Instruction Sheet
408-1559
Hand Crimping Tools
19 JUN 07
Rev P
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 Tool Ratchet
Control
Color Code for PIDG* and
PLASTI-GRIP* Products
Wire Size Range
Stamped Here
Color Code for
Sealed Splices
HAND CRIMPING TOOL PART NUMBERS
Insulation Crimp Adjustment
Pins in No. 3 Position
46121
47387
69151-1
47304
47907-1
69454
47386
48518-2
169485
47386-5
Figure 1
1. INTRODUCTION
This instruction sheet covers the Hand Crimping Tools
listed in Figure 1, which are used to crimp the
terminal types listed in Figure 2.
NOTE
i
Dimensions on this sheet are in millimeters
[with inch-equivalent dimensions in brackets].
Figures and illustrations are for identification only
and are not drawn to scale.
Reasons for reissue are provided in Section 9,
REVISION SUMMARY.
2. DESCRIPTION (Figure 1)
The handles and label (if applicable) of the crimping
tools are color–coded to match the color coding of the
E
2007 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
connectors to be applied, as listed in Figure 3. The
crimping tools may show more than one color code.
Check Figure 3 to be sure that the correct tool/
connector combination is being used.
For example, tool 47386 can be used to apply PIDG
terminals and splices with a yellow color code, as well
as spare wire caps with a red color code.
Figure 3 lists the number of dots (or rib) that appear
embossed on a crimped item when the connector is
crimped in the correct tooling.
The CERTI–CRIMP hand crimping tool ratchet control
ensures full crimping of terminals and splices. Once
engaged, the ratchet will not release until the tool
handles have been FULLY closed.
TOOLING ASSISTANCE CENTER 1-800-722-1111
This controlled document is subject to change.
PRODUCT INFORMATION 1-800-522-6752
For latest revision and Regional Customer Service,
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
visit our website at
www.tycoelectronics.com
1 of 10
LOC B
408-1559
Hand Crimping Tools
CONNECTOR
TYPE
WIRE
TYPE
PIDG Terminals and
Solid or Stranded
Splices
Copper
WIRE SIZE
[AWG]
30-14
Stranded Copper
6. Complete the crimp by closing the tool handles
until the ratchet releases.
PIDG Radiation
Stranded Copper
27-14
Stranded Copper
26-24
and Splices
PIDG FASTON*
Receptacles,
Part Nos 641321-1
(.187 Series) and
641324-1 (.110 Series)
PLASTI-GRIP
Solid or Stranded
Terminals
Copper
PLASTI-GRIP
Solid or Stranded
Butt Splices
Copper
Spare Wire Caps
Stranded Copper
22-14
26-22
22-14
7. Release the tool handles, allow the handles to
open fully, and remove the crimped terminal or
splice.
8. To crimp the other half of a splice, re–position
the uncrimped half of the splice in the tool as
shown in Figure 5. Follow the procedure used to
crimp the first splice half.
9. Refer to Section 4 and Figure 7 for terminal and
splice crimp inspection procedure.
3.2. For Spare Wire Caps
1. Strip the wire to the dimensions provided in
Figure 3.
Figure 2
CAUTION
!
The crimping areas bottom before the crimping
tool ratchet releases. This is a design feature that
assures maximum tensile performance of the
crimp. Do NOT re-adjust the ratchet.
Refer to Section 5 for information on the
insulation crimp adjustment.
i
3.1. For PIDG and PLASTI-GRIP Terminals and Splices
1. Strip the wire to the dimension provided in
Figure 3, being careful to avoid nicking or
damaging the conductor(s).
CAUTION
Do NOT use wire with nicked or missing
conductors.
!
2. Open the tool jaws by closing the tool handles
until the ratchet releases, then allow the handles to
open fully.
3. Place the terminal or splice in the dies as shown
in Figure 4 or Figure 5.
4. Close the tool handles until the terminal or splice
is held firmly in place. Do NOT deform the terminal
or splice wire barrel.
2 of 10
CAUTION
Do NOT use wire with nicked or missing
conductors.
!
NOTE
3. CRIMPING PROCEDURE
NOTE
Do NOT allow wire insulation to enter the
terminal or splice wire barrel.
26-14
nals
Resistant Terminals
CAUTION
!
PIDG Insulation
Restricting Nylon TermiĆ
5. Insert properly stripped wire(s) into the terminal
or splice, as shown in Figure 4 or Figure 5.
Make sure that the color coding on the spare wire
cap and the tool match.
i
2. Place the crimping tool’s insulation adjustment
pins in the No. 3 position.
3. Close the tool handles until the crimping jaws
partially close, but leave enough space for the cap
to be inserted between the dies.
4. Raise the locator so that the end of the cap
rests against the recessed surface of the locator,
as shown in Figure 6.
5. Close the tool handles until the cap is held firmly
in place. Do NOT deform the cap wire barrel.
6. Insert the properly stripped wire into the cap
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. Refer to Section 4 and Figure 7 for spare wire
cap crimp inspection procedure.
Tyco Electronics Corporation
Rev
P
408-1559
Hand Crimping Tools
PIDG Butt Splice
PLASTI-GRIP
Terminal
Spare Wire Cap
PIDG Type
Terminals
1/14 !64.2+ 10
(*.(6.10 +5.56(06
37(//9 !2()+* 1/14
!64.2+5 10 057/(6.10
+564.)6.0PLASTI-GRIP
Butt Splice
1/14 !64.2+ 10
(*.(6.10 +5.56(06
FASTON
Receptacle
TOOL NUMBER
WIRE
AND
RANGE
DESCRIPTION
(AWG)
D
AND DOT
%$
"
" ! !!
!" #"" !!
MIN.
MAX.
%$
&
'
&'
&'
&'
&'
&
'
&
'
&'
&'
&'
;;
;;
&'
&'
&'
&
'
# $"
"$ "!
"# " !#"
" !!""
! $" !" " !
! " # %$
"
!!"" " !
! " # "# $" %$ !" # "$
"!
SPLICES
MAX.
" !
" ! !!
!" " !
"
!!"" ;
"# " !#" $ !" "
!!""
" !
!!
&' #
&
'
"
!!"" ; "# " !#"
$# !" "
TERMINALS
MIN.
" ! !!
"
!!""
" ! !!
CODE
%$
%$
"
WIRE STRIP LENGTH
PRODUCT
INSULATION COLOR
PRODUCT
CODE
D
TOOL
COLOR
D "" !#" !# " $ ! $" " $ !#"
Figure 3 (cont’d)
+8 P
"9)1 /+)6410.)5 14214(6.10
3
1, 408-1559
Hand Crimping Tools
TOOL NUMBER
WIRE
AND
RANGE
DESCRIPTION
(AWG)
26
46121
INSUL
TOOL
DIA.
COLOR
RANGE
AND DOT
mm [in.]
CODE
WIRE STRIP
PRODUCT
LENGTH
INSULATION COLOR
PRODUCT
CODE
0.66-1.40
PIDG
YELLOW W/3
[.026-.055]
INSULATION
BLACK STRIPES
169485
MIN.
RESTRICTING
D
47304
0.79-1.40
24
RED
[.031-.055]
NYLON
YELLOW W/3
TERMINALS
BLUE STRIPES
MAX.
4.8
5.6
[3/16]
[7/32]
AND
26
47386
0.66-1.40
YELLOW
PIDG INSULATION
YELLOW W/3
[.026-.055]
ONE DOT
RESTRICTING
BLACK STRIPES
NYLON TERMINALS
47386-5
24
22
0.79-1.40
MS 7928/1-1
YELLOW W/3
[.031-.055]
THRU -10
BLUE STRIPES
0.97-2.79
RED W/3
[.038-.055]
GREEN STRIPES
47386
47386-5
D
20
YELLOW AND RED
ONE DOT (TOOL NO.
1.17-2.79
69151-1
RED STRIPES
PIDG
MOD. F IS CODED
6.4
7.1
[1/4]
9/32
INSULATION
RED ONLY)
1.42-2.79
18
RED W/3
69151-1
[.046-.110]
RESTRICTING
RED W/3
NYLON
WHITE STRIPES
[.056-.110]
TERMINALS
16
47387
BLUE AND
1.60-3.30
BLUE W/3
GREEN
[.063-.130]
BLUE STRIPES
TWO DOTS
D TIGHT INSULATION SUPPORT FOR WIRES WITH THIN WALL INSULATION
TOOL NUMBER
WIRE
AND
RANGE
DESCRIPTION
(AWG)
47386
TOOL
CODE
CODE
YELLOW
22-18
SPARE WIRE CAP
AND RED
BLUE AND
47387
16-14
SPARE WIRE CAP
GREEN
TOOL NUMBER
WIRE
AND
RANGE
DESCRIPTION
(AWG)
MAX.
8
8.7
[5/16]
[11/32]
BLUE
NO. 328308
TWO DOTS
MIN.
RED
NO. 328307
ONE DOT
LENGTH
INSULATION COLOR
PRODUCT
AND DOT
47386-5
WIRE STRIP
PRODUCT
COLOR
PRODUCT
WIRE STRIP
LENGTH
INSULATION COLOR
PRODUCT
CODE
MIN.
MAX.
YELLOW
48518-2
26-24
PIDG FASTON RECEPTACLES
NOTE: Color code is for
P/N 641321-1 (187 SERIES) AND P/N
reference only. Always order correct
641324-1 (110 SERIES)
tool by supplying part numbers of
4.8
5.6
[3/16]
[7/32]
receptacles being crimped.
Figure 3 (end)
PIDG and PLASTI-GRIP Terminals
“C”
“B”
“C”
“B”
PIDG
Terminal
PIDG
Insulation
Restricting
Terminal
Terminal Wire Barrel
Butts Against Locator
End of Wire Conductor
“C”
Butts Against Tool Locator
“B”
“C” “B”
(Note: Wire Butts Against
Wire Stop
FASTON Receptacle Wire
B" Equals
Stop)
Wire Barrel
C" Equals
PIDG FASTON Receptacle
4 of 10
PLASTI-GRIP Terminal
Insulation
Figure 4
Tyco Electronics Corporation
Barrel
Rev P
408-1559
Hand Crimping Tools
Butt Splices
C"
B"
Spare Wire Caps
Insulation
PIDG Splice
Adjustment
Pins in No. 3
Window Indent
Position
Locator
PLASTI-GRIP Splice
C"
Wire Stop
Wire Barrel
Window
B"
Indent
Raise Locator so
B" Equals Wire Barrel
that End of Cap
C" Equals Insulation Barrel
Rests Against
Wire Bottoms
Recessed Surface
First
Crimp
Locator Seats in
Wire Stop
in Cap
of Locator
Window Indent
Insulation Crimp Adjustment
of Splice
Figure 6
Pins in No. 3 Position
1. Insert the insulation crimp adjustment pins into
the No. 3 position. Refer to Figure 1 or Figure 5.
2. Place the terminal or splice into the crimping
jaws as shown in Figure 4 or Figure 5.
3. Insert the UNSTRIPPED wire into ONLY the
insulation barrel (refer to Figure 4 or Figure 5)
portion of the terminal or splice.
End of Wire Conductor Butts
Against Splice Wire Stop
4. Close the tool handles to complete the crimp.
Second
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 the insulation crimp adjustment pins to the
next higher position (No. 2).
End of Wire Conductor Butts
Against Splice Wire Stop
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.
CAUTION
Locator Seats in Window
!
Figure 5
5.2. For PLASTI-GRIP Terminals and Splices
4. CRIMP INSPECTION
Inspect crimped terminals and splices by checking the
features described in Figure 7. Terminals and splices
not meeting these conditions should NOT be used.
5. INSULATION CRIMP ADJUSTMENTS
PIDG terminals and splices feature a wire
insulation grip."
i
P
PLASTI-GRIP terminals and splices feature a
wire insulation support" only. The terminal or
i
splice insulation should ideally be in contact with
the wire insulation.
2. Set adjustment pins in position No. 2 for wire
having a medium insulation diameter.
3. Set adjustment pins in position No. 1 for wire
having a small insulation diameter.
The insulation crimping section of the hand tool has
three positions: 1 (tight), 2 (medium), and 3 (loose).
To adjust the section:
Rev
NOTE
1. Set adjustment pins in position No. 3 for wire
having a large insulation diameter.
5.1. For PIDG Terminals and Splices
NOTE
Make sure that both insulation crimp adjustment
pins are in the same position.
Indent of Splice
CAUTION
Make sure that both insulation crimp adjustment
pins are in the same position.
!
Tyco Electronics Corporation
5 of 10
408-1559
Hand Crimping Tools
A Dot Code (1 or 2 Dots) Must Appear
1
2
3
4
1
on All Crimped Items
5
5
(Rib code on bottom, dot code on top when
PIDG AND
PLASTI-GRIP
Terminals
3
crimped in tool No. 69454)
2
10
9
4
7
8
5
PLASTI-GRIP
Butt Splice
8
Wire Stop
Spare Wire
Caps
7
6
6
3
4
PIDG
Butt Splices
2
6
4
8
1
3
2
1
1
2
Wire Stop
1
2
No flash or extruded insulation.
Correct color code, dot code, and tool combination. Dot coding
disappears from sealed splices when they are heat sealed.
Insulation barrel is in firm contact with wire insulation.
Correct color code, dot code, and tool combination (Rib code
3
Correct wire size is used.
4
Wire insulation does not enter wire barrel of splice.
on bottom, dot code on top when crimped in tool No. 69454).
3
5
Wire size is within the wire range stamped under the terminal
4
5
End of conductor is against wire stop, is at least flush with, or
extends slightly beyond, the splice's wire barrel.
tongue or on the center of the splice.
Crimp is centered on the wire barrel.
Conductor end is flush with, or extends beyond, the end of the
6
End of conductor is bottomed in cap.
7
Full width of crimp is over wire barrel.
8
No nicked or missing conductor strands.
9
Crimp is centered on wire barrel.
terminal wire barrel.
6
Conductor end is against the wire stop, is at least flush with, or
extends slightly beyond, the wire barrel.
7
Wire insulation does not enter the wire barrel.
8
No nicked or missing conductor strands.
10
Splice insulation is in contact with wire insulation.
Figure 7
6. INITIAL TOOL 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
shipping container, file a claim with the carrier, and
notify Tyco Electronics immediately.
7. MAINTENANCE/INSPECTION
7.1. Daily Maintenance
1. Remove dust, moisture, and other contaminants
6
of 10
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.
Tyco Electronics Corporation
Rev
P
408-1559
Hand Crimping Tools
7.2. Periodic Inspection
Regular inspections should be performed by quality
control personnel. A record of scheduled inspections
should remain with the tool and/or be supplied to
supervisory personnel responsible for the tool.
Though 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:
A. 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.
3. Inspect crimping areas for pitted 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 8,
REPLACEMENT AND REPAIR.
B. Gaging the Crimping Areas
This inspection requires the use of plug gages
conforming to the dimensions listed in Figures 8
and 9. Tyco Electronics does not manufacture or
market these gages.
To gage the crimping area(s), refer to Figure 10 and
proceed as follows:
1. Close the crimping areas by squeezing the tool
handles together until the crimping dies have
bottomed, and then HOLD the tool handles in this
position. Do not force the dies beyond initial
contact.
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 11.
SUGGESTED PLUG GAGE DESIGN Ċ WIRE BARREL CRIMP
4
&) 4
3,
&) 4
Tool No. 69454 Only
&)
4
3,
&)
4
4
&
&
4
4
&)
TOOL NUMBER
&* 3,
&* 3,
4
&* 3,
Die Closure
Configuration
DIE CLOSURE DIM'S. A"{
GO
Die Closure
Configuration
GAGE ELEMENT{{ DIM'S. B" DIA.
NO-GO
GO
NO-GO
{ &# !(+.0-# "&)#*.&+*. ,,(3 2%#* 2&-#
{{ /#-&(7++( /##(
--#( '2. -#
+//+)#"
C"
MAX.
R"
RADIUS
77
77
0/ *+/ 0*"#- ,-#..0-#
Figure 8
#1
P
3!+ (#!/-+*&!. +-,+-/&+*
7 +$ 408-1559
Hand Crimping Tools
SUGGESTED PLUG GAGE DESIGN Ċ INSULATION CRIMP
%(
3 %(
%(
3
Die Closure
Configuration
3
3
2+
TOOL NUMBER
DIE CLOSURE DIM'S. F"{ (Set Insulation
Adjustment Pins at No. 1 Position)
GO
GAGE ELEMENT {{ DIM'S. G"
NO-GO
GO
NO-GO
WIDTH
W" (Max.)
{ %" '*-/," !%(")-%*)- ++'2 1$") 1%," ,,"' &1- ," *..*("! /. )*. /)!", +,"--/,"
{{ .",%'5**' .""'
Figure 9
2. Align the GO element of the gage with the
appropriate crimping area to be checked. Refer to
Figure 10. Push the element straight into the area
without using force. The GO element must pass
completely through the crimping area.
3. Align the NO–GO element of the gage with the
same crimping area, and try to insert the element.
The NO–GO element may start entry, but it must
not pass completely through the crimping area.
4. Repeat the gage inspection procedure for each
crimping area, making sure to use the correct plug
gage for each inspection.
If the crimping areas conform to the gage inspection,
the tool is considered dimensionally correct. If the
crimping areas do not conform to the inspection, the
tool must be repaired. Refer to Section 8,
REPLACEMENT AND REPAIR.
8 *# For additional information concerning the use of the
plug gage, refer to instruction sheet 408–7424.
C. CERTI-CRIMP Hand Crimping Tool Ratchet
Control Inspection
Obtain a .025–mm [.001–in.] shim that is suitable for
checking the clearance between the bottoming
surfaces of the crimping dies. To inspect the ratchet
control:
1. Refer to Figure 3 and select a terminal or splice
and wire (maximum size).
2. Position the terminal or splice in the appropriate
crimping area, according to the method described
in Paragraph 3.1, Steps 1 through 5.
3. While holding the wire in place, squeeze the tool
handles together until the ratchet releases. Hold
the tool in this position, maintaining just enough
pressure to keep the dies closed.
2 * '" .,*)% - *,+*,.%*)
"0
P
408-1559
Hand Crimping Tools
Detail A
Inspection of Wire Barrel Crimping Dies
Detail B
Inspection of Insulation Crimping Dies
Adjustment
Wire Barrel
Jaws Bottomed
But Not Under
Pins in No. 1
Position
Pressure
GO" element must pass completely
through the die closure.
NO-GO" element may
enter partially, but must not pass
completely through the die closure.
Figure 10
4. Check the clearance between the bottoming
surfaces of the crimping dies. 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 8,
REPLACEMENT AND REPAIR. If the tool
conforms to these inspection procedures, lubricate
it with a THIN coat of any good SAE 20 motor oil
and return it to service.
Replacement parts are listed in Figure 11. Parts other
than those listed in Figure 11 should be replaced by
Tyco Electronics to ensure quality and reliability of the
tool. Order replacement parts through your Tyco
Electronics Representative, or call 1–800–526–5142,
P
CUSTOMER SERVICE (38–35)
TYCO ELECTRONICS CORPORATION
P.O. BOX 3608
HARRISBURG, PA 17105–3608
For tool repair service, please contact a
representative at 1–800–526–5136.
9. REVISION SUMMARY
8. REPLACEMENT AND REPAIR
Rev
or send a facsimile of your purchase order to
1–717–986–7605, or write to:
Since the previous release of this sheet, the following
changes were made:
S Updated document to corporate requirements
S Added part number 47386–5 to tables in
Figures 1, 3, 8, 9, and 11
Tyco Electronics Corporation
9 of 10
408-1559
Hand Crimping Tools
1
12
6
2
7
4
11
10
8
Detail
A
Detail
B
Approx.
1
76.2 [3.00]
8
9
13
22.22
3
[.875]
Approx.
279.4 [11.00]
TOOL NUMBERS, DETAIL REF., AND COMPONENT PART NUMBERS
ITEM
DESCRIPTION
NO.
1
RING, Retaining
2
PIN, Retaining
3
PIN, Adjustment
4
SPRING
6
RING, Retaining
7
PIN, Retaining
8
SCREW
9
46121
47304
47386, 47386-5
47387
47907-1
DETAIL A
DETAIL B
DETAIL A
DETAIL A
DETAIL A
21045-3
21045-3
21045-3
21045-3
21045-3
1-23619-6
1-23619-6
1-23619-6
1-23619-6
1-23619-6
39207
39207
39207
39207
39207
39364
39364
39364
39364
39364
21045-6
21045-6
21045-6
21045-6
21045-6
2-23620-9
2-23620-9
2-23620-9
2-23620-9
2-23620-9
3-306105-9
3-21016-4
9-305927-1
9-305927-1
9-305927-1
SUPPORT
--
39193
--
--
--
10
STOP
--
302765
--
--
--
11
HOUSING LOCATOR
302994
--
302994
302994
302994
12
SPRING
301201
--
301201
301201
301201
13
LOCATOR
3-304052-6
--
302993
45965-6
303542
TOOL NUMBERS, DETAIL REF., AND COMPONENT PART NUMBERS
ITEM
DESCRIPTION
NO.
169485
48518-2
69151-1
69454
DETAIL A
DETAIL A
DETAIL A
DETAIL A
21045-3
21045-3
21045-3
21045-3
1-23619-6
1-23619-6
1-23619-6
1-23619-6
1
RING, Retaining
2
PIN, Retaining
3
PIN, Adjustment
39207
39207
39207
39207
4
SPRING
39364
39364
39364
39364
6
RING, Retaining
7
PIN, Retaining
8
SCREW
9
SUPPORT
21045-6
21045-6
21045-6
21045-6
2-23620-9
2-23620-9
2-23620-9
2-23620-9
9-305927-1
3-306105-9
9-305927-1
9-305927-1
--
--
--
--
10
STOP
--
--
--
--
11
HOUSING LOCATOR
302994
302994
302994
302994-1
12
SPRING
301201
301201
301201
2-304668-6
13
LOCATOR
575960-4
125644-7
302993
4-304052-6
Figure 11
10 of 10
Tyco Electronics Corporation
Rev P