Tyco Electronics 45449 Manuel utilisateur

Instruction Sheet

Hand Crimping Tools

45449 and 45450 for 408-1548

LOC B

of 5

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.ty oele troni s. om

23 OCT 07 Rev C

PLASTI-GRIP* Parallel Spli es

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

Anvil

Barrel

Jaw

Wire Size

Marking

Tool

Color

Code

CERTI-CRIM *

Ratchet

Indenter

(Crimper)

Jaw

1. INTRODUCTION

This instruction sheet covers the use of Hand

Crimping Tools 45449 and 45450 (see Figure 1)

which are designed to crimp PLASTI–GRIP parallel

splices shown in Figure 2. Read these instructions

thoroughly before using the tool.

Reasons for reissue are provided in Section 6,

REVISION SUMMARY.

All di ensions on this docu ent are in etric

units [with inches in brackets]. Figures and

illustrations are for identification only and are not

drawn to scale.

2. DESCRIPTION

Each tool features outer and inner crimping dies

(contained within the crimper and anvil jaws) and a

CERTI–CRIMP ratchet.

The outer crimping dies crimp the insulation barrels of

the splice and the inner dies crimp the wire barrel of

the splice.

The CERTI–CRIMP ratchet assures full crimping of

the splice. Once engaged, the ratchet will not release

until the handles have FULLY closed.

The cri ping dies botto before the

CERTI-CRIMP ratchet releases. This design

feature assures axi u electrical and tensile

perfor ance of the cri p. Do NOT re-adjust the

ratchet.

Tool 45449, which has red–colored labels on its

handles, is used to crimp red–colored PLASTI–GRIP

splices on wire sizes 22 through 16 AWG (wire sizes

1 through 2 for Navy Ships) and tool 45450, which

has blue–colored labels on its handles, is used to

crimp blue–colored PLASTI–GRIP splices on wire

sizes 16 through 14 AWG (wire sizes 2 1/2 through 4

for Navy Ships). Thus, the splice and tool handles are

color coded for a given wire size range as listed in

Figure 2. Additionally, each tool will impress a dot

code on the splice, when the splice is crimped

properly. A red color–coded tool impresses one dot

and a blue color–coded tool impresses two dots.

Wire Strip

Length Wire Barrel

Insert Wires in Splice as Shown Above

One Dot

NOTE:

Not to Scale

Finished Cri p

TOOL

WIRE COLOR AND WIRE STRIP LENGTH

TOOL

SIZE DOT CODE MIN. MAX.

45449 22-16 Red - One Dot

7 87 [ 310]

8 64 [ 340]

45450 16-14 Blue - Two Dots

87 [

310]

64 [

340]

Figure 2

NOTE

CAUTION

408-1548

Hand Crimping Tools 45449 and 45450

Rev

of 5 Tyco Electronics Corporation

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 crimping jaws,

before using the tool.

Refer to the chart in Figure 2 and select wire of

desired size (within the range of the tool being used).

Strip the wire to the length indicated. Do NOT cut or

nick the wire strands.

Select the appropriate PLASTI–GRIP splice (refer to

Catalog 82042 for desired size and part number).

Refer to Figure 2 and Figure 3 and proceed as

follows:

1. Open the tool’s jaws by squeezing the handles

until the ratchet releases and then allow the

handles to open FULLY.

2. Insert stripped wires into both ends of the splice.

3. Center splice (with wires inserted) in crimper

jaws.

4. To complete crimp, close handles until ratchet

releases. Allow handles to open FULLY. Crimped

splice may be removed.

Figure 3

Center Splice

Between Stops

Stops

4. MAINTENANCE AND INSPECTION PROCEDURE

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 hand tool is inspected before being shipped;

however, Tyco Electronics recommends that the tool

be inspected immediately upon its arrival at your

facility to ensure that the tool has not been damaged

during shipment. 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 Maint nanc

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 No. 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 dies. Store the tool in a clean, dry area.

4.2. Lubrication

Lubricate all pins, pivot points, and bearing surfaces

with SAE No. 20 motor oil as follows:

Tools used in daily production – lubricate daily

Tools used daily (occasional) – lubricate weekly

Tools 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. P riodic Insp ction

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, return the tool to

Tyco Electronics for evaluation and repair. See

Section 5, REPLACEMENT AND REPAIR.

4.4. Crimping Di Closur Insp ction

This inspection requires the use of plug gages

conforming to the dimensions shown in Figure 4. Tyco

Electronics does not manufacture or market these

gages.

NOTE

408-1548

Hand Cr mp ng Tools 45449 and 45450

of 5Rev

Tyco Electronics Corpor tion

A"

F"

C" E" 25.4

[1.00]

Min.

A"

Dim.

B"

F"

C" E" 25.4

[1.00]

Min.

B"

Dim.

Barrel Crimp Insulation Crimp

Suggested Plug Gage Design

GO Dim. GO Dim.NO-GO Dim. NO-GO Dim.

TOOL

NUMBER

BARREL CRIMP

DIMENSIONS

{

A" C" E" F"

INSULATION CRIMP

DIMENSIONS

{

B" C" E" F"

NUMBER

GO NO-GO GO NO-GO

45449 2.77

[.109] 2.92

[.115] 3.18

[.125] 8.00

[.315] 2.16

[.085] 2.59

[.102] 3.10

[.122] 3.18

[.125] 8.00

[.315] 2.16

[.085]

45450 3.02

[.119] 3.18

[.125] 3.18

[.125] 9.53

[.375] 2.74

[.108] 2.84

[.112] 3.35

[.132] 3.18

[.125] 9.53

[.375] 2.74

[.108]

{

Plug gage dimensions apply when tool is bottomed, but not under pressure.

Figure 4

To gage die closure, refer to Figure 5 and Figure 6

and proceed as follows:

1. Remove traces of oil or dirt from the crimping

chambers and plug gage.

2. Open tool crimping jaws and insert the GO

element of the proper wire barrel plug gage into the

space between the wire barrel die (inner) and the

insulation die (outer). Plug gage may be inserted

from either side of the tool.

Figure 5

Insert End of G ge Into

Sp ce Between Insul tion

B rrel Die nd Wire B rrel

Die

Wire B rrel

Die

Insul tion

B rrel Die

3. 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.

4. Align the GO element with the wire barrel

crimping chamber. Push element straight into the

crimping chamber without using force. The GO

element must pass completely through the

crimping chamber.

5. Check the wire barrel crimping chamber with the

NO GO element in the same manner as steps 2

through 4. The NO GO element may start entry,

but must not pass completely through the crimping

chamber.

6. Check both sets of insulation barrel crimping

dies with the proper insulation barrel plug gage in

the same manner as steps 2 through 5.

If both wire barrel and insulation barrel crimping dies

conform to the gage inspection, the crimping

chambers are considered dimensionally correct. If

correct, the tool should be lubricated with a thin coat

of any good SAE No. 20 motor oil and returned to

service. If not correct, the tool must be returned to

Tyco Electronics for further evaluation and repair.

Refer to Section 5, REPLACEMENT AND REPAIR.

For additional information regarding the use of a plug

gage, refer to Instruction Sheet 408–7424.

408-1548

Hand Crimping Tools 45449 and 45450

Rev

of 5 Tyco Electronics Corporation

Figure 6

Tool

Cri ping Jaws

Botto ed

Gage May be Inserted

in Either Side of Tool

When Gaging Wire

Barrel Die

Plug Gage

Wire Barrel

Die

Wire Barrel

Die

Insulation Barrel

Die

Insulation Barrel

Die

GO" Gage Must Pass Co pletely

Through the Cri ping Surface

NO-GO" Gage May Enter Partially, but

Must Not Pass Co pletely Through the

Length of the Cri ping Surface

Inspection of Wire Barrel

Crimping Dies with Plug Gage Inspection of Insulation Barrel

Crimping Dies with Plug Gage

4.5. CERTI-CRIMP Ra che Inspec ion

The CERTI–CRIMP ratchet feature on hand tools

should be checked to ensure that the ratchet does not

release prematurely, allowing the crimping 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

crimping dies. Proceed as follows:

1. Select the maximum size wires and strip them

according to dimensions listed in Figure 2.

2. Select splice corresponding to the selected wire

size (refer to Figure 2).

3. Position the splice and wires between the

crimping dies, as described in Section 3,

CRIMPING PROCEDURE.

4. Hold the splice and wires 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 dies

closed.

5. Check the clearance between the bottoming

surfaces of the crimping 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.

408-1548

Hand Crimping Tools 45449 and 45450

of 5R v

Tyco El ctronics Corporation

ITEM PART NUMBER DESCRIPTION QT

1 21045-3 RING, R taining 1

2 21045-6 RING, R taining 1

Figure 7

69–65

95.3

[3.75]

(Clos d)

279

[11.00]

19.1 [.75]

WEIGHT:

Approx. 526 g [1 lb. 3 oz.]

3 39364 SPRING 1

5. REPLACEMENT AND REPAIR

Replacement parts are listed in Figure 7. Parts other

than those listed in Figure 7 should be replaced 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

6. REVISION SUMMAR

This is a summary of changes and additions made to

this instruction sheet:

Updated document to corporate requirements

New format

Ce manuel convient aux modèles suivants

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