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TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners.
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.
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2. DESCRIPTION
(Figure 1)
The hand tool has a stationary (reservoir) lever and a movable lever. These levers are compressed to pump
hydraulic fluid behind the ram, moving it forward and thereby closing the dies. After the crimping is complete,
the movable lever is turned to depress the plunger. The moving die retracts to its original position, completing
the crimping cycle.
3. DIE SELECTION
(Figure 2)
1. Press head latch and open crimping head as shown.
2. Pull back the die latch and turn thumb knob until desired die size appears (embossed wire size
appears on side of each die position).
Press Head
Latch Here
Embossed
Wire Size
Thumb
Knob
Pull Back Die Latch
Then Turn Thumb Knob
Figure 2
3. Rotate thumb knob left or right until die latch locks die wheel in desired position.
4. Close head.
NOTE
In order to close head, die latch must
‘snap’
into locked position.
4. CRIMPING PROCEDURE
1. Strip wires to dimensions listed in Figure 1.
2. Insert terminal or splice in upper die as shown in Figure 3.
3. Pump movable lever until moving (lower) die grips terminal or splice.
CAUTION
Do not deform wire barrel of terminal or splice.
4. Insert stripped wire into wire barrel of terminal or splice.
5. Continue pumping moveable lever. A slight
‘click’
may be heard, indicating the pump has shifted into
the high-pressure stage. Continue pumping moveable lever. When dies have bottomed, an audible
‘pop’
will be heard. This indicates that the crimp is complete.
CAUTION
Potential damage to the tool may occur if the following Step 6 is not taken.
6. Retract movable die by opening the movable handle to the full open position. Turn the movable handle
(to actuate striker),
DO NOT TURN THE MOVABLE HANDLE WHILE IN THE CLOSED POSITION
AS YOU WILL DAMAGE THE PLUNGER (PRESSURE RELEASE),
and compress handles to
depress plunger (pressure release).
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7. Movable die will now retract.
8. Remove crimped terminal or splice.
NOTE
If terminal or splice sticks in die after crimping, apply a rocking action to remove it from die.
9. Inspect crimp for the following criteria:
Centering of crimp (crimp may be off center but not off end of wire barrel)
Wire size being used matches wire range stamped on die position and terminal
End of wire is flush with or extends slightly beyond end of wire barrel
There are no nicked or missing strands
10. Inspect crimped terminal or splice in accordance with inspection procedure on instruction sheet
packaged with the dies.
Terminal
B
Parallel Splice
B
Butt Splice
B
“B” Equals Wire Barrel
Center Terminal or Splice
Wire Barrel in Upper Die
When Brazed Seam on Terminal or
Splice Wire Barrel is Visible, Position
Seam Toward Moving (Lower) Die
Figure 3
5. INSPECTION AND MAINTENANCE
DANGER
Make sure hydraulic pressure is released before following maintenance and inspection procedures, unless otherwise specified
in the procedure.
It is recommended that an inspection and maintenance program be performed periodically to ensure
dependable and uniform terminations. Though recommendations call for at least one inspection per month,
frequency of inspection depends on:
The care, amount of use, and handling of the hand tool,
The presence of abnormal amounts of dust and dirt,
The degree of operator skill, and
Your own established standards.
The hand 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.
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5.1. Visual Inspection
1. Verify that all retaining pins are in place and secured with retaining rings. If replacements are
necessary, refer to parts listed in Figure 6.
2. Inspect head assembly for worn, cracked, or broken areas. If damage is evident, return the tool for
evaluation and repair. See Section 6, REPLACEMENT AND REPAIR.
NOTE
Once per year, or every 7,500 cycles (whichever comes first), the hydraulic head should be returned to TE for magnetic
particle inspection. Additionally, inspect and service the head every month or 1,000 cycles.
5.2. Daily Maintenance
1. Hand tool should be immersed (handles partially closed) in a reliable commercial degreasing
compound to remove accumulated dirt, grease, and foreign matter. When degreasing compound is
not available, tool may be wiped clean with a soft, lint-free cloth. DO NOT use hard or abrasive objects
that could damage the tool.
2. Make certain that the retaining pins are in place and that they are secured with retaining rings.
CAUTION
Do not remove the retaining pins as permanent damage to the tool could result.
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.
5.3. Crimping Pressure Inspection
Check the crimping pressure to ensure that dies are fully bottomed before pressure is reduced by the
internal bypass valve.
1. Select the largest wire and terminal size that will be crimped in the tool.
2. Select dies in accordance with Section 3, DIE SELECTION.
3. Place terminal or splice in dies in accordance with the instructions in Section 4, CRIMPING
PROCEDURE.
4. Perform crimping procedure as described in Steps 3 thru 5 of Section 4, CRIMPING PROCEDURE.
DO NOT release hydraulic pressure at this time.
5. When ram is fully extended and Steps 1 thru 4 are completed, a scribe line should appear on the ram
at the base of the cylinder head. This indicates that the pressure requirement has been met.
CAUTION
If the scribe is NOT visible, the tool is not performing properly and should be repaired as described in Section 6,
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.
5.4. Lubrication
Tool used in daily production:
Tool used daily (occasionally):
Tool used weekly:
Keep all pins, pivot points, and bearing surfaces lubricated with SAE 20 motor oil as follows:
lubricate daily
lubricate weekly
lubricate monthly
Wipe excess oil from tool, particularly from crimping area.
CAUTION
Oil transferred from the crimping area onto certain terminations may affect the electrical characteristics of an application.
SAE is a trademark.
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5.5. Hydraulic Fluid Level Inspection/Fill
(Figure 4)
1. Turn the tool upside down and clamp it in a vise so the tool levers are in an upright position.
2. Release all pressure in tool in accordance with instructions in Section 4, CRIMPING PROCEDURE,
Step 6.
Movable Lever in
Closed Position
Magnetic
Filler Plug
Pour Fluid
Here
Bladder
Tool Positioned
in Vise
Figure 4
3. Turn the movable lever and allow the lever to close until it stops. DO NOT depress the plunger when
closing the lever.
NOTE
Keep lever in CLOSED position for remaining steps in this procedure.
4. Loosen the setscrew in cap of stationary (reservoir) lever (see Figure 1).
5. With a view from the lever grip end, turn the lever COUNTERCLOCKWISE and remove the entire
reservoir lever to expose the bladder.
6. Remove the magnetic filler plug.
If the bladder is full, no further check is necessary and tool can be re-assembled.
If fluid level is low, proceed to the next step.
7. Fill the bladder with fluid.
NOTE
Use care to prevent air bubbles from forming while pouring the fluid.
NOTE
The recommended fluid is Dexron II; a transmission fluid available in automotive parts and department stores.
8. Refill the bladder to point of overflow, and replace the filler plug.
9. Re-assemble the stationary lever and tighten the cap setscrew.
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