Tyco Electronics 1804834-1 User manual

Instruction Sheet
Hand Crimping Tool 1804834- 1 and
Crimping Head 1- 1804834- 1 for Raychem 408--10048
LOC B
1of 5
E2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
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.tycoelectronics.com
09 DEC 09 Rev BMiniSeal* Splices
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.
Figure 1
20--26
16--20
12--16
CERTI--CRIMP*
Hand Tool Ratchet
Nest Jaw
Anvil Jaw
Handle(s)
Contact Locator
(On Back of Tool)
1. INTRODUCTION
Double Action Hand Tool (DAHT) 1804834--1 and
Crimping Head 1--1804834--1 (shown in Figure 1) are
used to crimp Raychem MiniSeal Splices listed in
Figure 2 onto stranded wire sizes 26--12 AWG.
Read these instructions thoroughly before using the
tool.
Dimensions in this instruction sheet are in
millimeters [with inch equivalents in brackets].
Figures and illustrations are for reference only
and are not drawn to scale.
Reasons for reissue of this instruction sheet are
provided in Section 7, REVISION SUMMARY.
2. DESCRIPTION
The tool consists of a ratchet, two crimping jaws
(indenter and anvil) containing three crimping
chambers, and a terminal locator. The tool is marked
with the wire size range for each crimping chamber.
SeeFigure1.Fullcrimpingofthespliceisassuredby
the ratchet. Once engaged, the ratchet does not
release until the tool handles have been FULLY
closed.
The crimping jaws bottom before the ratchet
releases. This feature ensures maximum
electrical and tensile performance of the crimp.
Do NOT re--adjust the ratchet.
MiniSeal Splice
Note: Not to Scale
T
E
H
a
n
d
Wire
TE Hand
Tool/
Crimping
Head
Raychem
Splice
No.D
Splice
Color
Code
Crimping
Chamber
Marked
Wire
Size
Range
(AWG)
Wire
Strip
Length
D--436--36 Red 20--26 20--26 7.9--8.6
[.31--.34]
1804834--1
1--1804834--1 D--436--37 Blue 16--20 16--20 7.9--8.6
[.31--.34]
8
0
8
3
D--436--38 Yellow 12--16 12--16 7.9--8.6
[.31--.34]
DQualified to MIL--S--81824/1
Figure 2
3. CRIMPING PROCEDURE
Strip the wire according to the dimensions listed in
Figure 2. The strip length is determined by the splice
and by the wire size. Do not nick or cut the wire
strands. Proceed as follows:
1. Close the tool handles until the ratchet releases.
Allow the tool handles to open fully.
2. Place the splice against the locator in the
appropriate crimp chamber. See Figure 3.
3. While holding the splice in place, squeeze the
tool handles together just until the jaws begin to
close on the wire barrel. Do NOT deform the wire
barrel.
4. Insert the stripped wire into the wire barrel,
making sure that the wire insulation does not enter
the wire barrel.
5. While holding the wire in place, squeeze the tool
handles together until the ratchet releases, then
allow the tool handles to open fully.
NOTE
i
CAUTION
!

408- 10048
Hand Crimping Tool 1804834- 1 and Crimping Head 1- 1804834- 1
Rev B2 of 5 Tyco Electronics Corporation
Figure 3
Splice Placed
Against Locator in
Crimping Chamber
S
t
e
p
1
Step 2
Upper Jaw
Upper Jaw
Lower Jaw
Lower Ja
w
Wire Being
Crimped
Wire Being
Crimped
1st Wire
1st Wire
Locator
Locator
Splice
If the wire is stripped correctly (Figure 2), the
conductor will be exposed slightly more than the
thickness of the locator. This will allow the
conductor to enter the slot in the locator
6. To crimp the other half of a butt splice, position
the crimped wire barrel against the locator. The
crimped wire will go through the slot in the locator.
The uncrimped barrel will line up with the crimping
chamber. Repeat the crimping procedure.
If the splice cannot be turned for crimping other
half, turn the tool around.
4. CRIMP INSPECTION
Inspect crimped terminals and splices by checking the
features described in Figure 4. Poor crimps can be
avoided by carefully following the procedures
provided in Section 3, and by following the tool
maintenance procedures provided in Section 5.
5. MAINTENANCE AND INSPECTION
Tyco Electronics recommends that a maintenance
and inspection program be performed periodically to
ensure dependable and uniform terminations.
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 tool is inspected before being shipped; however,
Tyco Electronics recommends that the tool be
inspected immediately upon arrival at your facility to
ensure that the tool has not been damaged during
shipment.
5.1. 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 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.
5.2. Lubrication
Lubricate all pins, pivot points, and bearing surfaces
with SAE 20 motor oil as follows:
Tools used in daily production—lubricate daily
Tools used daily (occasional)—lubricate weekly
Tools used weekly—lubricate monthly
5.3. Periodic Inspection
1. The tool should be immersed (handles partially
closed) in a reliable commercial degreasing
compound to remove accumulated dirt, grease,
and foreign matter.
NOTE
i

408- 10048
Hand Crimping Tool 1804834- 1 and Crimping Head 1- 1804834- 1
3of 5Rev BTyco Electronics Corporation
Wire Range
Stamped Here
Crimps centered. Crimps may be off center BUT NOT
OFF END OF WIRE BARREL.
Wire size matches wire color range on splice and
tool.
Wire insulation does not enter wire barrel.
Wire is visible through inspection hole of butt splices.
Wire is flush with or extends slightly beyond end of wire
barrel.
On parallel splices, bare wire ends must be flush
with or extended slightly beyond end of wire barrel.
Crimped off end of splice or terminal wire barrel.
Wire size does not match wire size or color range on
splice or tool.
Wire insulation entered wire barrel of terminal or
splice. CHECK FOR INCORRECT STRIP LENGTH.
Wire not inserted far enough in terminal or splice. End
of wire must be visible through inspection hole of butt
splices, and be flush with or extend slightly beyond end
of wire barrel.
Excessive “flash” on terminal or splice indicates damaged
jaws or wrong wire, splice, or tooling combination was
used.
Nicked or missing strands.
MiniSeal Splice
Figure 4
3
1
3
4
2
1
2
3
4
5
1
2
3
4
5
6
41
3
5
2
ACCEPT REJECT
2. 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 6, REPLACEMENT AND
REPAIR.
Figure 5
Pitted
Chipped
Edge
Flattened Area
Broken Corner
3. Inspect head assembly for worn, cracked, or
broken jaws. Refer to Figure 5. If damage is
evident, return the tool to Tyco Electronics for
evaluation and repair. See Section 6,
REPLACEMENT AND REPAIR.
5.4. Gaging the Crimping Chambers
This inspection requires the use of a plug gage
conforming to the dimensions provided in Figure 6.
Tyco Electronics does not manufacture or market
these gages. To gage the crimping chambers,
proceed as follows:
1. Remove traces of oil or dirt from the crimping
chambers and plug gage.
2. Close the tool handles until it is evident that the
jaws have bottomed; then hold in this position. Do
NOT force the jaws beyond initial contact.
3. Align the GO element with the crimping
chamber. Push element straight into the crimping
chamber without using force. The GO element
must pass completely through the crimping
chamber.

408- 10048
Hand Crimping Tool 1804834- 1 and Crimping Head 1- 1804834- 1
Rev B4 of 5 Tyco Electronics Corporation
Crimping
Chamber
GO
Element
NO--GO
Element
“GO” element must pass
completely through
crimping chamber.
“NO--GO” element may enter
partially, but must not pass
completely through the
crimping chamber.
DAHT 1804834--1 For Raychem MiniSeal Splices
Tool Die Closure “A” Gage Elements “B”
T
o
o
l
Cavity GO NO--GO GO NO--GO
20--26 0.64
[.025]
0.81
[.032]
0.635--0.643
[.0250--.0253]
0.836--0.838
[.0329--.0330]
16--20 1.07
[.042]
1.24
[.049]
1.067--1.074
[.0420--.0423]
1.267--1.27
[.0499--.0500]
12--16 1.57
[.062]
1.75
[.069]
1.575--1.582
[.0620--.0623]
1.775--1.778
[.0699--.0700]
Figure 6
NO--GO Dim.
“A” Dim.
GO Dim. Die Closure Configuration
“B”
Dia.
50.8 [2.00]
Min. Typ.
“B”
Dia.
4. Align the NO--GO element and try to insert it
straight into the same crimping chamber. The
NO--GO element may start entry, but must not
pass completely through the crimping chamber.
If the crimping chambers 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 for further evaluation and repair. Refer to
Section 6, REPLACEMENT AND REPAIR.
5.5. CERTI- CRIMP Ratchet Inspection
The CERTI--CRIMP ratchet should be checked to
ensure that the ratchet does not release prematurely,
allowing the jaws to open before they have fully
bottomed. Obtain a 0.025 [.001] shim suitable for
checking the clearance between the bottoming
surfaces of the crimping jaws. Proceed as follows:
1. Select a terminal or splice, and properly stripped
wire with maximum wire load (such as wire size 16
AWG and size 22--16 terminal).
2. Position the terminal or splice and wire between
the crimping jaws, as described in Section 3.
3. Hold the wire in place and squeeze the handles
until the CERTI--CRIMP ratchet releases. Hold the
handles in this position, maintaining just enough
tension to keep the jaws closed.
4. Check the clearance between the bottoming
surfaces of the crimping jaws. If the clearance is
0.025 [.001] or less, the ratchet is satisfactory. If
clearance exceeds 0.025 [.001], the ratchet is out
of adjustment and must be repaired. See Section
6, REPLACEMENT AND REPAIR.
6. REPLACEMENT AND REPAIR
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 necessary. Parts other than those listed
should be replaced by Tyco Electronics to ensure
quality and reliability. Order replacement parts
through your Tyco Electronics Representative, or call
1--800--526--5142, or send a facsimile of your
purchase order to 717--986--7605, or write to:
CUSTOMER SERVICE (038--035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105--3608
Tools may also be returned to Tyco Electronics for
evaluation and repair. For customer repair service,
please contact a Tyco Electronics Representative at
1--800--526--5136.
7. REVISION SUMMARY
Since the previous release, the following change was
made:
SChanged the strip length in Figure 3

408- 10048
Hand Crimping Tool 1804834- 1 and Crimping Head 1- 1804834- 1
5of 5Rev BTyco Electronics Corporation
76 [3] (Closed)
279 [11]
1
12
5
1
21
35 4
Replacement Parts
Item TE Part Number Description Qty Per Tool
121045--3 RING, Retaining 4
21--23619--6 PIN, Straight, Grooved 2
339364 SPRING 1
42--23620--9 PIN, Straight, Grooved 1
521045--6 RING, Retaining 2
Figure 7