Instruction Sheet Hand Crimping Tools 45160 and 45575-1 for 408-1502 PLASTI-GRIP* Butt Splices 22 SEP 11 Rev J PROPER USE GUIDELINES Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools. Hand tools are intended for occasional use a low volume applications. A wide selection of powered application equipment for extended-use, production operations is available. Insulation Crimp Adjustment Pins (Shown in Position 3) Tool Marking CERTI-CRIMP* Tool Crimping Ratchet Jaws Color-Coded Label Locator Figure 1 1. INTRODUCTION The locator positions the splice between the crimping jaws. The insulation crimp adjustment pins are used to TE Connectivity Hand Crimping Tools 45160 and regulate the crimp height of the splice insulation barrel 45575-1 (shown in Figure 1) are used to crimp sleeve. The ratchet assures full crimping of the splice. PLASTI-GRIP* butt splices (listed in Figure 2) onto Once engaged, the ratchet will not release until the stranded or solid wire sizes 22 through 14 AWG. tool handles have been FULLY closed. Dimensions in this instruction sheet are in NOTE millimeters [with inches in brackets]. Figures and The crimping jaws bottom before the CAUTION illustrations are for reference only and are not CERTI-CRIMP tool ratchet releases. This feature i drawn to scale. ensures maximum electrical and tensile ! performance of the crimp. Do NOT re-adjust the Reasons for reissue of this instruction sheet are ratchet. provided in Section 7, REVISION SUMMARY. 2. DESCRIPTION (Figure 1) 3. CRIMPING PROCEDURE Each hand tool consists of two crimping jaws, locator, Each hand tool is coated with a preservative to NOTE two insulation crimp adjustment pins, and a prevent rust or corrosion. Wipe this preservative CERTI-CRIMP tool ratchet. The FRONT of the tool, from the tool, particularly from the crimping jaws, i into which the splice is inserted, has the TE logo before using the tool. marked on the link. The tool handles have color- Refer to Figure 2 to make sure that the splice, wire coded labels which match the insulation color of the size, and tool are compatible. splices and correspond with a given wire size range. ©2011 Tyco Electronics Corporation, Berwyn, PA This controlled document is subject to change. TOOLING ASSISTANCE CENTER 1-800-722-1111 1 of 6 All Rights Reserved For latest revision and Regional Customer Service, PRODUCT INFORMATION 1-800-522-6752 TE logo and Tyco Electronics are trademarks visit our website at www.tycoelectronics.com *Trademark. Other products, logos, and company names might be trademarks of their respective owners. LOC B ORIGINAL INSTRUCTIONS 408-1502 Similar splices with an insulation color other than NOTE Crimping Butt Splice red or blue can be crimped with these tools; however, wire size must be used, instead of the i tool-to-product color code, to establish compatibility. End of Splice Resting Against Locator Typical PLASTI-GRIP Butt Splice 6.35-7.14 [.250-.281] Wire Strip Length Locator Insulation Wire Barrel Barrel Figure 3 5. Hold wire in place and squeeze tool handles together until the CERTI-CRIMP tool ratchet Color Code releases. Allow tool handles to open FULLY. Wire Size Splice (Splice and Tool Remove the crimped splice from the tool. Range (AWG) Tool) 6. To crimp other half of splice, position the 34203 uncrimped wire barrel in the tool, and crimp as 34067 described in Step 5. 34070 7. Remove the crimped splice from the tool, and 22-16 34178 Red 45160 34243 inspect the crimp. Make sure the proper crimp 55792-1 dot code is shown on the splice insulation for the 324138 appropriate hand tool. Refer to Figure 4. For detailed crimp inspection requirements, refer 34204 NOTE 34068 to Application Specification 114-2161. 34071 i 2-34071-2 8-34071-1 16-14 8-34071-4 Blue 45575-1 8-34071-5 35244 328427 Crimp Dot Code 8-328427-1 55785-1 Figure 2 A complete list of butt splice part numbers cannot NOTE be maintained on this document. For all part numbers and their description, refer to your TE i Representative. Tool Color Code Crimp Dot Code Proceed as follows: 45160 Red 1 Dot 1. Strip the wire using the appropriate strip length dimensions provided in Figure 2. Do NOT 45575-1 Blue 2 Dots nick or cut the wire strands. Figure 4 2. Open the crimping jaws by squeezing the tool handles together until the ratchet releases. 4. INSULATION CRIMP ADJUSTMENT 3. Insert stripped wire into the splice wire barrel. Each tool has three insulation crimp adjustment positions to adjust the wire insulation grip: 1—Tight, 4. Locate the splice—with the wire inserted— 2—Medium, and 3—Loose. To obtain the desired into the crimping jaws, as shown in Figure 3. The insulation grip, proceed as follows: end of the splice should rest against the locator. Rev J 2 of 6 408-1502 1. Insert pins into Position 3. 3. All pins, pivot points, and bearing surfaces should be protected with a thin coat of any good Both pins must be inserted into the same NOTE SAE‡ 20 motor oil. Do NOT oil excessively. adjustment position. 4. When the tool is not in use, keep handles i closed to prevent objects from becoming lodged in the crimping jaws. Store the tool in a clean, dry area. 2. Position splice into crimping jaws, as described in Section 3, Step 4. 5.2. Lubrication 3. Insert an UNSTRIPPED wire into just the Lubricate all pins, pivot points, and bearing surfaces splice insulation barrel. with SAE 20 motor oil as follows: 4. Crimp the splice using the procedure • Tools used in daily production—lubricate daily described in Section 3, Step 5. Remove the crimped splice from the crimping jaws, and • Tools used daily (occasional)—lubricate weekly check the insulation support by bending the wire • Tools used weekly—lubricate monthly back and forth once. Wipe excess oil from tool, particularly from crimping The insulation barrel should retain grip on the area. Oil transferred from the crimping area onto wire insulation. If the wire pulls out, move the certain terminations may affect the electrical insulation crimp adjustment pins to the next characteristics of an application. tighter position (Position 2) then proceed to Step 5. If the wire does not pull out, the pins are 5.3. Periodic Inspection properly adjusted. NOTE: Do NOT use a tighter 1. Hand tool should be immersed (handles setting than is required. partially closed) in a reliable commercial 5. Perform another test crimp. Adjust pins, as degreasing compound to remove accumulated necessary, until the desired insulation grip is dirt, grease, and foreign matter. obtained. 2. Close tool handles until ratchet releases and 5. MAINTENANCE AND INSPECTION then allow them to open freely. If they do not open quickly and fully, the spring is defective and TE recommends that a maintenance and inspection must be replaced. See Section 6, program be performed periodically to ensure REPLACEMENT AND REPAIR. dependable and uniform terminations. Frequency of inspection depends on: 3. Inspect head assembly for worn, cracked, or broken jaws. If damage is evident, refer to 1. The care, amount of use, and handling of the Section 6, REPLACEMENT AND REPAIR, for hand tool; customer repair service. 2. The presence of abnormal amounts of dust 5.4. Gaging the Crimping Chamber and dirt; This inspection requires the use of a plug gage 3. The degree of operator skill; and conforming to the dimensions provided in Figure 5. 4. Your own established standards. TE does not manufacture or market these gages. The tool is inspected before being shipped from the To gage the crimping chamber, proceed as follows: plant; however, TE recommends that the tool be 1. Remove traces of oil or dirt from the crimping inspected immediately upon arrival at your facility to chamber and plug gages. ensure that the tool has not been damaged during shipment. 2. Align the GO element of the wire barrel crimp plug gage with the wire barrel section of the 5.1. Daily Maintenance crimping chamber. Push element straight into 1. Remove dust, moisture, and other the crimping chamber without using force. The contaminants with a clean brush, or a soft, GO element must pass completely through the lint-free cloth. Do NOT use objects that could crimping chamber, as shown in Figure 6, damage the tool. Detail A. 2. Make certain that the retaining pins are in 3. Align the NO-GO element and try to insert it place and that they are secured with retaining straight into the same crimping chamber. The rings. NO--GO element may start entry, but must not pass completely through the crimping chamber. See Figure 6, Detail A. ‡ Society of Automotive Engineers is a trademark of SAE International Corporation. Rev J 3 of 6 408-1502 GO Diameter NO-GO Diameter GO Diameter NO-GO Diameter Suggested Plug Gage Design for Suggested Plug Gage Design for Wire Barrel Section Insulation Barrel Section Gage Element Diameter Gage Element Diameter Tool Tool “W” Width GO NO-GO GO NO-GO (Max) 2.769-2.776 2.918--2.921 0.762-0.770 1.267-1.270 45160 45160 1.91 [.075] [.1090--.1093] [.1149--.1150] [.0300-.0303] [.0499-.0500] 3.023--3.030 3.172--3.175 1.016-1.024 1.521-1.524 45575-1 45575-1 3.18 [.125] [.1190--.1193] [.1249--.1250] [.0400-.0403] [.0599-.0600] Figure 5 Inspection of Crimping Chamber Detail A Detail B Wire Barrel Plug Gage Insulation Barrel Wire Barrel Insulation Section Section Barrel Gage GO element must NO-GO element may enter GO element must NO-GO element may enter partially, but must NOT partially, but must NOT pass completely pass completely pass completely through pass completely through through the crimping through the crimping the crimping chamber. the crimping chamber. chamber. chamber. Figure 6 Rev J 4 of 6 408-1502 4. Insert insulation crimp adjustment pins into 4. Close the tool handles until it is evident that Position 1. the jaws have bottomed; then hold in this position. Do NOT force the jaws beyond initial 5. Check the insulation barrel section of the contact. crimping chamber using the insulation crimp plug gage in the same manner as in Steps 2 and 5. Check the clearance between the bottoming 3. See Figure 6, Detail B. surfaces of the crimping jaws. If the clearance is 0.025 mm [.001 in.] or less, the ratchet is If the crimping chamber conforms to the gage satisfactory. If clearance exceeds 0.025 mm inspection, the tool is considered dimensionally [.001 in.], the ratchet is out of adjustment and correct, and should be lubricated with a THIN coat of must be repaired. See Section 6, any good SAE 20 motor oil. If not, refer to Section 6, REPLACEMENT AND REPAIR. REPLACEMENT AND REPAIR for obtaining further evaluation and repair. 6. REPLACEMENT AND REPAIR For additional information regarding the use of plug gages, refer to Instruction Sheet 408-7424. Customer-replaceable parts are listed in Figure 7. A complete inventory should be stocked and controlled to prevent lost time when replacement of parts is 5.5. CERTI- CRIMP Tool Ratchet Inspection necessary. Parts other than those listed should be replaced by TE to ensure quality and reliability. Order The CERTI-CRIMP tool ratchet should be checked to replacement parts through your TE Representative, ensure that the ratchet does not release prematurely, or call 1-800-526-5142, or send a facsimile of your allowing the jaws to open before they have fully purchase order to 717-986-7605, or write to: bottomed. Obtain a 0.025 mm [.001 in.] shim that is suitable for checking the clearance between the CUSTOMER SERVICE (038-035) bottoming surfaces of the crimping jaws. Proceed as TYCO ELECTRONICS CORPORATION follows: PO BOX 3608 1. Select a splice and maximum size wire for the tool. HARRISBURG PA 17105-3608 2. Position the splice and wire in tool as described in Section 3, CRIMPING For customer repair service, please contact a PROCEDURE. TE Representative at 1-800-526-5136. 3. Hold the wire in place and squeeze the 7. REVISION SUMMARY handles until the ratchet releases. Hold the Revisions to this instruction sheet include: handles in this position, maintaining just enough tension to keep the jaws closed. • Corrected dimension in table in Figure 5 Rev J 5 of 6 408-1502 REPLACEMENT PARTS Item Part Number Description Qty Per Tool 1 305173 LOCATOR (Stop) -- Tool 45160 Only 1 1 305234 LOCATOR (Stop) -- Tool 45575-1 Only 1 2 8-59558-2 PIN, Retaining 2 3 39364 SPRING, Hold Down 1 4 2-23620-9 PIN, Straight, Grooved 1 5 21045-6 RING, Retaining 2 6 39207 PIN, Crimp Adjustment 2 7 21045-3 RING, Retaining 4 8 24367-4 WASHER, Spring Lock 1 9 4-21924-4 SCREW, Machine 1 Figure 7 Rev J 6 of 6