (width) go no - go go no - go 46121 169485 0.762 [.0300] 1.27 [.0500] 0.762 - 0.77 [.0300 - .0303] 1.267 - 1.27 [.0499 - .0500] 3.05 [.120] 47304 0.762 [.0300] 1.27 [.0500] 0.762 - 0.77 [.0300 - .0303] 1.267 - 1.27 [.0499 - .0500] 3.05 [.120] 47386 47386 - 5 0.762 [.0300] 1.27 [.0500] 0.762 - 0.77 [.0300 - .0303] 1.267 - 1.27 [.0499 - .0500] 3.05 [.120] 47387 1.016 [.0400] 1.524 [.0600] 1.016 - 1.024 [.0400 - .0403] 1.521 - 1.524 [.0599 - .0600] 4.75 [.187] 47907 - 1 0.762 [.0300] 1.27 [.0500] 0.762 - 0.77 [.0300 - .0303] 1.267 - 1.27 [.0499 - .0500] 2.36 [.093] 48518 - 2 0.762 [.0300] 1.27 [.0500] 0.762 - 0.77 [.0300 - .0303] 1.267 - 1.27 [.0499 - .0500] 3.05 [.120] 69151 - 1 0.762 [.0300] 1.27 [.0500] 0.762 - 0.77 [.0300 - .0303] 1.267 - 1.27 [.0499 - .0500] 3.05 [.120] 69454 0.762 [.0300] 1.27 [.0500] 0.762 - 0.77 [.0300 - .0303] 1.267 - 1.27 [.0499 - .0500] 3.05 [.120] 68343 - 1 1.828 [.0720] 2.337 [.0920] 1.828 - 1.836 [.0720 - .0723] 2.334 - 2.337 [.0919 - .0920] 4.75 [.187] ? jaw closure dimensions apply when wire barrel jaws are bottomed, but not under pressure . ?? material: tool steel figure 8 (end) figure 9 w 0.13 [.005] note: most insulation barrel gages are designed to check one side of the crimp nest at a time.
408 - 1559 rev u 10 of 10 item description part number for tool 46121 47304 47386 47386 - 5 47387 & 68343 - 1 1 ring, retaining 21045 - 3 21045 - 3 21045 - 3 21045 - 3 21045 - 3 2 pin, retaining 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, retaining 21045 - 6 21045 - 6 21045 - 6 21045 - 6 21045 - 6 7 pin, retaining 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 locator, housing 302994 --- 302994 302994 302994 12 spring 301201 --- 301201 301201 301201 13 locator 3 - 304052 - 6 --- 302993 302993 45965 - 6 item description part number for tool 47907 - 1 169485 48518 - 2 69151 - 1 69454 1 ring, retaining 21045 - 3 21045 - 3 21045 - 3 21045 - 3 21045 - 3 2 pin, retaining 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, retaining 21045 - 6 21045 - 6 21045 - 6 21045 - 6 21045 - 6 7 pin, retaining 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 --- --- --- --- --- 10 stop --- --- --- --- --- 11 locator, housing 302994 302994 302994 302994 302994 - 1 12 spring 301201 301201 301201 301201 2 - 304668 - 6 13 locator 303542 575960 - 4 125644 - 7 302993 4 - 304052 - 6 figure 10
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