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ORIGINAL INSTRUCTIONS
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.
408-1542
PRODUCT
HAND
TOOL
WIRE SIZE
(AWG) RANGE
AND TERMINAL
SIZE
22-16
16-14
12-10
CRIMPING
CHAMBER
MARKING
22-16
16-14
12-10
14-12
22-16
WIRES STRIP LENGTH
TERMINAL
(STANDARD)
4.37-5.16
[.172-.203]
6.35-7.14
[.250-.281]
4.37-5.16
[.172-.203]
4.37-5.16
[.172-.203]
4.37-5.16
[.172-.203]
TERMINAL
(LONG
BARREL)
---
BUTT
SPLICE
6.35-7.14
[.250-.281]
7.94-8.73
[.313-.344]
6.35-7.14
[.250-.281]
6.35-7.14
[.250-.281]
PARALLEL
SPLICE
7.94-8.73
[.313-.344]
---
7.94-8.73
[.313-.344]
7.94-8.73
[.313-.344]
STRATO-THERM
46447
49592
49935
525693
574573
49935
525693
574573
1490046-1
SOLISTRAND
47410
49935
525693
574573
1490047-1
14-12
22-16
---
6.35-7.14
[.250-.281]
6.35-7.14
[.250-.281]
16-14
16-14
12-10
12-10
6.35-7.14
[.250-.281]
3.17-3.97
[.125-.156]
4.37-5.16
[.172-.203]
---
---
6.35-7.14
[.250-.281]
3.57-4.37
[.141-.172]
5.16-5.95
[.203-.234]
4.37-5.16
[.172-.203]
---
26-24
69363
22-20
24-20
26-24
22-20
22-20
Figure 2
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5. While holding the wire in place, squeeze the tool handles together until the ratchet releases, then
allow the tool handles to open fully.
6. To crimp the other half of a butt splice, position the uncrimped wire barrel in the crimping chamber,
and repeat the crimping procedure.
NOTE
If splice cannot be turned for crimping other half, turn the tool around.
NOTE
Terminals and splices can also be rotated 180° with the seam toward the nest.
4. CRIMP INSPECTION
Inspect crimped terminals and splices by checking the features described in Figure 4. Poor crimps can be
avoided by carefully following the procedures provided in Section 3, and by following the tool maintenance
procedures provided in Section 5.
Rev P
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408-1542
Terminals and Splices Can Also Be Rotated 180° with the Seam Toward the Nest
Figure 3
5. MAINTENANCE AND INSPECTION
The tool is inspected before being shipped, however TE recommends that the tool be inspected immediately
upon arrival at your facility to ensure that the tool has not been damaged during shipment.
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; and
4. Your own established standards.
5.1. 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
crimping jaws. Store the tool in a clean, dry area.
5.2. Lubrication
Lubricate all pins, pivot points, and bearing surfaces with SAE 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.
Rev P
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408-1542
Figure 4
5.3. Periodic Inspection
1. The 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 6, REPLACEMENT AND
REPAIR.
3. Inspect head assembly for worn, cracked, or broken jaws. Refer to Figure 5. If damage is evident,
return the tool to TE for evaluation and repair. See Section 6, REPLACEMENT AND REPAIR.
Rev P
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408-1542
Figure 5
5.4. Gaging the Crimping Chambers
(Figure 7)
This inspection requires the use of a plug gage conforming to the dimensions provided in Figure 6.
TE does not manufacture or market these gages. To gage the crimping chambers, proceed as follows:
Remove traces of oil or dirt from the crimping chambers and plug gage.
1. 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.
2. Align the GO element with the crimping chamber. Push element straight into the crimping chamber
without using force. The GO element must pass completely through the crimping chamber.
3. 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.
NOTE
The jaws in Tools 49935 and 574573 are not symmetrically located; make sure that the tool conforms to the symmetry
requirements shown in Figure 8.
If the crimping chambers 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, the tool must be returned for further
evaluation and repair. Refer to Section 6, REPLACEMENT AND REPAIR.
For additional information regarding the use of a plug gage, refer to Instruction Sheet
408-7424.
5.5. Ratchet Inspection
The CERTI-CRIMP tool ratchet should be checked to ensure that the ratchet does not release prematurely,
allowing the jaws to open before they have fully bottomed. Obtain a 0.025 mm [.001 in.] shim suitable for
checking the clearance between the bottoming surfaces of the crimping jaws. Proceed as follows:
1. Select a terminal or splice, and properly stripped wire with
maximum
wire load (such as wire size 16
AWG and size 22-16 terminal).
2. Position the terminal or splice and wire between the crimping jaws, as described in Section 3.
3. Hold the wire in place and squeeze the handles until the CERTI-CRIMP tool ratchet releases. Hold the
handles in this position, maintaining just enough tension 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.
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