instruction sheet 408--8547 loc b 1 of 4 e 2011 tyco electronics corporation, a te connectivity ltd. company all rights reserved *trademark te connectivity, te connectivity (logo), and te (logo) are trademarks. other logos, product and/or company names may be trademarks of their respecti ve 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.te.com 26 sep 11 rev j certi- crimp* ii straight action hand tools 1. introduction the certi--crimp ii straight action hand tools are designed to crimp a variety of loose piece terminals. refer to http://tooling.te.com/data.asp ?documentation? -- ?data sheets? for a list of loose piece terminals that may be crimped by the certi--crimp ii straight action hand tool. the website also contains instructions in various languages. the wire crimper bottoms against the anvil before the ratchet releases. this is a design feature that assures maximum electrical and tensile performance of the crimp. do not re--adjust the ratchet. http://tooling.te.com/data.asp ?documentation?--?data sheets? 1. introduction les pinces action directe certi--crimp ii permettent de sertir diffrents types de cosses en vrac. la liste complte des cosses en vrac sertissables l?aide de la p ince action directe certi--crimp ii est consultable sur le site http://tooling.te.com/data.asp ?documentation? -- ?data sheets? ce site comporte galement des instructions dans diffrentes langues. le poin?on du fil vient en bute contre l?enclume avant le dbloc age de la crmaillre certi--crimp. cette fonctionnalit permet d?assurer des performances de sertissage optimales tant sur le plan lectrique que sur celui de la tenue en traction du fil. ne pas retoucher au rglage de la crmaillre. http://tooling.te.com/data.asp ?documentation? --?data sheets? 1. einfhrung die certi--crimp ii handzange ist dazu vorgesehen, unterschiedliche klemmen zu crimpen. siehe http://tooling.te.com/data.asp ?documentation? -- ?data sheets? fr eine aufstellung von lp--kontakte, die mit der certi--crimp handzange gecrimpt werden k?nnen. die websit e enth?lt auch anleitungen in verschiedenen sprachen. das werkzeugoberteil f?hrt immer auf block mit den ambo?, bevor die certi--crimp handzange die ratsche freigibt. dies ist ein konstruktionsmerkmal, welches maximale verpressung und zugfestigkeit des crimp--kontaktes gew?hrleistet. die ratsche darf nicht verstellt werden. 1. introduzione gli attrezzi manuali certi--crimp ii straight action sono progettati per aggraffare vari tipi di terminali sciolti. per la lista dei terminali sciolti che possono essere aggraffa ti con l?attrezzo manuale certi--crimp ii straight action, consultare il sito multilingua http://tooling.te.com/data.asp ?documentation? -- ?data sheets?. prima del rilascio del cricchetto, la matrice di aggraffatura appoggiata sull?incudine. tale condizione garantisce prestazioni ottimali dell?aggraffatura in termini di elettricit e tensione. non modificare la regolazione del cricchetto. original instructions note caution remarque attention anmerkung vorsicht nota attenzione
408- 8547 rev j 2 of 4 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 volum e applications. a wide selection of powered application equipment for extended--use, production operations is available. figure 1 wire crimper terminal support wire anvil insulation adjustment knob d (shown in position 1) locator/ insulation stop stripped wire front of tool insulation crimper insulation anvil 1 d some tools do not have an insulation adjustment knob. these tools are fixed at one position with a spring pin. 2. description the front of the tool, is marked with the tool part number, wire size ranges, and crimp height specifications. the tool features a fixed die (crimper), a movable die (anvil), a locator/insulation stop, and a ratchet. many tools feature an insulation adjustment knob which is used to regulate the crimp height of the contact insulation barrel during the crimping operation. the locator/insulation stop positions the contact, and limits the insertion distance of the stripped wire into the contact. in use, the locator/insulation stop rests in the locator slot of the contact (see figures 1 and 2). the ratchet assures full crimping of the contact. once engaged, the ratc het will not rel ease until the dies have been fully closed. 3. crimping procedure refer to the table at http://tooling.te.com/data.asp to ensure that the wire intended for use is compatible with the wire size and insulation diameter specified in the table. strip the wire to the length indicated in the table. do not cut or nick the wire strands during wire stripping. proceed as follows: 1. hold the tool so that the front side is facing you. 2. ensure that the tool ratchet is released by squeezing the tool handles and allowing them to open fully. 3. holding the contact by its mating portion and looking straight into the crimp section, insert the contact from the back of the tool into the appropriate crimp chamber. 4. position the contact between the crimpers so that the locator/insulation stop enters the slot in the contact. the wire barrel should butt against the locator/insulation stop. refer to figures 1 and 2. 5. holding the contact in this position, apply light inward pressure against the locator, and squeeze the tool handles together until the insulation anvil starts entry into the insulation crimper (usually two ratchet clicks). do not deform the insulation barrel or wire barrel. 6. insert a properly stripped wire through the locator slot and into the wire barrel of the contact until the insulation butts against the locator/insulation stop. 7. holding wire in place, crimp contact to the wire by squeezing the tool handles together until the ratchet releases. 8. allow tool handles to open fully and remove the crimped contact from the tool. 4. insulation adjustment procedure on many tools, the insulation barrel crimp height is regulated by the insulation adjustment knob (figure 1). the insulation crimp should hold the insulation firmly without cutting into the insulation. figure 2 typical socket contact typical pin contact mating portion wire barrel insulation barrel locator slot wire strip length note: not to scale caution !
408- 8547 3 of 4 rev j to determine the proper insulation crimp setting, test crimp a loose piece contact using the setting that corresponds to the insulation diameter: (1) small, (2) and (3) medium, or (4) large. if the crimped insulation barrel is too tight or loose, change the setti ng by pu lling out and rotating the adjustment knob to the desired setting. 5. maintenance and inspection it is recommended that a maintenance and inspection program be performed periodically to ensure dependable and uniform terminations. frequency of inspection depends on: s the care, amount of use, and handling of the hand tool, s the presence of abnormal amounts of dust and dirt, s the degree of oper ator skill, and s your own established standards. the hand tool is inspected before being shipped; however, it is recommended that the tool be inspected immediately upon its arrival a t your facility t o 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. see figure 4. 3. all pins, pivot points, and bearing surfaces should be protected with a thin coat of any good sae 20 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 oil as follows: tools used in daily production ? lubricate daily tools used daily (occasional) ? lubricate weekly tools used weekly ? lubricate monthly wipe excess oil from tool, particularly from crimping area. oil transferred from the crimping area onto certain terminations may affect the electrical characteristics of an application. 5.3. periodic inspection 1. hand tool may be immersed (handles partially closed) in a reliable commercial degreasing compound (suitable for plastics) to remove accumulated dirt, grease and foreign matter. 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 the section 5. 3. inspect head assembly for worn, cracked, or broken jaws. if damage is evident, return it for evaluation and repair. 5.4. crimp height inspection this inspection requires the use of micrometer with a modified anvil (commonly referred to as a crimp height comparator) as shown in figure 3. te connectivity does not market crimp height comparators. refer to instruction sheet 408--7424 for detailed information on obtaining and using a crimp height comparator. proceed as follows: 1. select a contact and a wire (maximum size) for each crimp section listed in the appropriate table at http://tooling.te.com . 2. refer to the section 3, and crimp the contact(s). 3. using a crimp height comparator, measure wire barrel crimp height as shown in figure 3. if the crimp height conforms to that marked on the tool, the tool is considered dimensionally correct. if not, return tool to te for evaluation and repair (refer to section 6). figure 3 modified anvil position point on center of wire barrel opposite seam wire barrel crimp height 5.5. ratchet inspection the ratchet feature on these hand tools should be checked to ensure that the ratchet does not release prematurely, allowing the crimping 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: 1. select the maximum size wire and strip it according to dimensions listed in the drawing shipped with the tool. 2. select contact and crimp section corresponding to the selected wire size (refer to the drawing shipped with the tool). 3. position the contact and wire in the crimping dies, as described in the section 3, crimping procedure.
408- 8547 rev j 4 of 4 4. hold the wire in place and squeeze the handles until the ratchet releases. hold the handles in this position, maintaining just enough tension to keep the dies closed. 5. check the clearance between the bottoming surfaces of the wire crimper and the wire anvil. see figure 1. if the clearance is 0.025 mm [.001 in.] or less (on at least two of the bottoming surfaces), the ratchet is satisfactory. if clearance exceeds 0.025 mm [.001 in.], the ratchet is out of adjustment and must be repaired. see section 5. the insulation crimper does not bottom on the insulation anvil. 6. replacement and repair the replaceable part is listed in figure 4. parts other than that listed in figure 4 should be replaced by te to ensure quality and reliability of the tool. order replacement parts through your local te representative, or call 1--800--526--5142, or refer to the appropriate website: ? toolrepair@te.com ? asia.tool@te.com ? jp_tool@te.com ? uktoolingservicecentre@te.com tools may also be returned for evaluation and repair. for tool repair service, call 1--800--526--5136, or refer to the appropriate website above. 7. revision summary revisions to this instruction sheet include: s changed web address in section 3, crimping procedure 70.36 [2.770] d 76.71 [3.020] 50.04 [1.970] 41.91 [1.650] 220.22 [8.670] 15.75 [.620] 296.93 [11.690] 27.43 [1.080 ] 1 29.46 [1.160] 12.19 [.480] 19.81 [.780] d closed to last ratchet point before release note: dimensions are in millimeters [ with inches in brackets ] . replaceable part item part number description qty per tool 1 21045--3 ring, retaining 4 figure 4 note i
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