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 ratchet will not release until the dies have been fully closed. Refer to Figure 2 for wire preparation information before applying the terminal. 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 Figure 1 open fully. 3. Holding the contact by its mating portion and looking straight into the crimp section, insert the CAT–HT–169–1620–11 (straight–action hand tool) contact from the back of the tool into the was designed to crimp C&69/ (IP%'–Series) appropriate crimp chamber. FRQWDFWs. 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 Figure 1. 5. Holding the contact in this position, 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 The front of the tool, is marked with the tool part locator/insulation stop. number, wire size ranges, and crimp height 7. Holding wire in place, crimp contact to the wire specifications. by squeezing the tool handles together until the The tool features a fixed die (crimper), a movable die ratchet releases. (anvil), a locator/insulation stop, and a ratchet. Many tools feature an insulation adjustment knob which is 8. Allow tool handles to open fully and remove the used to regulate the crimp height of the contact crimped contact from the tool. Figure 2 The care, amount of use, and handling of the hand tool, The presence of abnormal amounts of dust and dirt, Your own established standards. 9. If a terminal becomes jammed in a crimp nest, open the tool jaws using the“Emergency Ratchet The hand tool is inspected before being shipped; Release Button” on the moving handle lever. however, it is recommended that the tool be inspected immediately upon its arrival at your facility to ensure that the tool has not been damaged during shipment. On many tools, the insulation barrel crimp height is regulated by the insulation adjustment knob (Figure 3). The insulation crimp should hold the 1. Remove dust, moisture, and other contaminants insulation firmly without cutting into the insulation. with a clean brush, or a soft, lint–free cloth. Do not To determine the proper insulation crimp setting, test use objects that could damage the tool. crimp a loose piece contact using the setting which corresponds to the insulation diameter: (1) –– small; 2. Make certain that the retaining pins are in place (2) and (3) –– medium; or (4) –– large. If the crimped and that they are secured with retaining rings. insulation barrel is too tight or loose, change the 3. All pins, pivot points, and bearing surfaces setting by pulling out and rotating the adjustment should be protected with a thin coat of any good knob to the desired setting. 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. 5. Store the tool in a clean, dry area. 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 Figure 3 characteristics of an application. 1. The hand tool may be immersed (handles It is recommended that a maintenance and inspection partially closed) in a reliable commercial program be performed periodically to ensure degreasing compound (suitable for plastics) to dependable and uniform terminations. Frequency of remove accumulated dirt, grease and foreign inspection depends on: matter. 2. Close tool handles until the ratchet releases and prematurely, allowing the crimping dies to open before then allow the handles to open freely. If they do not they have fully bottomed. Obtain a 0.025–mm open quickly and fully, the spring is defective and [.001–in.] shim that is suitable for checking the must be replaced. clearance between the bottoming surfaces of the crimping dies. Proceed as follows: 3. Inspect the head assembly for worn, cracked, or broken jaws. If damage is evident, return it for Proceed as follows: evaluation and repair. 1. Select the maximum size wire and strip it according to the dimensions listed in the drawing shipped with the tool. This inspection requires the use of micrometer with a modified anvil as shown in Figure 4. 2. Select the contact and crimp section corresponding to the selected wire size (refer to A recommended Crimp Height Comparator is the drawing shipped with the tool). RS–1019–5LP, which can be purchased from: 3. Position the contact and wire in the crimping dies, as described in Section 3, CRIMPING PROCEDURE. 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 Proceed as follows: the dies closed. 1. Select a contact and a wire (maximum size) for 5. Check the clearance between the bottoming each crimp section. surfaces of the wire crimper and the wire anvil. See Figure 1. If the clearance is 0.025 mm [.001 in.] or 2. Refer to the Section 3, and crimp the contact(s). less (on at least two of the bottoming surfaces), the 3. Using a crimp height comparator, measure wire ratchet is satisfactory. If clearance exceeds barrel crimp height as shown in Figure 4. If the 0.025 mm [.001 in.], the ratchet is out of crimp height conforms to that marked on the tool, adjustment and must be repaired. the tool is considered dimensionally correct. Refer to Figure 5 for tool dimensions. Figure 4 Since the previous release of this document, the following changes have been made: Updated document to corporate requirements Changed views in Figure 5 The ratchet feature on these hand tools should be Changed titles in table in Figure 2 checked to ensure that the ratchet does not release Figure 5