Tyco Electronics 46073 User manual

Instruction Sheet
408--1536
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
25 AUG 10 Rev HHand Crimping Tools 46073 and 46074
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
Anvil (Stationary)
Die
Indenter (Crimper)
Die
CERTI--CRIMP*
Tool Ratchet
Tool Part Number
Marking (Ref)
Color--Coded
Label (Ref)
1. INTRODUCTION
Hand Crimping Tools 46073 and 46074 are designed
to crimp CERTI--SEAL* moisture proof splices onto
stranded copper wire sizes 24 through
16 AWG. Read these instructions carefully before
using the tool.
Dimensions in this instruction sheet are in metric
units [with U.S. customary units in brackets].
Figures are not drawn to scale.
Reasons for reissue of this instruction sheet are
provided in Section 6, REVISION SUMMARY.
2. DESCRIPTION (Figure 1)
The hand tools are designed with two indenter
(crimper) dies, two anvil (stationary) dies, a locator,
and a CERTI--CRIMP tool ratchet. When closed, the
dies form one crimping chamber. The ratchet assures
full crimping of the splice. Once engaged, the ratchet
will not release until the tool handles have been
FULLY closed.
The dies bottom before the ratchet releases. This
design feature ensures maximum electrical and
tensile performance of the crimp. Do NOT
re--adjust the ratchet.
3. CRIMPING PROCEDURE
Each hand tool is coated with a preservative to
prevent rust or corrosion. Wipe this preservative
from the tool, particularly from the dies, before
using the tool.
1. Select the correct splice for the wire size and
wire insulation diameter being used. Observe color
coding of splice, rings, adaptors, and tools. See
Figure 2.
2. Strip the wire to dimensions listed in Figure 2.
Do NOT nick or cut the wire strands.
3. Open the dies by squeezing the tool handles
together until the ratchet releases.
4. Select the proper color--coded end of splice
(when applicable) for the wire insulation diameter
being used. See Figure 2.
5. Insert stripped wire into splice until it bottoms
against wire stop. End of conductor should be
visible through transparent window indent of splice.
NOTE
i
CAUTION
!
NOTE
i

408- 1536
Hand Crimping Tools 46073 and 46074
Rev H2 of 5 Tyco Electronics Corporation
CEnd
Ring Splice
Body
Window
Indent
Insulation Ring
DEnd
Adapter BWire Stop
Transparent
Window Indent
Adapter A
Wire Strip Length
W
I
R
E
SPLICE
W
I
R
E
SPLICE
WIRE
S
P
L
I
C
E
ADAPTER RING COLOR
W
I
R
E
STRIP
S
P
L
I
C
E
BODY
A
N
D
T
O
O
L
T
O
O
L
SIZE RANGE
(AWG)
INSUL DIA (Max)
(mm [in.])
S
P
L
I
C
E
A B C D
S
T
R
I
P
LENGTH
(mm [in.])
A
N
D
T
O
O
L
COLOR
CODE
T
O
O
L
1.65 [.065] 324987
Y
e
s
Y
e
s
Green Green
1.85 [.073] 1--324987--0
Y
es
Y
es Orange Orange 7.37 [.290]
24--20 1.85 [.073]
1
3
2
4
9
8
7
1
—Yes —Orange
[
]
Tin (White) 46073
2.54 [1.00] 1--324987--1 —Tin —
6
3
5
[
2
5
0
]
(
)
2.54 [.100] 324544
—
—Tin Tin 6.35 [.250]
2
0
1
8
2.57 [.101] 324988 Yes Yes Green Green 7.87 [.310]
R
e
d
4
6
0
7
4
20--18 3.38 [.133] 324548 — — Tin Tin 7.11 [.280] Red 46074
Figure 2
Figure 3
Locator Splice Bottomed
in Locator
Splice Window Indents
Aligned with Locator
Crimping Splice
6. Align splice window indents with tool locator,
and push splice into locator until splice bottoms.
SeeFigure3.
7. Hold wire in place and squeeze tool handles
together until the CERTI--CRIMP ratchet releases.
Allow tool handles to open FULLY. Crimped splice
may be removed.
8. To crimp other half of splice, position uncrimped
half in tool and follow same procedure used to
crimp first half of splice. If splice cannot be turned,
turn tool around.
9. Refer to Figure 4 for splice crimp inspection.
4. 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.

408- 1536
Hand Crimping Tools 46073 and 46074
3of 5Rev HTyco Electronics Corporation
The hand tool is inspected before being shipped from
the plant; however, it is recommended that the tool be
inspected immediately upon arrival to ensure that the
tool has not been damaged during shipment.
Wire ends should butt against wire stop; however,
application is acceptable if wire ends are flush with or
protrude beyond inside ends of wire barrels.
Observe crimped rings for splitting. split rings indicate
possible damaged dies or wire insulation diameter is too
large (refer to Figure 2). Conductor strands may fracture
if over--sized insulation diameter is used.
Figure 4
2
Reject
1
1
2
Crimping Inspection
Due to the precision design, it is important that
no parts of these tools be interchanged except
those replacement parts listed in Figure 7.
4.1. 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
dies. Store the tool in a clean, dry area.
4.2. 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
area. Oil transferred from the crimping area onto
certain terminations may affect the electrical
characteristics of an application.
4.3. Periodic Inspection
1. Hand tool should be immersed (handles partially
closed) in a reliable commercial degreasing
compound to remove accumulated dirt, grease,
and foreign matter.
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 5, REPLACEMENT AND
REPAIR.
3. Inspect head assembly for worn, cracked, or
broken dies. If damage is evident, see Section 5,
REPLACEMENT AND REPAIR, for information on
obtaining customer repair service.
A. Gaging the Crimping Chamber
This inspection requires the use of a plug gage
conforming to the dimensions provided in Figure 5.
Tyco Electronics does not manufacture or market
these gages. To gage the crimping chamber, proceed
as follows:
1. Remove traces of oil or dirt from the crimping
chamber and plug gage.
2. Close the tool handles until it is evident that the
dies have bottomed; then hold in this position. Do
NOT force the dies beyond initial contact.
3. Align the GO element with the wire barrel
crimping section. Push element straight into the
crimping chamber without using force. The GO
element must pass completely through the
crimping chamber. See Figure 6.
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.
SeeFigure6.
5. With dies bottomed, check insulation (ring)
crimping section using the appropriate plug gage in
same manner as Steps 3 and 4.
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, refer to Section 5,
REPLACEMENT AND REPAIR, for information on
obtaining further evaluation and repair.
For additional information regarding the use of a plug
gage, refer to instruction sheet 408--7424.
NOTE
i

408- 1536
Hand Crimping Tools 46073 and 46074
Rev H4 of 5 Tyco Electronics Corporation
NO--GO
Diameter
GO
Diameter
Su
g
g
e
s
ted
P
l
u
g
G
a
g
e
D
e
s
i
g
n
fo
r
Wire Barrel Section
50.8 mm [2.00 in.] Min Typ
Die Closure
Co
n
f
i
g
u
r
a
t
i
o
n
T
O
O
L
GAGE ELEMENT DIAMETER (mm [in.])
TOOL GO NO--GO
46073 2.464--2.471
[.0970--.0973]
2.614--2.616
[.1029--.1030]
46074 3.000--3.005
[.1180--.1183]
3.147--3.150
[.1239--.1240]
NO--GO
Diameter
GO
Diameter
Suggested Plug Gage Design for
Insulation Barrel (Ring) Section
50.8 mm [2.00 in.] Min Typ
Die Closure
Co
n
f
i
g
u
r
a
t
i
o
n
For Tool 46073
GAGE ELEMENT DIAMETER (mm [in.])
GO NO--GO
3.150--3.157 [.1240--.1243] 3.325--3.327 [.1309--.1310]
NO--GO
Diameter
GO
Diameter
Suggested Plug Gage Design for
Insulation Barrel (Ring) Section
25.4 mm [1.00 in.]
Min Typ
Die Closure
Co
n
f
i
g
u
r
a
t
i
o
n
For Tool 46074
“W” “R”
GAGE ELEMENT DIAMETER
(mm [in.]) W (Width)
Max
(
mm
R (Radius)
Max
(
mm
GO NO--GO
M
a
x
(
m
m
[in.])
M
a
x
(
m
m
[in.])
3.480--3.487
[.1370--.1373]
3.655--3.658
[.1439--.1440] 3.15 [.124] 1.57 [.062]
Figure 5
Figure 6
“GO” Element Must Pass
Completely Through
Crimping Chamber
“NO--GO” Element May
Enter Partially, But Must
Not Pass Completely
Through Crimping
Chamber
Inspection of
Wire Barrel Section
Dies Bottomed But
Not Under Pressure
Gage for
Tool 46073
Flats on Gage Parallel
to Die Movement
Inspection of Insulation
Barrel (Ring) Section
Gage for
Tool 46074
B. CERTI- CRIMP Ratchet Inspection
The CERTI--CRIMP tool ratchet on these 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
dies. Proceed as follows:
1. Refer to Figure 2, and select a splice and
maximum size wire for the tool.
2. Position the splice and wire between the dies,
as described in Section 3, CRIMPING
PROCEDURE.
3. Hold the wire in place and squeeze the handles
until the ratchet releases. Hold the handles in this
position, maintaining just enough tension to keep
the dies closed.
4. Check the clearance between the bottoming
surfaces of the dies. 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 5, REPLACEMENT AND REPAIR.

408- 1536
Hand Crimping Tools 46073 and 46074
5of 5Rev HTyco Electronics Corporation
5. 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 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
For customer repair service, please contact a Tyco
Electronics representative at 1--800--526--5136.
6. REVISION SUMMARY
Since the previous release of this instruction sheet,
the TE logo has been applied.
76.2 mm
[3.00 in.]
(Closed)
22.22 mm [.875 in.]
279.4 mm [11.00 in.]
1
26 7 54
3
REPLACEMENT PARTS
ITEM PART NUMBER DESCRIPTION QTY PER TOOL
121045--3 RING, Retaining 6
2304197--5 PIN, Retaining 2
31--23619--6 PIN, Retaining 2
439366-- COLLAR 1
539364-- SPRING 1
62--23620--9 PIN, Retaining 1
721045--6 RING, Retaining 2
Figure 7