408-1559 TEC | Alldatasheet
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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
- 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 reissue 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 occasional use and low volume applications. A wide selection of powered 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
- 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) that 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 conductor(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
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 (cont’d)
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 [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 [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
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] 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] Green 2 Spare Wire Cap 328308 Blue 16-14 --- 48518-2 --- --- PIDG FASTON Receptacles 641321-1 (.187 Series) and 641324-1 (.110 Series) [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 – (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
- 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, 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. Inspect crimped product according to Figure 7. Product not meeting these conditio ns should NOT be used. Figure 7
- INSULATION CRIMP ADJUSTMENT 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 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 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 diameter — 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 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 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 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. 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
- 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.
- 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.
- Inspect crimping areas for pitted or chipped surfaces.
- Close the tool handles until the ratchet releases, then allow handles to open freely. If they do not open
- 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.
- 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.
- Align the NO-GO element of the gage with the same crimp section, and try to insert the element. The
- Repeat the gage inspection for the insulation crimp section of the crimping chamber, making sure to
For additional information concerning the use of the plug gage, refer to Instruction Sheet 408 -7424.
- Refer to Figure 3, and select a product and maximum size wire.
- Position the product in the crimping chamber according to Paragraph 3.1, Steps 1 through 5 or
Paragraph 3.2, Steps 1 through 6.
- While holding the wire in place, squeeze the tool handles together until the ratchet releases. Holding
the tool in this position, maintain just enough pressure to keep the jaws closed.
- Check the clearance between the bottoming surfaces of the jaws. If the clearance is .025 mm
Corporation, PO Box 3608, Harrisburg, PA 17105-3608.
- 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♦♦ DIAMETER B DIMENSION GO NO-GO GO NO-GO C (WIDTH) R (RADIUS) 46121 [.0630-.0633] 1.750-1.753 [.0689-.0690] --- --- [.0630-.0633] 1.750-1.753 [.0689-.0690] 47386 [.1090-.1093] 2.918-2.921 [.1149-.1150] 47387 [.1190-.1193] 3.172-3.175 [.1249-.1250] [.0890-.0893] 2.410-2.413 [.0949-.0950] [.0630-.0633] 1.750-1.753 [.0689-.0690] [.1090-.1093] 2.918-2.921 [.1149-.1150] [.1030-.1033] 2.715-2.718 ♦Jaw closure dimensions apply when wire barrel jaws are bottomed, but not under pressure. ♦♦Material: Tool Steel Figure 8 (cont’d)
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
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