TE Connectivity 2844594-1 User manual

Instruction Sheet
1 of 7
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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.
408-35007
14 DEC 16 Rev D
Figure 1
1. INTRODUCTION
This instruction sheet covers hand crimping tool PN 2844594-1 used to crimp STRATO-THERM terminals (PN
321897 and PN 321898) to 20 and 18 AWG high temperature wire.
NOTE
Dimensions on this instruction sheet are in millimeters [with inches in brackets]. Figures and illustrations are for identification
only and are not drawn to scale.
2. DESCRIPTION
Each tool features a head containing two stationary crimping dies (anvils) and two movable crimping dies
(indenters), a locator, an insulation crimping adjustment pin, and a CERTI-CRIMP hand crimping tool ratchet
control (see Figure 1).
When closed, the crimping dies form one crimping chamber with two sections: an insulation barrel section and
a wire barrel section. Simultaneously, the insulation barrel section crimps the terminal onto the wire insulation
and the wire barrel section crimps the terminal wire barrel onto the stripped wire. The locator positions the
terminal in the crimping chamber. The insulation crimping adjustment pin is used to regulate the height of the
insulation crimp.
The CERTI-CRIMP hand crimping tool ratchet control ensures full crimping of the terminal. Once engaged, the
ratchet will not release until the tool handles have been FULLY closed.
CAUTION
The crimping dies bottom before the CERTI-CRIMP hand crimping tool ratchet control releases. This design feature ensures
maximum electrical and 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.
Hand Tool; PN 2844594-1, for
Crimping STRATO-THERM* Terminals;
PN 321897 and PN 321898
Restricted to SAFRAN

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Hand Tool
Part Number
Wire Size
(AWG)
Terminal
Part Number
Strip Length
Min.
Max.
2844594-1
20-18
321897
5.16 [0.203]
5.94 [0.234]
321898
Figure 2
3. CRIMPING PROCEDURE
NOTE
Refer to Section 5 for information on the insulation crimp adjustment.
Refer to Figure 3 and the following steps for terminal crimping procedures.
Figure 3
1. Strip the wire to the dimension provided in Figure 2, 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 in the dies so that the wire barrel butts against the locator.
4. Close the tool handles until the terminal is held firmly in place. Do NOT deform the terminal.
5. Insert properly stripped wire into the terminal until the end of the conductor butts against the locator.
CAUTION
Do NOT allow wire insulation to enter the terminal wire barrel.
6. Complete the crimp by closing the tool handles until the ratchet releases.
7. Release the tool handles, allow the handles to open fully, and remove the crimped terminal.
8. Refer to Section 4 and Figure 4 for terminal crimp inspection procedure.
Hold Down;
PN 2844561-1

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4. CRIMP INSPECTION
Inspect crimped terminals by checking the features described in Figure 4. Terminals, not meeting the
described conditions should NOT be used.
Figure 4
7
7
Tooling mark is normal, acceptable and no cause for rejection

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5. INSULATION CRIMP ADJUSTMENTS
The insulation crimping section of the hand tool has three positions: No.1 (tight), No.2 (medium), and No.3
(loose). To adjust the section:
1. Insert the insulation crimp adjustment pins into the No.3 position (refer to Figure 1).
2. Place the terminal into the crimping jaws as shown in Figure 3.
3. Insert the UNSTRIPPED wire into ONLY the insulation barrel (refer to Figure 3) portion of the terminal.
4. Close the tool handles to complete the crimp.
5. Removed the crimped terminal and check the insulation crimp by bending the wire back and forth
once. The terminal 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).
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
Make sure that both insulation crimp adjustment pins are in the same position.
6. MAINTENANCE AND INSPECTION PROCEDURE
TE Connectivity recommends that a maintenance and inspection program be performed periodically to ensure
dependable and uniform terminations. Though recommendations call for at least one inspection per month,
frequency of inspection depends on:
1. The care, amount of use, and handling of the hand tool.
2. The presence of abnormal amounts of dust and dirt.
3. The degree of operator skill.
4. Your own established standards.
The hand tool is inspected before being shipped; however, TE recommends that the tool be inspected
immediately upon arrival to ensure the tool has not been damaged during shipment.
6.1. Daily Maintenance
1. Hand tool should be immersed (handles partially closed) in a reliable commercial degreasing
compound to remove accumulated dirt, grease, and foreign matter. When degreasing compound is
not available, tool may be wiped clean with a soft, lint-free cloth. Do NOT use hard or abrasive objects
that could damage the tool.
2. Make certain that the retaining pins are in place and that they are secured with retaining rings.
3. All pins, pivot points, and bearing surfaces should be 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 handles closed to prevent objects from becoming lodged in the
crimping jaws. Store the tool in a clean, dry area.
6.2. Periodic Inspection
Lubrication
1. Lubricate all pins, pivot points, and bearing surfaces with SAE 20 motor oil as follows:
Tool used in daily production: lubricate daily
Tool used daily (occasional): lubricate weekly
Tool used weekly: lubricate monthly
2. Wipe excess oil from tool, particularly from crimping area.
NOTE
Oil transferred from the crimping area onto certain terminations may affect the electrical characteristics of an application.

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Visual Inspection
1. 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 Section 7, REPLACEMENT AND
REPAIR.
2. Inspect head assembly for worn, cracked, or broken jaws. If damage is evident, return the tool to TE
for evaluation and repair. See Section 7, REPLACEMENT AND REPAIR.
Crimping Die Closure Inspections
1. Each tool is inspected for proper die closure before shipment. However, die closure must be inspected
periodically due to the effects of wear. This inspection requires the use of plug gages conforming to
the dimensions shown in Figure 5.
NOTE
TE Connectivity does not manufacture or sell these gages.
a. To gage die closure, refer to Figure 6 and proceed as follows:
(1) Remove traces of oil or dirt from the crimping chamber and plug gage.
(2) Remove Hold Down.
(3) Close the tool handles until the wire barrel dies are bottomed. Do not apply additional pressure
to the tool handles.
(4) With wire barrel dies bottomed, inspect the wire barrel crimp die closure using the proper plug
gage. Press the spring-loaded locator down and hold gage in alignment with the die closure.
(5) Align the GO element with the wire barrel section of the crimping chamber. Push element
straight into the crimping chamber without using force. The GO element must pass completely
through the crimping chamber (see Figure 6).
(6) Align the NO-GO element and try to insert it straight into the same section of the crimping
chamber. The NO-GO element may start entry, but must not pass completely through the
crimping chamber (see Figure 6).
(7) Insert tool insulation crimping adjustment pin into position No.1.
(8) With crimping dies bottomed, check the insulation barrel section of the crimping chamber as
described in Steps (4) and (5).
(9) Re-install Hold Down.
If the crimping chamber conforms to the gage inspection, the tool is considered dimensionally correct, and
should be lubricated with a THIN coat of any good SAE 20 motor oil. If not, the tool must be returned to TE for
further evaluation and repair. Refer to Section 7, REPLACEMENT AND REPAIR.
For additional information regarding the use of plug gages, refer to Instruction Sheet 408—7424
Figure 5
Wire Barrel Crimp Chamber
Insulation Barrel Crimp Chamber
GO
NO-GO
GO
NO-GO
Width (W)
2.362-2.370
[.0930-.0933]
2.461-2.464
[.0969-.0970]
1.067-1.074
[.0420-.0423]
1.471-1.473
[.0579-.0580]
4.39
[.173]
Suggested Plug Gage Design for Insulation
Barrel Section of Crimping Chamber
Suggested Plug Gage Design for Wire
Barrel Section of Crimping Chamber
GO Dim.
GO Dim.
NO-GO Dim.
NO-GO Dim.
50.8 [2] Min Typ
Die Closure
Configuration
6.35 [.250] Min Typ
Die Closure
Configuration

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Figure 6
CERTI-CRIMP Hand Crimping Tool Ratchet Control Inspection
1. The CERTI-CRIMP hand crimping tool ratchet control feature on TE hand tools should be checked to
ensure that the ratchet does not release prematurely, allowing the 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:
a. Select the maximum size wire for the tool and a terminal.
b. Position the terminal and wire between the crimping dies as described in Section 3.
c. Hold wire in place and squeeze tool handles until the CERTI-CRIMP hand crimping tool ratchet
control releases. Hold the handles in this position; maintaining just enough tension to keep the dies
closed.
d. Check the clearance between the bottoming surfaces of the crimping dies with the 0.025 mm [.001
in.] shim. If the clearance is 0.025 mm [.001 in.] or less, the ratchet is considered satisfactory. If the
clearance exceeds 0.025 mm [.001 in.], the ratchet is out of adjustment and must be repaired.
NOTE: Remove Hold
Down to gage wire
barrel die.

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7. REPLACEMENT AND REPAIR
Replaceable parts are listed in Figure 7. Parts other than those listed in Figure 7 should be replaced by TE to
ensure quality and reliability of the tool. Order replacement parts through your TE Representative, or call 1-800-
526-5142, or send a facsimile of your purchase order to 1-717-986-7605, or write to:
CUSTOMER SERVICE (38-35)
Tyco Electronics Corporation
P.O. BOX 3608
HARRISBURG, PA 17105-3608
For tool repair service, please contact a TE Representative at 1-800-526-5136.
Item
No.
Description
Qty
Per Tool
Replacement
Part Number
Item
No.
Description
Qty
Per Tool
Replacement
Part Number
1
Pin, Retaining
2
300388
8
Spring
1
7-59683-6
2
Ring, Retaining
4
525108
9
Screw
2
59580-6
3
Pin, Retaining
1
300389
10
Stationary Die, Insulation
1
576788-1
4
Ring, Retaining
2
21045-6
11
Moving Die, Insulation
1
576785-1
5
Pin, Adjustment
1
1752891-1
12
Pin
1
21028-4
6
Locator, Stop
1
1901238-2
13
Hold Down
1
2844561-1
7
Pin
1
5-21028-7
14
Screw
1
18023-2
Figure 7
8. REVISION SUMMARY
Revisions to this Instruction Sheet include:
Revised RESTRICTION on top of page 1.
Added Note 7 and applicable image to Figure 4.