Instruction Sheet Mini Straight Action Hand Tools (SAHT) 2255139-1, 2255140-1, 2255141-1, and 408-32126 2255142-1 for D1000 Dynamic Series 13 MAR 15 Rev A1 Contacts 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. Crimper Back of Tool 0 0 0 0 Anvil Ratchet NOTE: 2255139-1 is Shown, but Other SAHTs on this Document are Similar Figure 1 1. INTRODUCTION This instruction sheet covers the use of TE Connectivity Hand Crimping Straight Action Hand Tools (SAHT) 2255139-1, 2255140-1, 2255141-1, and 2255142-1 with flip locators which crimp D1000 Dynamic Series contacts listed in Figure 2. NOTE Dimensions are in metric units with inches in brackets . Figures and illustrations are for reference only and are not drawn to scale. Read these instructions thoroughly before crimping any contacts. 2. DESCRIPTION (Figure 1 and Figure 3) The FRONT OF TOOL (contact side), is where the contact is inserted. The BACK OF TOOL (wire side), is where the wire is inserted and has the wire size markings above each crimp section. Each tool features a fixed die (crimper), a movable die (anvil), two crimp sections with applicable wire size markings, a flip locator, a wire stop, and a ratchet release lever. Once engaged, the ratchet will not release until the handles have been FULLY closed. CAUTION The ratchet ensures full crimping of the contact. This is a design feature that ensues maximum electrical and tensile performance of the crimp. Do NOT readjust the ratchet. 2015 TE Connectivity family of companies TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. 1 of 4 All Rights Reserved PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, *Trademark visit our website at www.te.com. 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 408-32126 The flip locator positions the contact in the crimping die, and the wire stop aids in locating the wire in the contact. In use, it rests in the transition area of the connector. See Figure 1 and Figure 3. The flip locator prevents the contact from bending during the crimping procedure. The ratchet release lever enables the user to open the partially closed tool handles when necessary. The ratchet is used to control the crimp height of the terminals wire barrel and ensures full crimping of the terminal. Wire Strip Length 1.7 to 2.3 .067 to .090 CRIMP WIRE SIZE CONTACT SECTION (WIRE HAND TOOL (AWG) SIZE MARKING) 30 1827586-2 30 S 2255139-1 28 1903115-2 28 28-26 1827587-2 28-26 1871743-1 M 2255140-1 24-22 24-22 1903116-2 1903124-1 1939992-2 28-26 1827588-2 28-26 L 2255141-1 1871744-1 24-22 24-22 1903117-2 22-20 1827589-2 22-20 2L 2255142-1 1871745-1 18 18 1903118-2 1903126-1 Figure 2 3. CRIMPING PROCEDURE Refer to the table in Figure 2 and ensure compatibility between the wire, contact, and crimping tool. Wire size must be within the specified range for the contact. Strip the wire to the length indicated. CAUTION Do NOT cut or nick the wire strands. The hand crimping tool must be the one designed for crimping the wire and contact. Identify the appropriate crimp section (according to the wire size markings on the BACK of the tool). Refer to Figure 3 and proceed as follows: 1. Hold tool so BACK (wire side) is facing you. 2. Make sure the ratchet is released by squeezing the tool handles and allowing them to open FULLY. 3. Open flip locator. Insert contact into the flip locator (make sure contact is inserted properly). 4. Close flip locator. 5. Pre-close the handles slightly, and insert the wire into the contact. 6. Close the handles until the automatic ratchet releases. 7. Open flip locator. Take wire with contact out of locator. Rev A1 2 of 4