Hand Crmpng Tool 607949-1 (For Insulated Heat Shrnk Splces) Instructon Sheet 408-4087 23 JAN 12 PROPER USE GUIDELINES Cumulatve Trauma Dsorders can result from the prolonged use of manually powered hand tools. Hand tools are ntended for occasonal use and low volume applcatons. A wde selecton of powered applcaton equpment for extended-use, producton operatons s avalable. Front of Tool Crmper Anvl Read these nstructons thoroughly before crmpng any contacts. All dmensons on ths document are n metrc unts [wth U.S. customary unts n brackets]. Illustratons and fgures are for reference only and are not drawn to scale Reasons for ressue of ths nstructon sheet are provded n Secton 7, REVISION SUMMARY. ORIGINAL INSTRUCTIONS Ratchet 2. DESCRIPTION The tool features crmper and anvl jaws, color coded wre sze markng, sprng actuated handles wth cushoned hand grps, and a ratchet mechansm whch wll not release untl the tool handles have been FULLY closed, thus ensurng a relable crmp termnaton. If the ratchet should need adjustment, refer to Paragraph 4.2.C. Fgure 1 Cushoned Hand Grps 1. INTRODUCTION Hand Crmpng Tool 607949-1, a three-cavty, two-jaw crmpng tool s desgned to crmp the conductor porton of nsulated heat-shrnk splces n the followng range of wre szes: RED - Wre szes 22 to 16 AWG, outer cavty. BLUE - Wre szes 16 to 14 AWG, mddle cavty. YELLOW - Wre szes 12 to 10 AWG, nner cavty. 3. CRIMPING PROCEDURES (Fgure 2) 1. Close the tool handles untl the ratchet releases, then allow the tool handles to open fully. 2. Select the approprate cavty for the splce beng crmped. 3. Algn conductor porton of termnal n the cavty as shown n Fgure 2. 4. Close the tool carefully untl the jaws grp the termnal lghtly and hold t n place wthout dstorton. 5. Insert a properly strpped wre (Fgure 2) nto the termnal untl t bottoms. 6. To crmp, hold the wre n place, squeeze the handles untl the ratchet releases, allow the jaws to open FULLY, and remove crmped splce. 4. MAINTENANCE/INSPECTION 4.1. Daly Mantenance Mantenance and nspecton should be performed regularly. Tool should be wped clean wth specal emphass on the crmpng cavtes. 2012 Tyco Electroncs Corporaton, Berwyn, PA TOOLING ASSISTANCE CENTER 1-800-722-1111 All Rghts Reserved PRODUCT INFORMATION 1-800-522-6752 TE logo and Tyco Electroncs are trademarks. *Trademark. Other products, logos, and company names mght be trademarks of ther respectve owners. Ths controlled document s subject to change. For latest revson and Regonal Customer Servce, vst our webste at www.tycoelectroncs.com 1 of 5 LOC B
Crmpng Conductor Crmp Area L = 7.14 [.281] 22-16-14 AWG L= 9.53 [.375] 12-10 AWG L Splce Strpped Wre Fgure 2 4.2. Perodc Inspecton Hand tool should be mmersed (handles partally closed) n a relable commercal degreasng compound whch does not attack pant or plastc materal, to remove accumulated drt, grease, and foregn matter. The tool should be re-lubrcated after cleanng. The tool may then be wped clean wth a soft, lnt-free cloth. Do NOT use hard or abrasve objects that could damage the tool. Ensure that the tool conforms to the nformaton n Fgure 6. A. Lubrcaton Lubrcate all pns, pvot ponts, and bearng surfaces wth SAE 20 motor ol as follows: Tools used n daly producton - lubrcate daly Tools used daly (occasonally) - lubrcate weekly Tools used weekly - lubrcate monthly Wpe excess ol from tool, partcularly from crmpng area. Ol transferred from the crmpng area onto certan termnatons may affect the electrcal characterstcs of an applcaton. B. Vsual Inspecton 1. Close tool handles untl ratchet releases and then allow them to open freely. If they do not open quckly and fully, the tool s defectve and must be replaced. See Secton 6, REPLACEMENT. 2. Inspect jaws for worn, cracked, or broken areas. If damage s evdent, the tool must be replaced. See Secton 6, REPLACEMENT. C. Gagng the Crmpng Chamber Ths nspecton requres the use of plug gages conformng to the dmensons n Fgure 3. TE Connectvty does not manufacture or market these gages. To gage the crmpng chamber, proceed as follows: 1. Remove traces of ol or drt from crmpng chamber and plug gages. 2. Close the tool handles untl t s evdent that the jaws have bottomed, then HOLD n ths poston. Do NOT force the jaws beyond ntal contact. 3. Algn the GO element wth the crmpng chamber. Push element straght nto the crmpng chamber wthout usng force. The GO element must pass completely through. Refer to Fgure 3. 4. Now algn the NO-GO element and try to nsert t straght nto the same crmpng chamber. The NO- GO element may start entry but must not pass completely through as shown n Fgure 3. If the crmpng chamber conforms to the gage nspecton, t s consdered dmensonally correct and should be lubrcated wth a THIN coat of any good SAE 20 motor ol. If not, the tool must be replaced. See Secton 6, REPLACEMENT. D. Ratchet Inspecton Obtan a.025 mm [.001 n.] shm that s sutable for checkng the clearance between the bottomng surfaces of the crmpng jaws. (See Fgure 3). Proceed as follows: 1. Select a contact and wre (maxmum sze) for the tool (see Fgure 3). SAE s a trademark. 2 of 5
25.4 [1.00] Mn Typ GO Element Must Pass Completely Through the Secton GO Element NO-GO Element May Enter Partally But Must Not Pass Completely Through the Secton Bottomng Surfaces Gage dmenson G wth the handles closed to ratchet stop. NO-GO Element NEST DIMENSION G WIRE SIZE (AWG) GO DIAMETER NO-GO-DIAMETER 22-16 2.29 [.090] 2.39 [.094] 16-14 2.65 [.1045] 2.78 [.1095] 12-10 3.68 [.145] 3.84 [.151] Fgure 3 2. Poston the contact and wre between the crmpng jaws, accordng to Secton 3, CRIMPING PROCEDURE (Steps 1 through 6). Holdng the wre n place, squeeze the tool handles together untl the ratchet releases. Hold the tool handles n ths poston, mantanng just enough pressure to keep the jaws closed. 3. Check the clearance between the bottomng surfaces of the crmpng jaws. If the clearance s 025 mm [.001 n.], or less, the ratchet s satsfactory. If clearance exceeds.025 mm [.001 n.] the ratchet s out of adjustment and must be adjusted (see Secton 5, TOOL ADJUSTMENT). E. Tool Force Values 1. Apply force as shown untl ratchet releases. The force at a pont 44.45 mm [1.75 n.] from handle ends should be 35 to 45 pounds. See Fgure 4. Apply Force as Shown Untl Ratchet Releases. The force at Pont 44.45 mm [1.75 n.] from the Handle Ends Should Be 1.88-2.42 kg [35-45 lb.] 44.45 [1.75] Fgure 4 3 of 5
Ratchet Locknut Adjustment Screw Clockwse to tghten; Counterclockwse to Loosen Fgure 5 2. To adjust the tool to obtan the proper force values, open the handles and loosen the locknut wth Spanner Wrench 127298-1 (avalable from TE). See Secton 5, TOOL ADJUSTMENT. 3. On the opposte sde of the tool, turn the eccentrc stud CLOCKWISE to ncrease the handle load; or COUNTERCLOCKWISE to decrease the handle load. Tghten locknut, measure force and contnue to adjust f necessary. 5. TOOL ADJUSTMENT (Fgure 5) If the ratchet must be adjusted, use the spanner wrench, and proceed as follows: 1. Loosen the ratchet locknut on the back of the tool (sde wth wre sze markngs). 2. Check bottomng of tool jaws accordng to Paragraph 4.2.C. Turn screw on front of tool CLOCKWISE to tghten ratchet (must reduce crmp heght) or COUNTERCLOCKWISE to loosen ratchet (may ncrease crmp heght). 3. When tool jaws bottom properly, retghten the nut. It may be necessary to hold the ratchet screw whle securng the ratchet locknut. 6. REPLACEMENT Ths tool s not reparable and a spare should be stocked to prevent lost tme when replacement of tools s necessary. Order replacement tools through your representatve, or call 1-800-526-5142, or send a facsmle of your purchase order to 1-717-986-7605, or wrte to: CUSTOMER SERVICE (038-035) TYCO ELECTRONICS CORPORATION PO BOX 3608 HARRISBURG PA 17105-3608 7. REVISION SUMMARY Updated document to corporate requrements Removed AMPLIVERSAL n all nstances n document 4 of 5
228.6 [9.00] 57.15 [2.25] 4.95 [.195] Weght: 340 kg [.75 lb.] Fgure 6 5 of 5