Tyco Electronics 46121 User manual

Instruction Sheet
408-1559
LOC B
1 of 10
E 2007 Tyco Electronics Corporation, Harrisburg, A
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
RODUCT 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
19 JUN 07 Rev
Hand Crimpin Tools
PROPER USE GUIDELINES
CumulativeTraumaDisorderscanresultfromthe prolongeduseofmanually poweredhandtools.Hand toolsareintendedfor occasionaluseandlowvolume
applications. A wide selection of powered application equipment for extended-use, production operations is available.
Figure 1
HAND CRIMPING TOOL PART NUMBERS
46121
47304
47386
47386-5
47387
47907-1
48518-2
69151-1
69454
169485
Wire Size Range
Stamped Here
Insulation Crimp Adjustment
ins in No. 3 osition
Color Code for
Sealed Splices
Color Code for IDG* and
LASTI-GRI * roducts
CERTI-CRIM * Hand
Crimping Tool Ratchet
Control
1. INTRODUCTION
This instruction sheet covers the Hand Crimping Tools
listed in Figure 1, which are used to crimp the
terminal types listed in Figure 2.
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 9,
REVISION SUMMARY.
2. DESCRIPTION (Figure 1)
The handles and label (if applicable) of the crimping
tools are color–coded to match the color coding of the
connectors to be applied, as listed in Figure 3. The
crimping tools may show more than one color code.
Check Figure 3 to be sure that the correct tool/
connector combination is being used.
For example, tool 47386 can be used to apply PIDG
terminals and splices with a yellow color code, as well
as spare wire caps with a red color code.
Figure 3 lists the number of dots (or rib) that appear
embossed on a crimped item when the connector is
crimped in the correct tooling.
The CERTI–CRIMP hand crimping tool ratchet control
ensures full crimping of terminals and splices. Once
engaged, the ratchet will not release until the tool
handles have been FULLY closed.
NOTE
i

408-1559
Hand Crimping Tools
Rev P2 of 10 Tyco Electronics Corpor tion
CONNECTOR
TYPE WIRE TYPE WIRE SIZE AWG]
PIDG Termin ls nd
Splices Solid or Str nded Copper 30-14
PIDG Insul tion
Restricting Nylon TermiĆ
n ls Str nded Copper 26-14
PIDG R di tion
Resist nt Termin ls
nd Splices Str nded Copper 27-14
PIDG FASTON*
Recept cles,
P rt Nos 641321-1
(.187 Series) nd
641324-1 (.110 Series)
Str nded Copper 26-24
PLASTI-GRIP
Termin ls Solid or Str nded Copper 22-14
PLASTI-GRIP
Butt Splices Solid or Str nded Copper 26-22
Sp re Wire C ps Str nded Copper 22-14
Figure 2
The crimping areas bottom before the crimping
tool ratchet releases. This is a design feature that
assures maximum tensile performance of the
crimp. Do NOT re-adjust the ratchet.
3. CRIMPING PROCEDURE
Refer to Section 5 for information on the
insulation crimp adjustment.
3.1. For PIDG and PLASTI-GRIP Terminals and Splices
1. Strip the wire to the dimension provided in
Figure 3, being careful to avoid nicking or
damaging the conductor(s).
Do NOT use ire ith nicked or missing
conductors.
2. Open the tool jaws by closing the tool handles
until the ratchet releases, then allow the handles to
open fully.
3. Place the terminal or splice in the dies as shown
in Figure 4 or Figure 5.
4. Close the tool handles until the terminal or splice
is held firmly in place. Do NOT deform the terminal
or splice wire barrel.
5. Insert properly stripped wire(s) into the terminal
or splice, as shown in Figure 4 or Figure 5.
Do NOT allo ire insulation to enter the
terminal or splice ire barrel.
6. Complete the crimp by closing the tool handles
until the ratchet releases.
7. Release the tool handles, allow the handles to
open fully, and remove the crimped terminal or
splice.
8. To crimp the other half of a splice, re–position
the uncrimped half of the splice in the tool as
shown in Figure 5. Follow the procedure used to
crimp the first splice half.
9. Refer to Section 4 and Figure 7 for terminal and
splice crimp inspection procedure.
3.2. For Spare Wire Caps
1. Strip the wire to the dimensions provided in
Figure 3.
Do NOT use ire ith nicked or missing
conductors.
Make sure that the color coding on the spare ire
cap and the tool match.
2. Place the crimping tool’s insulation adjustment
pins in the No. 3 position.
3. Close the tool handles until the crimping jaws
partially close, but leave enough space for the cap
to be inserted between the dies.
4. Raise the locator so that the end of the cap
rests against the recessed surface of the locator,
as shown in Figure 6.
5. Close the tool handles until the cap is held firmly
in place. Do NOT deform the cap wire barrel.
6. Insert the properly stripped wire into the cap
until the wire bottoms.
7. Hold the wire in position and complete the crimp
by closing the tool handles until the ratchet
releases.
8. Release the tool handles, allow the handles to
open fully, and remove the crimped spare wire cap.
9. Refer to Section 4 and Figure 7 for spare wire
cap crimp inspection procedure.
CAUTION
!
NOTE
i
CAUTION
!
CAUTION
!
CAUTION
!
NOTE
i

408-1559
H nd Crimping Tools
3 1, +8 P
"9)1 /+)6410.)5 14214(6.10
TOOL NUMBER
AND
DESCRIPTION
WIRE
RANGE
(AWG)
TOOL
COLOR
AND DOT
CODE
PRODUCT PRODUCT
INSULATION COLOR
CODE
WIRE STRIP LENGTH
TERMINALS SPLICES
MIN. MAX. MIN. MAX.
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PLASTI-GRIP
Terminal Spare Wire Cap
PIDG Butt Splice
PLASTI-GRIP
Butt Splice
PIDG Type
Terminals
FASTON
Receptacle
 37(//9 !2()+* 1/14
!64.2+5 10 057/(6.10
+564.)6.0-
1/14 !64.2+ 10
(*.(6.10 +5.56(06
Figure 3 (cont’d)
1/14 !64.2+ 10
(*.(6.10 +5.56(06

408-1559
Hand Crimping Tools
Rev P4 of 10 Tyco Electronics Corporation
TOOL NUMBER
AND
DESCRIPTION
WIRE
RANGE
(AWG)
TOOL
COLOR
AND DOT
CODE
PRODUCT PRODUCT
INSULATION COLOR
CODE
WIRE STRIP
LENGTH
46121
169485
47304 D
26
MIN. MAX.
4.8
[3/16] 5.6 [7/32]
INSUL
DIA.
RANGE
mm [in.
0.66-1.40
[.026-.055]
RED
AND
YELL W
NE D T
PIDG
INSULATI N
RESTRICTING
NYL N
TERMINALS
YELL W W/3
BLACK STRIPES
YELL W W/3
BLUE STRIPES
24 0.79-1.40
[.031-.055]
26 0.66-1.40
[.026-.055]
24 0.79-1.40
[.031-.055]
PIDG INSULATI N
RESTRICTING
NYL N TERMINALS
MS 7928/1-1
THRU -10
YELL W W/3
BLACK STRIPES
YELL W W/3
BLUE STRIPES
69151-1 D
22 0.97-2.79
[.038-.055]
20 1.17-2.79
[.046-.110]
18 1.42-2.79
[.056-.110]
YELL W AND RED
NE D T (T L N .
69151-1
M D. F IS C DED
RED NLY)
PIDG
INSULATI N
RESTRICTING
NYL N
TERMINALS
RED W/3
GREEN STRIPES
RED W/3
RED STRIPES
RED W/3
WHITE STRIPES
6.4
[1/4] 7.1 9/32
47387 16 1.60-3.30
[.063-.130]
BLUE AND
GREEN
TW D TS
BLUE W/3
BLUE STRIPES
D TIGHT INSULATI N SUPP RT F R WIRES WITH THIN WALL INSULATI N
TOOL NUMBER
AND
DESCRIPTION
WIRE
RANGE
(AWG)
TOOL
COLOR
AND DOT
CODE
PRODUCT PRODUCT
INSULATION COLOR
CODE
WIRE STRIP
LENGTH
22-18
MIN. MAX.
8
[5/16] 8.7 [11/32]
YELL W
AND RED
NE D T
SPARE WIRE CAP
N . 328308 BLUE
47387 16-14 BLUE AND
GREEN
TW D TS
SPARE WIRE CAP
N . 328307 RED
TOOL NUMBER
AND
DESCRIPTION PRODUCT PRODUCT
INSULATION COLOR
CODE
WIRE STRIP
LENGTH
26-24
MIN. MAX.
4.8
[3/16] 5.6 [7/32]
48518-2 PIDG FAST N RECEPTACLES
P/N 641321-1 (187 SERIES) AND P/N
641324-1 (110 SERIES)
YELL W
N TE: Color code is for
reference only. Always order correct
tool by supplying part numbers of
receptacles being crimped.
Figure 3 (end)
B" Equals
Wire Barrel
C" Equals
Insulation
Barrel
Terminal Wire Barrel
Butts Against Locator
End of Wire Conductor
Butts Against Tool Locator
(Note: Wire Butts Against
FAST N Receptacle Wire
Stop)
PIDG and PLASTI-GRIP Terminals
“C” “B”
PIDG
Terminal
“C” “B”
“C” “B”
Wire Stop
PIDG FASTON Receptacle PLASTI-GRIP Terminal
“C” “B”
PIDG
Insulation
Restricting
Terminal
WIRE
RANGE
(AWG)
Figure 4
47386
47386-5
47386
47386-5
47386
47386-5

408-1559
Hand Crimping Tools
5 of 10Rev P
Tyco Electronics Cor oration
Figure 5
Butt Splices
C" B"
PIDG Splice
B" Equals Wire Barrel
C" Equals Insulation Barrel
C" B"
PLASTI-GRIP Splice
Window Indent
Wire Sto
Wire Sto
Window
Indent
Locator Seats in
Window Indent
of S lice
First
Crimp
End of Wire Conductor Butts
Against S lice Wire Sto
Insulation Crim Adjustment
Pins in No. 3 Position
Second
Crimp
Locator Seats in Window
Indent of S lice
End of Wire Conductor Butts
Against S lice Wire Sto
4. CRIMP INSPECTION
Inspect crimped terminals and splices by checking the
features described in Figure 7. Terminals and splices
not meeting these conditions should NOT be used.
5. INSULATION CRIMP ADJUSTMENTS
5.1. For PIDG Terminals and Spli es
PIDG terminal and plice feature a wire
in ulation grip."
The insulation crimping section of the hand tool has
three positions: 1 (tight), 2 (medium), and 3 (loose).
To adjust the section:
Figure 6
Spare Wire Caps
Wire Barrel Locator
Insulation
Adjustment
Pins in No. 3
Position
Wire Bottoms
in Ca
Raise Locator so
that End of Ca
Rests Against
Recessed Surface
of Locator
1. Insert the insulation crimp adjustment pins into
the No. 3 position. Refer to Figure 1 or Figure 5.
2. Place the terminal or splice into the crimping
jaws as shown in Figure 4 or Figure 5.
3. Insert the UNSTRIPPED wire into ONLY the
insulation barrel (refer to Figure 4 or Figure 5)
portion of the terminal or splice.
4. Close the tool handles to complete the crimp.
5. Remove the crimped terminal or splice and
check the insulation crimp by bending the wire
back and forth once. The terminal or splice should
retain its grip on the wire insulation. If the wire pulls
out, set the insulation crimp adjustment pins to the
next higher position (No. 2).
6. Perform another crimp and repeat the
adjustment as necessary until the correct insulation
grip is attained. Do not use a tighter setting than
required.
Make ure that both in ulation crimp adju tment
pin are in the ame po ition.
5.2. For PLASTI-GRIP Terminals and Spli es
PLASTI-GRIP terminal and plice feature a
wire in ulation upport" only. The terminal or
plice in ulation hould ideally be in contact with
the wire in ulation.
1. Set adjustment pins in position No. 3 for wire
having a large insulation diameter.
2. Set adjustment pins in position No. 2 for wire
having a medium insulation diameter.
3. Set adjustment pins in position No. 1 for wire
having a small insulation diameter.
Make ure that both in ulation crimp adju tment
pin are in the ame po ition.
NOTE
i
CAUTION
!
NOTE
i
CAUTION
!

408-1559
Hand Crimping Too s
Rev P6 of 10 Tyco Electronics Corporation
Figure 7
1Insulation barrel is in firm contact with wire insulation.
2Correct color co e, ot co e, an tool combination (Rib co e
on bottom, ot co e on top when crimpe in tool No. 69454).
3Wire size is within the wire range stampe un er the terminal
tongue or on the center of the splice.
4Crimp is centere on the wire barrel.
5Con uctor en is flush with, or exten s beyon , the en of the
terminal wire barrel.
6Con uctor en is against the wire stop, is at least flush with, or
exten s slightly beyon , the wire barrel.
7Wire insulation oes not enter the wire barrel.
8No nicke or missing con uctor stran s.
1No flash or extru e insulation.
2Correct color co e, ot co e, an tool combination. Dot co ing
isappears from seale splices when they are heat seale .
3Correct wire size is use .
4Wire insulation oes not enter wire barrel of splice.
5En of con uctor is against wire stop, is at least flush with, or
exten s slightly beyon , the splice's wire barrel.
6En of con uctor is bottome in cap.
7Full wi th of crimp is over wire barrel.
8No nicke or missing con uctor stran s.
9Crimp is centere on wire barrel.
10 Splice insulation is in contact with wire insulation.
PIDG AND
PLASTI-GRIP
Terminals
PIDG
Butt Splices
PLASTI-GRIP
Butt Splice
Spare Wire
Caps
1245
3
7 8
63
462
1
A Dot Co e (1 or 2 Dots) Must Appear
on All Crimpe Items
(Rib co e on bottom, ot co e on top when
crimpe in tool No. 69454)
31
5
2
10
9
485
Wire Stop
48
6
7
2
13
Wire Stop
6. INITIAL TOOL INSPECTION
Hand crimping tools are inspected before
shipment. The tool received should be inspected
immediately upon arrival to ensure that the tool has
not been damaged during shipment, and that it
performs according to the criteria described in this
sheet. If a tool is damaged upon arrival, retain the
shipping container, file a claim with the carrier, and
notify Tyco Electronics immediately.
7. MAINTENANCE/INSPECTION
7.1. Dai y Maintenance
1. Remove dust, moisture, and other contaminants
from the tool with a clean brush or a soft, lint–free
cloth. Do NOT use objects that could damage the
tool.
2. Make sure that the proper retaining pins are in
place and are secured with the proper retaining
rings.
3. Make certain that all pins, pivot points, and
bearing surfaces are 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 the handles
closed to prevent objects from becoming lodged in
the crimping areas and store the tool in a clean,
dry area.

408-1559
Hand Crimping Tools
7 +$ #1 P
3!+ (#!/-+*&!. +-,+-/&+*
7.2. 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.
Though recommendations call for at least one
inspection per month, the inspection frequency should
be based on the amount of use, working conditions,
operator training and skill, and established company
standards. These inspections should be performed in
the following sequence:
A. 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 that all retaining pins are in place
and are secured with retaining rings. If
replacements are necessary, refer to the parts list
in Figure 11.
3. Inspect crimping areas for pitted or chipped
surfaces.
4. Close the tool handles until the ratchet releases,
then allow handles to open freely. If they do not
open quickly and fully, the spring is defective and
must be replaced. Refer to Section 8,
REPLACEMENT AND REPAIR.
B. Gaging the Crimping Areas
This inspection requires the use of plug gages
conforming to the dimensions listed in Figures 8
and 9. Tyco Electronics does not manufacture or
market these gages.
To gage the crimping area(s), refer to Figure 10 and
proceed as follows:
1. Close the crimping areas by squeezing the tool
handles together until the crimping dies have
bottomed, and then HOLD the tool handles in this
position. Do not force the dies beyond initial
contact.
Figure 8
TOOL NUMBER DIE CLOSURE DIM'S. A"
{ GAGE ELEMENT {{ DIM'S. B" DIA.
GO NO-GO GO NO-GO
C"
MA . R" RADIUS
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      
 
      

 
      
 
      
 
      
 
      
 
      
 
          
77 77
{ &# !(+.0-# "&)#*.&+*. ,,(3 2%#* 2&-# --#( '2. -# +//+)#" 0/ *+/ 0*"#- ,-#..0-#
{{ /#-&(7++( /##(
SUGGESTED PLUG GAGE DESIGN Ċ WIRE BARREL CRIMP

&) 4
4
&)
 
&* 3,
4
3,
 
&* 3,
4
4
3,  &) 4
Tool No. 69454 Only
Die Closu e
Configu ation

&)
4

 &)
Die Closu e
Configu ation
4
&
  &* 3,
4
&

408-1559
Hand Crimping Tools
"0 P8 *#  2 * '" .,*)% - *,+*,.%*)
Figure 9
TOOL NUMBER
DIE CLOSURE DIM'S. F" { (Set Insulation
Adjustment Pins at No. 1 Position) GAGE ELEMENT
{{ DIM'S. G"
GO NO-GO GO NO-GO
IDTH
 " (Max.)

 
      

 
      




{ %" '*-/," !%(")-%*)- ++'2 1$") 1%," ,,"' &1- ," *..*("! /. )*. /)!", +,"--/,"
{{ .",%'5**' .""'
SUGGESTED PLUG GAGE DESIGN Ċ INSULATION CRIMP
 %(  %(
3 3
3
 

  2+
3 %(
Die Closure
Configuration





        

        

        

        

        

        


2. Align the GO element of the gage with the
appropriate crimping area to be checked. Refer to
Figure 10. Push the element straight into the area
without using force. The GO element must pass
completely through the crimping area.
3. Align the NO–GO element of the gage with the
same crimping area, and try to insert the element.
The NO–GO element may start entry, but it must
not pass completely through the crimping area.
4. Repeat the gage inspection procedure for each
crimping area, making sure to use the correct plug
gage for each inspection.
If the crimping areas conform to the gage inspection,
the tool is considered dimensionally correct. If the
crimping areas do not conform to the inspection, the
tool must be repaired. Refer to Section 8,
REPLACEMENT AND REPAIR.
For additional information concerning the use of the
plug gage, refer to instruction sheet 408–7424.
C. CERTI-CRIMP Hand Crimping Tool Ratchet
Control Inspection
Obtain a .025–mm [.001–in.] shim that is suitable for
checking the clearance between the bottoming
surfaces of the crimping dies. To inspect the ratchet
control:
1. Refer to Figure 3 and select a terminal or splice
and wire (maximum size).
2. Position the terminal or splice in the appropriate
crimping area, according to the method described
in Paragraph 3.1, Steps 1 through 5.
3. While holding the wire in place, squeeze the tool
handles together until the ratchet releases. Hold
the tool in this position, maintaining just enough
pressure to keep the dies closed.

408-1559
Hand Cri ping Tools
9 of 10Rev P
Tyco Electronics Corporation
Figure 10
GO" ele ent ust pass co pletely
through the die closure.
NO-GO" ele ent ay
enter partially, but ust not pass
co pletely through the die closure.
Detail A
Inspection of Wire Barrel Crimping Dies
Detail B
Inspection of Insulation Crimping Dies
Wire Barrel
Jaws Botto ed
But Not Under
Pressure
Adjust ent
Pins in No. 1
Position
4. Check the clearance between the bottoming
surfaces of the crimping dies. If the clearance is
.025 mm [.001 in.] or less, the ratchet is
satisfactory. If clearance exceeds .025 mm
[.001 in.], the ratchet is out of adjustment, and
must be repaired. Refer to Section 8,
REPLACEMENT AND REPAIR. If the tool
conforms to these inspection procedures, lubricate
it with a THIN coat of any good SAE 20 motor oil
and return it to service.
8. REPLACEMENT AND REPAIR
Replacement parts are listed in Figure 11. Parts other
than those listed in Figure 11 should 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
1–717–986–7605, or write to:
CUSTOMER SERVICE (38–35)
TYCO ELECTRONICS CORPORATION
P.O. BOX 3608
HARRISBURG, PA 17105–3608
For tool repair service, please contact a
representative at 1–800–526–5136.
9. REVISION SUMMARY
Since the previous release of this sheet, the following
changes were made:
S Updated document to corporate requirements
S Added part number 47386–5 to tables in
Figures 1, 3, 8, 9, and 11

408-1559
H nd Crimping Tools
Rev P10 of 10 Tyco Electronics Corpor tion
Detail
B
Detail
A
22.22
[.875]
Approx.
279.4 [11.00]
1 2
3
4
1
67
8
10
9
11 12
13
8
Approx.
76.2 [3.00]
ITEM
DESCRIPTION
TOOL NUMBERS, DETAIL REF., AND COMPONENT PART NUMBERS
ITEM
NO.
DESCRIPTION
46121
DETAIL A 47304 DETAIL B 47386, 47386-5 DETAIL A 47387 DETAIL A 47907-1 DETAIL A
1 RING, Ret ining 21045-3 21045-3 21045-3 21045-3 21045-3
2 PIN, Ret ining 1-23619-6 1-23619-6 1-23619-6 1-23619-6 1-23619-6
3 PIN, Adjustment 39207 39207 39207 39207 39207
4 SPRING 39364 39364 39364 39364 39364
6 RING, Ret ining 21045-6 21045-6 21045-6 21045-6 21045-6
7 PIN, Ret ining 2-23620-9 2-23620-9 2-23620-9 2-23620-9 2-23620-9
8 SCREW 3-306105-9 3-21016-4 9-305927-1 9-305927-1 9-305927-1
9 SUPPORT -- 39193 -- -- --
10 STOP -- 302765 -- -- --
11 HOUSING LOCATOR 302994 -- 302994 302994 302994
12 SPRING 301201 -- 301201 301201 301201
13 LOCATOR 3-304052-6 -- 302993 45965-6 303542
ITEM
DESCRIPTION
TOOL NUMBERS, DETAIL REF., AND COMPONENT PART NUMBERS
ITEM
NO.
DESCRIPTION
169485
DETAIL A 48518-2 DETAIL A 69151-1 DETAIL A 69454 DETAIL A
1 RING, Ret ining 21045-3 21045-3 21045-3 21045-3
2 PIN, Ret ining 1-23619-6 1-23619-6 1-23619-6 1-23619-6
3 PIN, Adjustment 39207 39207 39207 39207
4 SPRING 39364 39364 39364 39364
6 RING, Ret ining 21045-6 21045-6 21045-6 21045-6
7 PIN, Ret ining 2-23620-9 2-23620-9 2-23620-9 2-23620-9
8 SCREW 9-305927-1 3-306105-9 9-305927-1 9-305927-1
9 SUPPORT -- -- -- --
10 STOP -- -- -- --
11 HOUSING LOCATOR 302994 302994 302994 302994-1
12 SPRING 301201 301201 301201 2-304668-6
13 LOCATOR 575960-4 125644-7 302993 4-304052-6
Figure 11