Instruction Sheet Hand Crimping Tools 45160 and 45575-1 for 408-1502 PLASTI-GRIP* Butt Splices 22 SEP 11 Rev J PROPER USE GUIDELINES Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools. Hand tools are intended for occasional use a low volume applications. A wide selection of powered application equipment for extended-use, production operations is available. Insulation Crimp Adjustment Pins (Shown in Position 3) Tool Marking CERTI-CRIMP* Tool Crimping Ratchet Jaws Color-Coded Label Locator Figure 1 1. INTRODUCTION The locator positions the splice between the crimping jaws. The insulation crimp adjustment pins are used to TE Connectivity Hand Crimping Tools 45160 and regulate the crimp height of the splice insulation barrel 45575-1 (shown in Figure 1) are used to crimp sleeve. The ratchet assures full crimping of the splice. PLASTI-GRIP* butt splices (listed in Figure 2) onto Once engaged, the ratchet will not release until the stranded or solid wire sizes 22 through 14 AWG. tool handles have been FULLY closed. Dimensions in this instruction sheet are in NOTE millimeters with inches in brackets . Figures and The crimping jaws bottom before the CAUTION illustrations are for reference only and are not CERTI-CRIMP tool ratchet releases. This feature i drawn to scale. ensures maximum electrical and tensile performance of the crimp. Do NOT re-adjust the Reasons for reissue of this instruction sheet are ratchet. provided in Section 7, REVISION SUMMARY. 2. DESCRIPTION (Figure 1) 3. CRIMPING PROCEDURE Each hand tool consists of two crimping jaws, locator, Each hand tool is coated with a preservative to NOTE two insulation crimp adjustment pins, and a prevent rust or corrosion. Wipe this preservative CERTI-CRIMP tool ratchet. The FRONT of the tool, from the tool, particularly from the crimping jaws, i into which the splice is inserted, has the TE logo before using the tool. marked on the link. The tool handles have color- Refer to Figure 2 to make sure that the splice, wire coded labels which match the insulation color of the size, and tool are compatible. splices and correspond with a given wire size range. 2011 Tyco Electronics Corporation, Berwyn, PA This controlled document is subject to change. TOOLING ASSISTANCE CENTER 1-800-722-1111 1 of 6 All Rights Reserved For latest revision and Regional Customer Service, PRODUCT INFORMATION 1-800-522-6752 TE logo and Tyco Electronics are trademarks visit our website at www.tycoelectronics.com *Trademark. Other products, logos, and company names might be trademarks of their respective owners. LOC B ORIGINAL INSTRUCTIONS408-1502 Similar splices with an insulation color other than NOTE Crimping Butt Splice red or blue can be crimped with these tools however, wire size must be used, instead of the i tool-to-product color code, to establish compatibility. End of Splice Resting Against Locator Typical PLASTI-GRIP Butt Splice 6.35-7.14 .250-.281 Wire Strip Length Locator Insulation Wire Barrel Barrel Figure 3 5. Hold wire in place and squeeze tool handles together until the CERTI-CRIMP tool ratchet Color Code releases. Allow tool handles to open FULLY. Wire Size Splice (Splice and Tool Remove the crimped splice from the tool. Range (AWG) Tool) 6. To crimp other half of splice, position the 34203 uncrimped wire barrel in the tool, and crimp as 34067 described in Step 5. 34070 7. Remove the crimped splice from the tool, and 22-16 34178 Red 45160 34243 inspect the crimp. Make sure the proper crimp 55792-1 dot code is shown on the splice insulation for the 324138 appropriate hand tool. Refer to Figure 4. For detailed crimp inspection requirements, refer 34204 NOTE 34068 to Application Specification 114-2161. 34071 i 2-34071-2 8-34071-1 16-14 8-34071-4 Blue 45575-1 8-34071-5 35244 328427 Crimp Dot Code 8-328427-1 55785-1 Figure 2 A complete list of butt splice part numbers cannot NOTE be maintained on this document. For all part numbers and their description, refer to your TE i Representative. Tool Color Code Crimp Dot Code Proceed as follows: 45160 Red 1 Dot 1. Strip the wire using the appropriate strip length dimensions provided in Figure 2. Do NOT 45575-1 Blue 2 Dots nick or cut the wire strands. Figure 4 2. Open the crimping jaws by squeezing the tool handles together until the ratchet releases. 4. INSULATION CRIMP ADJUSTMENT 3. Insert stripped wire into the splice wire barrel. Each tool has three insulation crimp adjustment positions to adjust the wire insulation grip: 1Tight, 4. Locate the splicewith the wire inserted 2Medium, and 3Loose. To obtain the desired into the crimping jaws, as shown in Figure 3. The insulation grip, proceed as follows: end of the splice should rest against the locator. Rev J 2 of 6