TE Connectivity MR-1 User manual

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TOOLING ASSISTANCE CENTER 1-800-722-1111
PRODUCT INFORMATION 1-800-522-6752
This controlled document is subject to change.
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visit our website at www.te.com.
Instruction Sheet
408-7306
24 NOV 14 Rev C
Figure 1
1. INTRODUCTION
Model MR-1 Hand Crimping Tool 251101-1 is designed to crimp PICABOND Connectors in through, tapping,
and bridging operations. The tool can be hand-held or it can be used in Tool Holder 251852-1 with or without
the Frame Adapter 229175-1. Read the instructions packaged with these accessories.
NOTE
All dimensions on this document are in metric units [with U.S. customary units in brackets]. Figures and illustrations are for
reference only and are not drawn to scale.
Reasons for reissue of this sheet are provided in Section 11, REVISION SUMMARY.
2. DESCRIPTION (Figure 1)
The tool features two wire supports, a set of dies (anvils and crimpers), a wire cutter, and a handle assembly.
In use, the wire supports hold and position the wires in the crimpers. As the tool is cycled, the wire cutter cuts
off excess wire, then the crimping dies crimp the connector to the wires. Continuous pressure applied to the
moving handle forces the link to snap the tool handles closed, thus completing the crimp cycle. After the cycle
is completed, depress the release lever to open the handles and remove the crimped connector.
3. CONNECTOR SELECTION
Determine the wire gage and combination of conductors to be joined. Then refer to Figure 2 for the correct
connector. Note the PICABOND connectors can be used for 28 through 19 AWG copper conductors that are
insulated with plastic, paper, or pulp materials.
WIRE RANGE (AWG)
CONNECTOR DESCRIPTION
NUMBER
COLOR
28-24
61899-1▪
Orange
26-22
60945-4▪
Green
61226-2▪
Purple
24-19
60947-3†
Red
61292-2†
Yellow
▪Use any 1 or 2 wire combination. †Only one (1) 19 AWG can be used per connector end. This can be in combination with any other wire size up to 24 AWG.
Figure 2
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.
Model MR-1 Hand Crimping
Tool 251101-1 for PICABOND*
Connectors
Release Lever
Moving Handle
WD-40 is a Trademark.
Lubrication Points
■WD-40
Grease
■
Link
Color Code
Label
Wire Notch
Wire Cutter
Splitter Pin
Anvil
Fixed Handle
Support Tool Here to
Keep it from Moving
During Crimp Cycle

Wire Support
■
Crimpers
ORIGINAL INSTRUCTIONS

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4. PREPARING CABLE
Open and prepare the cable in the usual manner. There is no special procedure required when using the Model
MR-1 tool.
5. WIRE PLACEMENT
NOTE
The essential difference of the various connections is the placement of the wires in the wire supports.
Determine the type of connection to be made, then refer to the applicable Paragraph (5.1, 5.2, or 5.3) and
insert the wire accordingly.
5.1. Through Connections (See Figure 3)
NOTE
Always start with the cable units to the REAR of the cable opening.
1. Take a pair of conductors from one side of the cable opening. Separate them far enough that one wire
can be inserted into the wire support.
2. Holding the tool in one hand, lace the wire into the wire support and out between the crimpers. Make
sure the wire has sufficient slack, then bottom it in the wire support.
3. Repeat Steps 1 and 2 using a pair of conductors from the other side of the cable opening. Be sure to
match tip to tip and ring to ring.
4. Insert a connector and crimp it according to Section 6, CRIMPING PROCEDURES. Join the other
conductors of the same pair in the same manner.
Figure 3
5.2. Tap Connections (See Figure 4)
The following method is accomplished without cutting and interrupting service of a through conductor. It is
especially helpful when tapping into taut wires.
1. Lace tap wire into wire support below the pin.
2. Take a pair of through conductors from the cable unit and separate them enough to insert individual
wires into the tool.
3. Place one wire into a connector and then insert the connector into the tool as shown in Figure 4. Make
sure the wire cutter enters the slots in the center of the connector and that the notch in the wire cutter
does NOT interfere with the connector.
4. Position the through wire in the notch of the wire cutter, then lace it into the wire supports above the
pin.
5. Crimp the connector according to Section 6, CRIMPING PROCEDURES.
Center Slot
Wire Support
Through Splice
Anvil
Pin
Connector
Wire Cutter
Through
Wire
Crimper
Top of Tool
Through
Wire

408-7306
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Figure 4
5.3. Bridging Connectors (See Figure 5)
1. Take a pair of through conductors from one side of the cable opening and separate them enough to
insert individual wires into the tool.
2. Lace the bridge wire(s) into the wire support(s) below the pin(s).
3. Lace the through wires into the wire support above the pin. Make sure you use matching wires - tip to
tip and ring to ring.
4. Insert a connector into the tool as shown in Figure 5. Make sure the wire cutter enters the slots in the
center of the connector.
NOTE
When butt splicing, insert one wire above the pin and one wire below the pin on the same side of the tool.
Figure 5
6. CRIMPING PROCEDURES
CAUTION
The tool must be held steady during the crimping procedure. If it moves before the crimp is completed, the wires may pull out
of the connector. See Figure 1.
After placing the wire(s) and connector in the tool in accordance with Section 5, WIRE PLACEMENT, proceed
as follows:
1. Make sure there is sufficient slack in the wires, otherwise, they could pull out of the connector during
the crimp cycle.
2. Place the tool in one hand so that you are supporting the center portion of the fixed handle as
indicated in Figure 1.
3. Crimp the connector by squeezing the tool handles until they snap over center.
4. Open the tool handles by depressing the release lever, and then remove the crimped connector.
Double Half-Tap
Connector
Wire Support
Through
Wire
Crimper
Top of Tool
Single Half-Tap
Wire Cutter
Pin
Notch
Tap Wire
Anvil
Center Slot
Single Bridge
Double Bridge
Butt Splice
Center Slot
Top of Tool
Crimper
Wire Support
Connector
Through Wire
Wire Cutter
Through Wire
Bridge Wire
Pin
Anvil

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7. SPLICE BUILD-UP
During the splicing, you should arrange groups of finished connections along the splice opening in order to
build a uniform, compact splice. To do this, move the tool along the splice opening about 31.75 mm [1.25 in.]
after crimping every 25 to 50 pairs. Alternate the direction in which you move the tool, first to one side of center,
then to the other.
8. INSPECTIONS
Make the following inspections on the first and last connection made during a shift. If you find any improperly
crimped or defective connections, return the tool to your supervisor, unless otherwise instructed. In addition,
replace any defective connections.
8.1. Gaging Crimped Connectors
Use the crimp gage within a short time of crimping the connection, and check the connector as follows:
1. Select the proper gage end. The color dots on the end of the gage must match the color of the
connector you are gaging. See Figure 6.
2. Place the connector in the gage so the seam in the connector aligns with the double rib on the gage.
Position the connector so it is flush with the side of the gage. See Figure 6.
Figure 6
3. Hold the free end of the connector and slide the gage off using only very slight force. The gage must
slide off easily. If it does, repeat the test for the other end of the connector.
4. If either end of the connector sticks in the gage, the connection is improperly crimped. Make a few
sample crimps and gage them. If they gage properly, continue using the tool. If they do not gage
properly, return the tool for repair. In either case, go back and re-crimp any improperly crimped
connections.
Figure 7
8.2. Visual Inspection (See Figure 7)
1. Check for wire protruding from the center of the connector. If you find any, replace the connection. If
this problem occurs frequently, return the tool for adjustment.
Green or
Purple Dot
Orange Dot
Wire Size
Boss
Double Rib
Gage
Red or
Yellow Dot
Double Rib
Seam
End of Connector Flush
with Side of Gage
Boss
Two Wires on Same
Side of Seam
Protruding Wire
Cut and Score Marks
Improper Connector
Placement

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2. Make certain there are no wires missing from the connector. If there is, the tool probably moved during
crimping and the connector must be replaced.
3. Check for a metal leg protruding from the center of the connector. This is caused by improper location
of the connector in the tool. If you find any, replace the connections. Be especially careful to insert the
connector in the tool so that the slot in the connector engages the wire cutter, and that the notch in the
wire cutter does NOT interfere with the connector. See Figures 3, 4, and 5.
4. If you are tapping or bridging, make sure the end of the connector with two conductors contains one
conductor on each side of the seam.
If both conductors are on the same side, replace the connection. Be very careful to place the
conductors in the wire support correctly. If the condition persists, return the tool to your supervisor.
5. Check the plastic wire support brackets. If they are damaged, or if the pins in the supports are bent or
have a rough surface, replace the supports. Use Repair Kit 229188-1 and follow the instructions in the
kit.
9. MAINTENANCE AND CLEANING
TE Connectivity recommends Cleaning Kit 229333-1 for cleaning this tool. This kit consists of: (1) a bristle
brush for general purpose cleaning, (2) a tube cleaner for cleaning the crimping dies, (3) a tube brush for
cleaning inside the tool, (4) an extractor for removing scrap wire and plastic particles from inside the crimping
dies, and (5) extractor case. If you do not have this kit, it can be purchased from TE.
NOTE
A lubricant, WD-40, which can be purchased locally, is recommended for loosening dirt and lubricating the tooling.
NOTE
A spray solvent/cleaner, which can be purchased from Orb Industries, Upland, PA (215-874-2537), under part number 590, is
recommended for removing accumulated film.
Remove all loose dirt with a clean bristle brush. Then liberally spray the tool with solvent/cleaner and allow it to
dry. Remove any particles that you have loosened. Lubricate the tool with WD-40 lubricant and all-purpose
grease. See Figure 1 for lubrication points.
As the operator of the tool, you should: (1) clean and lubricate the tool regularly, (2) inspect the crimped
connectors, and (3) use the tool in accordance with these instructions. If you find a defect in the tool's
operation, return it to your supervisor.
10. ORDERING INFORMATION AND REPAIR
Order additional tools 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 (038-035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
Tools may be returned to TE for evaluation and repair. For tool repair service, please contact a TE
Representative at: 1-800-526-5136.
In Canada, send the tool to:
TE CONNECTIVITY OF CANADA (BLDG. 1)
20 ESNA PARK DRIVE
MARKHAM, ONTARIO
CANADA, L3R 1E1
ATTENTION: PICABOND TOOL REPAIR
11. REVISION SUMMARY
Updated document to corporate requirements
New logo

Mouser Electronics
Authorized Distributor
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