Tyco Electronics 2063811-1 User manual

Instruction Sheet
Hand Crimping Tool
2063811- 1 for STRATO- THERM* 408--10367
LOC B
1of 5
E2010 Tyco Electronics Corporation, Berwyn, PA
All Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other product names, logos, or company names might be trademarks 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
GTrademark of E.I. Du Pont de Nemours & Co.
11 JUN 10 Rev APre- Insulated Spare Wire Caps
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
Color Coded to Indicate Wire
Insulation Diameter Range of Cap
Unstripped Wire
Color Code of
Crimping Dies
Crimping Die
Color Codes
“A”
Ring
“B”
Ring
Spare
Wire Cap
Orange
Green
White
1. INTRODUCTION
This instruction sheet covers the application,
maintenance, and inspection of Hand Crimping Tool
2063811--1, which is used to apply STRATO--THERM
pre--insulated spare wire caps on unstripped
TEFLONGinsulated wire having an insulation
diameter range of 0.91 -- 3.50 mm [.036 --.138 in.].
Read this sheet thoroughly before proceeding. Refer
to Catalog 82011 for product part numbers, wire
insulation diameter, and proper color codes.
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 7,
REVISION SUMMARY.
2. DESCRIPTION
The tool features three crimping areas, tool handles,
and a CERTI--CRIMP* Hand Crimping Tool Ratchet
Control. Tool dies and spare wire cap rings are color
coded for a given wire insulation diameter range.
Crimp the color coded ring (“B”) in the matching color
coded dies. See Figures 1 and 2. Example: If
insulation diameter of wire is within a range of 1.422
to 1.63 mm [.056 --.064 in.], use ring “A.”
3. CRIMPING PROCEDURE
To apply the wire cap, proceed as follows:
1. Open crimping dies by closing handles until
CERTI--CRIMP ratchet releases. Note that, once
ratchet is engaged, handles cannot be opened until
they are first fully closed.
2. Place cap in matching color coded dies (ring “B”
on cap must match die color code). Be sure cap is
fully bottomed in tool and rings are centered in
crimping dies. See Figure 3.
Figure 2
Cap Bottomed
and Rings
Centered in
Dies
Ring “B”
Matches
Color
Code of
Dies
Unstripped
Wire
3. Close handles until cap is firmly in place. Do
NOT deform cap.
4. Insert UNSTRIPPED wire all the way into cap.
5. To complete crimp, close handles until
CERTI--CRIMP ratchet releases. Open the handles
and remove the crimped cap.
6. Refer to Section 4 and Figure 3 for spare wire
cap crimp inspection procedure.
7. “REJECT” spare wire caps can be avoided
through careful use of instructions in Section 2,
and by performing regular tool maintenance as
instructed in Section 5.
4. CRIMP INSPECTION
1. Inspect crimped spare wire caps by checking
the features described in Figure 3.
NOTE
i

408- 10367
STRATO- THERM Wire Cap Crimping Tool 2063811- 1
Rev A2 of 5 Tyco Electronics Corporation
2. Use only the spare wire caps that meet the
conditions shown in “ACCEPT” column.
3. “REJECT” spare wire caps can be avoided
through careful use of instructions in Section 3,
and by performing regular tool maintenance as
instructed in Section 5.
5. MAINTENANCE AND INSPECTION PROCEDURE
Tyco Electronics recommends that a
maintenance/inspection program be performed
periodically to ensure dependable and uniform
terminations. The tool should be inspected at least
once per month. Frequency of inspections depends
on:
SThe care, amount of use, and handling of the
tool.
SThe type and size of products crimped.
SThe degree of operator skill.
SThe presence of abnormal amounts of dust and
dirt.
SYour own established standards.
The hand tool is inspected before being shipped;
however, Tyco Electronics recommends that the tool
be inspected immediately upon arrival to ensure that
the tool has not been damaged during shipment.
5.1. 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. 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.
Accept
1
2
3
4Ring “B”
Ring “A”
5
12
3
4Ring “B”
Ring “A”
Reject
1.Wire fully bottomed in cap. 1. Wire not fully bottomed in cap.
2. Full length of both rings crimped (cap was bottomed in tool and
rings centered in dies).
2. Full length of rings not crimped (Cap was not fully bottomed in
tool; see Figure 2).
3. Ring “B” color code matches color code of dies. 3. Ring “B” color code did not match color code of dies.
4. Wire insulation diameter is within range of color coded (Ring
“A”) cap. See Figure 1.
4. Wire insulation diameter is not within range of color coded
(Ring “A”) cap. See Figure 1.
5. Excessive flash or cracked ring. Wire insulation diameter too
large (see Figure 1) or damaged dies.
Figure 3

408- 10367
STRATO- THERM Wire Cap Crimping Tool 2063811- 1
3of 5Rev ATyco Electronics Corporation
Figure 4
Broken Edge
or Corner
Pitted
Area
4. 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.
5.2. Periodic Inspection
A. Lubrication
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
Wipe excess oil from tool, particularly from crimping
jaws. Oil transferred from the crimping area onto
certain terminations may affect the electrical
characteristics of an application.
B. Visual Inspection
1. Inspect the tool for missing parts or retaining
rings. If parts are missing or defective, see Section
6, REPLACEMENT AND REPAIR.
2. Inspect head assembly for worn, cracked, or
broken jaws. See Figure 4. If damage is evident,
return the tool to Tyco Electronics for evaluation
and repair. See Section 6, REPLACEMENT AND
REPAIR.
C. Gaging the Crimping Chamber
Each tool is inspected for proper die closure before
packaging. An inspection should be performed
periodically to check the die closure for excessive
wear.
The die closure inspection is accomplished using plug
gages. Tyco Electronics neither manufactures nor
sells plug gages. Suggested designs and dimensions
for the plug gage elements are listed in Figure 5. The
following procedure is recommended for inspecting
the three die closures.
1. Clean oil or dirt from the die closure and plug
gage elements.
2. Close handles of tool until crimping dies are
bottomed. Do not apply additional pressure to tool
handles.
Suggested Plug Gage Design
R2
NO--GO Dim. “A”
GO Dim. “A”
R1
Die Closure
Crimp Configuration
25.4 mm
[1.0 in.]
DIE COLOR GAGE ELEMENT DIM’S. “A”
R
1
R
2
D
I
E
C
O
L
O
R
CODE GO NO--GO
R
1
R
2
Green 3.124 -- 3.132
[.1230 --1233]
3.274 -- 3.277
[.1289--.1290] 1.30 [.051] 1.47 [.051]
Orange 3.404 --3.411
[.1340--[.1343
3.553 -- 3.556
[.1399--.1400] 1.57 [.062] 1.57 [.062]
White 4.445 -- 4.452
[.1750--.1753]
4.595 -- 4.597
[.1809--.1810] 2.03 [.080] 2.03 [.080]
Figure 5

408- 10367
STRATO- THERM Wire Cap Crimping Tool 2063811- 1
Rev A4 of 5 Tyco Electronics Corporation
Figure 6
“GO” element must pass
completely through the
die closure.
“NO--GO” element may
enter partially, but must not
pass completely through the
die closure.
Inspection of Die Closures with Plug Gage
Dies are
Bottomed
But Not
Under
Pressure
Flats on Gage
Parallel to
Length
of Tool
3. With crimping dies bottomed, check the selected
die closure using the proper plug gage. Hold gage
in straight alignment with the die closure and
carefully try to insert, without forcing, the GO
element. See Figure 6. The GO element must pass
completely through the die closure. See Figure 6.
4. Try to insert the NO--GO element. The NO--GO
element may enter partially, but must not pass
completely through the die closure. See Figure 6.
5. If all three closures meet the plug gage
conditions, The die closures may be considered
dimensionally correct. If you find that the die
closures do not conform to the gage conditions,
contact your local Tyco Electronics Representative.
D. CERTI- CRIMP Ratchet Inspection
Check the CERTI--CRIMP Hand Crimping Tool
Ratchet Control to ensure that ratchet does not
release prematurely, allowing 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 dies. To check
the ratchet feature:
1. Thoroughly clean bottoming surfaces of dies.
2. Position the terminal and wire between the
crimping jaws, as described in Section 3,
CRIMPING PROCEDURE.
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
force to keep the jaws closed.
4. Check the clearance between the bottoming
surfaces of the crimping jaws. If the clearance is
0.025 mm [.001 in.] or less, the ratchet is
satisfactory. If clearance exceeds 0.025 mm
[.001 in.], the ratchet is out of adjustment and
must be repaired. See Section 6, REPLACEMENT
AND REPAIR.
6. REPLACEMENT AND REPAIR
The parts listed in Figure 7 are customer--
replaceable. A complete inventory can be stocked
and controlled to prevent lost time when replacement
of parts is necessary. Parts other than those listed in
Figure 7 must 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, or send a
facsimile of your purchase order to 717--986--7605, or
write to:
CUSTOMER SERVICE (038--035)
TYCO ELECTRONICS CORPORATION
P.O. BOX 3608
HARRISBURG, PA 17105--3608
7. REVISION SUMMARY
SInitial release of document

408- 10367
STRATO- THERM Wire Cap Crimping Tool 2063811- 1
5of 5Rev ATyco Electronics Corporation
REPLACEABLE PARTS
ITEM PART NUMBER DESCRIPTION QTY PER TOOL
121045--3 RING, Retaining 4
Figure 7