TE Connectivity 2255140-1 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.
For latest revision and Regional Customer Service,
visit our website at www.te.com.
Instruction Sheet
408-32126
13 MAR 15 Rev A1
Figure 1
1. INTRODUCTION
This instruction sheet covers the use of TE Connectivity Hand Crimping Straight Action Hand Tools (SAHT)
2255139-1, 2255140-1, 2255141-1, and 2255142-1 with flip locators which crimp D1000 Dynamic Series
contacts listed in Figure 2.
NOTE
Dimensions are in metric units with [inches in brackets]. Figures and illustrations are for reference only and are not drawn to
scale.
Read these instructions thoroughly before crimping any contacts.
2. DESCRIPTION (Figure 1 and Figure 3)
The FRONT OF TOOL (contact side), is where the contact is inserted. The BACK OF TOOL (wire side), is
where the wire is inserted and has the wire size markings above each crimp section.
Each tool features a fixed die (crimper), a movable die (anvil), two crimp sections with applicable wire size
markings, a flip locator, a wire stop, and a ratchet release lever.
Once engaged, the ratchet will not release until the handles have been FULLY closed.
CAUTION
The ratchet ensures full crimping of the contact. This is a design feature that ensues maximum electrical and tensile
performance of the crimp. Do NOT readjust 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.
Mini Straight Action Hand Tools (SAHT)
2255139-1, 2255140-1, 2255141-1, and
2255142-1 for D1000 Dynamic Series
Contacts
Crimper
Back of Tool
Ratchet
Anvil
NOTE: 2255139-1 is
Shown, but Other SAHTs on
this Document are Similar
0000
ORIGINAL INSTRUCTIONS

408-32126
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The flip locator positions the contact in the crimping die, and the wire stop aids in locating the wire in the
contact. In use, it rests in the transition area of the connector. See Figure 1 and Figure 3.
The flip locator prevents the contact from bending during the crimping procedure.
The ratchet release lever enables the user to open the partially closed tool handles when necessary.
The ratchet is used to control the crimp height of the terminal’s wire barrel and ensures full crimping of the
terminal.
Figure 2
3. CRIMPING PROCEDURE
Refer to the table in Figure 2 and ensure compatibility between the wire, contact, and crimping tool. Wire size
must be within the specified range for the contact. Strip the wire to the length indicated.
CAUTION
Do NOT cut or nick the wire strands.
The hand crimping tool must be the one designed for crimping the wire and contact. Identify the appropriate
crimp section (according to the wire size markings on the BACK of the tool).
Refer to Figure 3 and proceed as follows:
1. Hold tool so BACK (wire side) is facing you.
2. Make sure the ratchet is released by squeezing the tool handles and allowing them to open FULLY.
3. Open flip locator. Insert contact into the flip locator (make sure contact is inserted properly).
4. Close flip locator.
5. Pre-close the handles slightly, and insert the wire into the contact.
6. Close the handles until the automatic ratchet releases.
7. Open flip locator. Take wire with contact out of locator.
Wire Strip Length 1.7 to 2.3
[.067 to .090]
WIRE SIZE
(AWG)
CONTACT
CRIMP
SECTION (WIRE
SIZE MARKING)
HAND TOOL
30
S
1827586-2
1903115-2
30
2255139-1
28
28
28-26
M
1827587-2
1871743-1
1903116-2
1903124-1
1939992-2
28-26
2255140-1
24-22 24-22
28-26
L
1827588-2
1871744-1
1903117-2
28-26
2255141-1
24-22 24-22
22-20
2L
1827589-2
1871745-1
1903118-2
1903126-1
22-20
2255142-1
18 18

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Figure 3
4. TOOL CERTIFICATION
These instructions have been approved by TE Design, Production, and Quality Control Engineers to provide
documented maintenance and inspection procedures.
Through TE test laboratories and the inspection of production assembly, the procedures described herein have
been established to ensure quality and reliability of TE hand crimping tools.
5. INSPECTION PROCEDURES
5.1. Daily Maintenance
It is recommended that each operator of the tool be made aware of, and responsible for, the following four
steps of daily maintenance:
1. Remove dust, moisture, and other contaminants with a clean brush, or a soft lint-free cloth. Do NOT
use objects that could damage the tool.
2. Make sure the proper retaining pins are in place and secured with the proper retaining rings.
3. Make certain all pins, pivot points, and bearing surfaces are protected with a THIN coat of any good
SAE No. 20 motor oil. Do NOT oil excessively.
4. When the tool is not is use, keep the handles closed to prevent objects from becoming lodged in the
crimping dies and store the tool in a clean dry area.
5.2. 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. Through
recommendations call for at least one inspection a month, the inspection frequency should be based on the
amount of use, ambient working conditions, operator training and skill, and established company standards.
These inspections should be performed in the following sequence:
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.
2. Make certain all retaining pins are in place and secured with retaining ring.
3. Close the tool handles until the ratchet releases, then allow handles to open freely. If they do not open
quickly and fully, return the tool to TE for evaluation and repair.
Flip Locator

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Inspect the head assembly with special emphasis on checking for worn, cracked, or broken die. If damage to
any part of the head assembly is evident, return the tool to TE for evaluation and repair.
Crimp Height Inspection
This inspection requires the use of a micrometer with a modified anvil as shown in Figure 4.
Proceed as follows:
Refer to the table in Figure 4 and select a contact and a wire (maximum size) for each crimp section listed
in the table.
1. Refer to Section 3, CRIMPING PROCEDURE and crimp the contact(s) accordingly.
2. Using a crimp height comparator, measure the wire barrel height as shown in Figure 4. If the crimp
height conforms to that shown in the table, the tool is considered dimensionally correct. If not, return
the tool to TE for evaluation and repair.
TE does not market crimp height comparators. Refer to Instruction Sheet 408-7424 for detailed
information on obtaining and using a crimp height comparator.
Figure 4
6. REVISION SUMMARY
Changed format.
HAND
TOOL CONTACT
CRIMP SECTION
(WIRE SIZE
MARKING)
CRIMP HEIGHT
DIMENSION “A”
2255139-1
S 1827586-2
1903115-2
30
0.54 ±0.05
[.021 ±.002]
28 0.57 ±0.05
[.022 ±.002]
2255140-1
M
1827587-2
1871743-1
1903116-2
1903124-1
1939992-2
28-26 0.64 ±0.05
[0.25 ±.002]
24-22 0.74 ±0.05
[.029 ±.002]
2255141-1
L
1827588-2
1871744-1
1903117-2
1903125-1
28-26 0.64 ±0.05
[0.25 ±.002]
24-22
0.74 ±0.05
[.029 ±.002]
2255142-1
2L
1827589-2
1871745-1
1903118-2
1903126-1
22-20 0.85 ±0.05
[.033 ±.002]
18 1.15 ±0.05
[.045 ±.002]