Instruction Sheet CERTI-CRIMP* Heavy Head Hand Tool 59054 for 408-1257 DIAMOND GRIP* Terminals and Splices 05 OCT 10 Rev A 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. Crimping 3. CRIMPING PROCEDURE Chamber Indenter Anvil The hand tool is coated with a preservative to NOTE Crimping Crimping prevent rust or corrosion. Wipe this preservative Dies Dies from the tool, particularly from the crimping dies, i before using the tool. 1. Strip the wire within the dimensions given in Figure 2. 2. Open the crimping dies by squeezing the handles until the ratchet releases and then allow the handles to open FULLY. Head Ratchet 3. Insert the terminal or splice into the crimping Insulation Crimping Adjustment Pin chamber as shown in Figure 3. (Shown in Position 3) 4. Close tool handles slowly until the terminal or splice is held firmly in place. DO NOT deform the wire barrel. Figure 1 5. Insert the stripped wire into terminal or splice wire barrel until the end of the wire butts against 1. INTRODUCTION the end of the wire barrel. CERTI-CRIMP Heavy Head Hand Tool 59054, shown 6. Holding the wire in place, close the tool in Figure 1, is designed to crimp DIAMOND GRIP handles until ratchet releases. Allow the handles terminals and splices onto stranded wire sizes 12 to open FULLY. through 10 AWG. Read these instructions thoroughly before using the tool. 7. To crimp the other half of the splice, position the un-crimped wire barrel into the crimping dies Dimensions in this instruction sheet are in NOTE and follow the same steps used to crimp the first millimeters with inches in brackets . Figures are half. If the splice cannot be turned, turn the tool. not drawn to scale. i Terminal Reasons for reissue of this instruction sheet are Wire Strip Length provided in Section 7, REVISION SUMMARY. AB (See Table) 2. DESCRIPTION The tool features a head that holds four crimping dies Splice (2 anvils and 2 indenters), an insulation crimping Wire Strip Length adjustment pin, locator stop, and ratchet. When (See Table) closed, the crimping dies form one crimping chamber with a wire barrel section and an insulation barrel section. The insulation crimping adjustment pin is used to AB BA A Equals Insulation Barrel control the crimp height of the terminal or splice B Equals Wire Barrel insulation barrel. The tool is marked on the back with the wire size range. The ratchet assures full crimping of the terminal or splice. Once engaged, the ratchet WIRE STRIP LENGTH RANGE WIRE SIZE will not release until the handles have FULLY closed. RANGE (AWG) TERMINAL SPLICE The crimping dies bottom before the ratchet CAUTION 6.35-7.14 8.73-9.52 releases. This feature assures maximum electrical 12-10 .250-.281 .344-.375 and tensile performance of the crimp. DO NOT re-adjust the ratchet. Figure 2 2010 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 B408-1257 4. Check the insulation support by bending the Crimping Terminal wire back and forth once. The insulation barrel should retain grip on the wire insulation. If the wire pulls out, move the insulation crimping Crimping adjustment pin to the next tighter position (2) Bottom of Terminal Chamber and perform another test crimp. If the wire does Tongue Facing not pull out, the pin is properly adjusted and the Top of Tool Stripped Wire tool is ready for crimping. Do not use a tighter crimp than necessary. Adjust pin as necessary until the desired NOTE insulation grip is obtained. Crimp should hold wire insulation firmly without cutting into it. i Wire Barrel Against Tool 5. MAINTENANCE AND INSPECTION Locator Stop It is recommended that a maintenance and inspection program be performed periodically to ensure dependable and uniform terminations. Frequency of Crimping Splice inspection depends on: 1. The care, amount of use, and handling of the Crimping hand tool. Chamber 2. The presence of abnormal amounts of dust and dirt. Stripped Wire 3. The degree of operator skill. 4. Your own established standards. The hand tool is inspected before being shipped however, it is recommended that the tool be inspected immediately upon arrival at your facility to Wire Barrel ensure that the tool has not been damaged during Against Tool shipment. Due to the precision design, it is important Locator Stop that no parts of these tools be interchanged except those replacement parts listed in Section 6. 5.1. Daily Maintenance 1. Remove dust, moisture, and other Figure 3 contaminants with a clean brush, or a soft, lint-free cloth. DO NOT use objects that could damage the tool. 8. Inspect the crimped terminal or splice according to Figure 4. 2. Make certain that the retaining pins are in place and that they are secured with retaining rings. 4. INSULATION CRIMPING ADJUSTMENT 3. All pins, pivot points, and bearing surfaces The insulation barrel section of the crimping chamber should be protected with a thin coat of any good of the tool has three positions to adjust the wire SAE 20 motor oil. DO NOT oil excessively. insulation grip: 1-Tight, 2-Medium, and 3-Loose. To determine the proper insulation crimp setting, 4. When the tool is not in use, keep handles proceed as follows: closed to prevent objects from becoming lodged in the crimping dies. Store the tool in a clean, dry 1. Insert the insulation crimping adjustment pin area. into Position 3 as shown in Figure 1. 2. Position a terminal or splice into the crimping 5.2. Lubrication dies as described in Section 3, CRIMPING Lubricate all pins, pivot points, and bearing surfaces PROCEDURE. with SAE 20 motor oil as follows: 3. Insert an UNSTRIPPED wire into ONLY the Tools used in daily productionlubricate daily insulation barrel of the terminal or splice. Crimp Tools used daily (occasional)lubricate weekly the terminal or splice and remove it from the Tools used weeklylubricate monthly crimping dies. 2 of 6 Rev A