411-5796
Contents
1. 11 Instruction Sheet BY tent HAS 411 5796 5 MAINTENANCE When not in use keep the tool in a clean dark place For keeping reliable performance of the tool care must be taken to handle it moderately The following cautions should be observed a Do not throw nor drop the tool onto the floor nor strike things with tools b Avoid crimping terminals of the sizes other than instructed as shown Fig 1 c Apply a thin coat of machine oil of good quality which is equivalent to SAE 20 to the bearing surfaces but do not oil excessively d Remove dirt and greasy foreign matters from the tool with the use of soft lint free cloth wiping off gently After using wipe the die surfaces and close the handles for preventing foreign matters from entering into the die e For replacements of the parts other than noted in this instruction sheet take proper adjustment for this tool 6 REPAIR AND SPARE PARTS The parts listed in Fig 11 are customary replaceable Parts other than listed should replaced by TE to ensure quality and reliability of the tool Order replacement parts through TE representative For repair and adjustments send the tool with a written description of the problem to your TE representative This TE controlled document is subject to change For latest revision call local TE representative Rev B 9of92. MEZZO EAN HITS A SETS SS A i C i amaa PIDG RE SURF PIDG BUTT SPLICE Fig 7 a Rev B 5of9 i connectivity BY tent HAS ACCEPT 64 ORBLGRARELHATWS ORFTOBELFy be 7OMASHOHTANELY ORAHA IDI TFNUVYAA ANER CE LTD Qiks REE BBO P L CHB SRTWS ABAD VBA D PIPL ETU QREGH CHART ODS TRAIT NAF FSECHV TVS CHEB AA BE CA 2 THRU OVANEN Honk LT Tw Av Qi REDISY ATH TRV REI DEBERIAN TVS QORMTFTOB LF Y bY 7OHMASHEAE o TNA DATA XI MFTAX AMER RExLIO Wo Q RERH E SULTUEBFENTODO GAD SER BRIS FET Ao TU CER LT Vid QOBRFONVPM ELTVOS REA CORRE BE CAD TVS ATRAL bh ORLY LTA Rev B PG BUTT SPLICE PG REBUVERTF JAZZ kT WIRE STOP MITA x REO amp Fy F7 I7D0 Terminal Size Color for Terminal Numbers of Dots Instruction Sheet 411 5796 Fig 7 b ACCEPT O Insulation barrel is in firm contact with insulation Correct color code dote code and tool combination 3 Wire size is within wire range stamped under terminal tongue or center of splice Crimp not centered on wire barrel Terminal was not butted against locator Loe End of conductor is flush with or extends beyond end of terminal wire barrel End of conductor against wire stop of splice or at least flush with or extended slightly beyond wire barrel Wire insulation does not enter wire barrel No nicked or missing conductor strands O No exc
3. turn the tool to have the handle side farther so that the terminal will be positioned in the die easily 4 2 CRIMPING BUTT SPLICES There are two types of butt splices being available One type of them has a window recession in the middle while the other has not The former type can be crimped by the hand tool rightly as is since the locator engages on the recession However the one having no window recession in the middle cannot be done so since the locator interferes the splice from the correct seating in the die at the reversed position Therefore before crimping the butt splice of having no window recession remove locator by screwing the locator At this time be careful not to lose the spring set inside the locator housing The crimping without locator should be done with proper care to place splice in the correct position in the die so that the wire barrel and insulation barrel will be applied correctly for crimping respectively After completion of crimping the removed locator must replaced as it was before on the tool Refer to Fig 6 4 3 INSPECTION OF CRIMPED TERMENA LS When crimping of terminals is completed the crimped terminals should be inspected according to the acceptance criteria as shown Fig 7 a and 7 b Use only the terminals and splices that meet the conditions shown in ACCEPT column REJECT terminals and splices can be avoided through careful use of instructions 3of9 TE connect
4. 411 5796 f Instruction Sheet gt TE sanm 07 NOV 2013 Rev B AMP DOUBLE ACTION HAND TOOL FOR CRIMPING PG AND PIDG TERNINALS AMP PG PIDG MTI BAT POLL FIL TOOL P N 409775 1 409776 1 SHLAA OMESACAT SS PROPER USE GUIDELINES FATTE tE ELURBMEATSCARICES Cumulative Trauma Disorders can result from the EERScCEMHHO ESF TEOFRHLAMGRORA prolonged use of manually powered hand tools TE PPBOARATIKRBELTHEF TE tt Mt CHV BRODY ATOLLS ER T EMLTED ET OC BEROFEECSHOE TAE GIA CRA FSU 1 4Cr AMPY PVT 7 Y a FE 1 4 409775 1 409776 1 DAER EFgIKCRL CHS THIMFig 20K L 72 AMP PG PIDG i PROBE E TNRERAWG22 P61L6O4ARUAWGIOM 5 14D FADE DR EEBTALONDLOTCT fase HO HTC ES Bie FAL Locator m Ky pee gt o gt D Wiresize BEHA xis are marked here Z 24230 Fp y eL LTSS CERTI CRIMP H gt 740UYT Ratchet FE TI 38 BU ee et x E gt ASS PO ma f 13 HRA tf Fig l TSH Tool Numbers 0 25 1 6 H22 16 16 14 Fig 2 2013 Tyco Electronics Japan G K Trademark Fa aS hte x a TE Connectivity Ltd Company All Rights Reserved TE logo is a trademark Bet X WireSize BARRED amp 4 mm Insulation Stripping Length mm PG RUPIDGHF PGRUPIDGRStkRit AWG PG amp PIDG Terminals PG amp PIDG Butt Splices 5 2 6 0 6 4 7 1 5 2 6 0 6 4 7 1 PRA AMADA Other products logos and company names might be trademarks of their respective owners hand tools are intended for occasional use and low volume a
5. EEE BECLUOFE QESMSRO ARRE TTT oC FS ERY IA MOAI TVD FEMS SBSOMARRE ITO TFin ERY A ARBRE RBH AADK MECHA EARL Fig 8E ES AABMOTDN RAOMERLET Rev B Instruction Sheet 411 5796 4 4 INSULATION CRIMP ADJUSTMENT The insulation crimping section of the hand tool has three positions 1 Tight 2 Medium and 3 Loose 1 Insert insulation crimp adjustment pin No 3 position See Fig 1 2 Place terminal or splice in crimping jaws as shown Fig 2 3 Insert UNSTRIPPED wire into only the insulation barre portion of terminal Note Do not crimp the wire barrel when making test crimp Note Use position No 3 or No 2 on the hole of insulation crimp adjustment pin to prevent Crimp jaws from overloading 4 Make test crimp and remove crimped terminal or splice and check insulation gnp as follows Bend the wire back and forth again 5 If wire pulls out set insulation crimp adjustment pins in next tighter position NO 2 6 Make test crimp and repeat adjustment necessary until desired insulation grip is obtained Do not use a tighter setting than required Always make certain that both insulation crimp adjustment pins are in the same position 4 5 INSPECTION HAND TOOL 1 Inspect the too for missing parts or retaining rings If parts are missing or defective replace them Refer to Section 5 and 6 2 Inspect the die closure surfaces for flattened broken or chipped condition Aithough dies may gage within permis
6. LEITOR XPRZOnNBWE EH TAtBELELCRAE J SPM FER b c d le T DEL TO 4 2 RENERT RES DCB PRR AARNA SO LOLSRAHRIK Bo TUA 4 OMAT NE Fo MATS OL OSRETFOURCUT 7ABS AAT FOE ERRTF LEAR ASE CSET OT ECO FIR CHa LO F Sh LREL OL DISHED AKC Zo TOT 07 FRRAECREUCAPS OF F ORYENLT HO ALEA hb EA ESOC THE A OB E eR x ORES E RAC FA ANTE Li tntnoReceQrea a LHP OTKEW E A OBR bet eR h A RMOALAUST Pit SHRM ORLWHOMECA URN AF THVT E Fig 65H 4 3 0 TAR Fig 7 2 7 DONS TERADI ERE L CRS SH LERMENTWARHSBHLLT VCIRFSERFORAEBRLTTEN FEBS QUE PREF SHAVES EY Rev B 8 Instruction Sheet B TE HY thy sit HA E 411 5796 4 CRIMPING PROCEDURE 4 1 CRIMPING OF TERMINALS a To open the handle close them by squeezing until the CERTI CRIMP Ratchet releases When released the handles will open automatically b Place the terminal in the crimping die in the correct position as shown in Fig 5 a 5 b and 5 c c Close the handles lightly just enough to hold the terminal in place DO NOT CLOSE THE WIRE BARREL STRONGLY Terminal must not be deformed at this stage d Insert stripping wire end into the wire barrel of the terminal until it stops in the bottom e Holding the wire in place close the handles strongly as far as they go until the ratchet releases f Remove the wire crimped terminal from the tool This completes the crimping For crimping the terminal on the other end of the securely fixed wire
7. ed with CERTI CRIMP pressure regulation equipment Once it applies this equipment unless respectively suitable load is added a handle will not be released again The handles are color coded to indicate the proper terminals to be crimped The color code shown in Fig 4 corresponds with the color of insulation of the terminals to be applied Make sure the color code when you select the terminal and hand tool In KF JL 45 Handle Color Codes TRUE 0 25 1 6 409775 1 3 O TRIATLEET SMT ETORRA LR ei LC HEORS3CHBME Ro TIA EDESA RELFIg2CRTFEBOTIT HBO E EHC KOT POF ath meot LSKEPERLTESY BON LES LTIVIFECA RNE SECC TAS ET Rev B Be A X Wire Size NY ELERS Tool Number OoOo m AWG Handle Color Codes 22 16 409776 1 16 14 Fig 4 3 INSULATION STRIPPING Wire end must be stripping to the proper length prior to crimping Remove insulation as indicated in Fig 2 When stripping Never CUT nor NICK the conductor Care must be taken not to damage the wire 20f9 connectivity 4 FEDER 4 1 D a TECH PA DIV PEDRE TVS OCHBAY a tH Ki FF xy k NSEC MEME ET Fay bH NAMA LINY FINA tH ET b CRORGY a k Te RAT tleaya Tt ELl HRAT Figs a b c BH e AY FLR ACT wT ORR tE a CRACHOTBHEET LOL ERTETEK stTinhgts mT PBR ORME WETEA U RE TENERTE NERO AR EXRECBALETO e BRETOMMACRMALE y NP ECARTS FVERC ET f DAZ Y OMMLEBST AK BREE BAL CHS EPREBY ERA b
8. essive flush or extended insulation REJECT Wire insulation extruded Insulation crimp too tight on PIDG terminals and splices Wrong dot code color code combination Wire size is not within wire range stamped on terminal tongue or splice Crimp not centered on wire barret Terminal was not butted against locator GHEnd of conductor is not flush with or extending beyond end of terminal wire barrel Check for correct strip length Excessive flash or extruded insulation wrong tool terminal or splice combination or damaged dies Wire insulation entered wire barrel Nicked or missing conductor strands 6 of 9 gt TE connectivity BY tent HAS PDB L TS Broken corner Chipped edge ARKRBLTOSo Fig 8 EPEE ERORE BLUR MED LCR ROS ERE EFOREMALTTEN OAL Y ORNO3IEACEHO ZACH LT ORTINUERNTPIEAD a Ktey LTF V3 DFAMBTAFPU Y ZLTA EROS Y AVY IVAN NAESICRSE BEA ECHAL TES FR ETAL SGT l ERRER EVITA AB EY a BAHN PA9De BAKO WEE YORONO 3E ZNNo 2eHATZIL HHL ET OETA bEIVER LMF ROBT TD e E 4A YAL YBYAY Y TOMB CT OT TS Va ETA VE MB HITTER SY BREE eels IAA YAVY a YRTIT YRL HAESRHRTYSZUF CFT Ob LOA VAMFELMUBAT O WR ETORENC2OMBRELICA TF EV Ose DEER FTFA RE O BELWAYAV YaAa YA 9 TAG GNA ECHEN RL Fo TF SU LTZ L th bE EGO REI LAW CSE SU FPOA ALVA VS YY SOMBAED RCUMECL To TK SU 4 5 FHTSORE KOFMLAMARRESTIOTF SY OED UF Y VIR EY REEL WRWDPORLTF SU b LB RETO TE Y
9. ivity BY tent HAS PGRUPIDGR OLE Fig S a ARIS TRAPCRE APARTE Fig S b PGR EA DUVEMTOLS aC fH US 32 YH Unscrew and remove locator Instruction Sheet 411 5796 CRIMPING OF PG amp PIDG TERMINALS Se FO ANBREE E amp ry PILE MTS Front edge of the barrel must align the locator CRIMPING OF STRANDED PG amp PIDG SPLICE OF 4Z4EREHTS Front edge of the barrel must align the locator CRIMPING OF PG BUTT SPLICE PRO HABIT RAS E F BERT s OMA 5 L6mm Be HS Fig 5 c The end of splice protrudes 1 6mm beyond the edge of insulation crimping jaws ATA Ake LOHR CAUTION FOR CRIMPING BUTT SPLICE Mean E PRITIAAAO DADA TD A Ald ZOZERBMWRET PRIM YAAANCWAT IA Ald Fig 1licme ATOBA Y a TVYVVYFCHAULTERL HF Fig llOZAF VV EMMA LIC Fin EXECU THOT RE Fig 6 Rev B The butt splices with the center window can be crimped as is Locator engages The butt splices without the center window cannot be crimped unless first remove the locator after screwing screw shown in Fig 11 Be sure not to lose a Spring shown in Fig 1l when removing Replace it when finished as is Locator engages 4of 9 3 Instruction Sheet a Ssg TE ERA 411 5796 connectivity ACCEPT A DOT CODE 1 OR 2 DOTS MUST REJECT APPEAR ON ALL CRIMPED ITEMS RARER ko hr QELA Diot orini PIDG amp PLASTI GRIP TERMINALS AAA PIDG EU Ss Za PG Saf a a E Le rol Tat A
10. pplications TE offers a wide selection of powered application equipment for extended use production operations 1 INTRODUCTION AMP Double Action Hand Tools P N 409775 1 409776 1 shown in Fig 1 are designed to crimp AMP PG and PIDG terminals in Fig 2 onto stranded wire sizes No 22 through 16 AWG and No 16 through 14 AWG each other READ THIS INSTRUCTION ANUAL THOROUGHLY BEFORE USING THE HAND TOOL EAZ Crimp dies BRAS Insulation crimp height BASSE gt adjustment pins Color codes E TE Connectivity Ltd 4 7 1 of 9 LOC B i Fi connectivity BY tent HAS 2 HZ FIAK BPI BREEBTAS AALS RIEBTAS AAD ND So CHAKRA TH EG MmSmeerv t FT47VYT EARHRESD SHRSHCWET OF F7IESTAL SATE ELMEHET DRAE TO RBS SME CY SRB OAK MIGU CHIE SITS GAaeReL WET AY ENRI FF 4 ZV YH ERMA Eh WTWEFOC MIRACOBBNDPRPRDE Tir Cn GO ARTERIA SNA MORO VY Fic EL EAS NY PURKI Fg 4 BT k FBI SAT TS BOT ART OMRRROBL RALTVETH DO AREER OTP OERAVET Instruction Sheet 411 5796 2 DESCRIPTION These tools consist of a set of wire crimping jaws a set of insulation crimping jaws locator insulation crimp height adjust pins CERTI CRIMP Ratchet and handles The locator assists to set terminal to be place in correct position for crimping and insulation crimp height adjustment pins make proper crimp height setting of insulation crimping which depends on the size of wire insulation to crimped These handles are equipp
11. pth on die closure it is reject 3 Make sure that NO GO member must not pass through the die closure The end of gage may enter partially but must not pass through the die closure as shown in Fig 9 a b If NO GO member enters more than 1 thirds of depth on die closure it is reject FEE No Customer Gage No REBT Y No Gage No Wire FLAS Tool Part No 409776 937050 1 Rev B ESR UNO Gage No Insulation 409775 1 937048 1 937049 1 289903 025 289905 001 l 937051 1 BEER 4 Y No Old customer Gage No EMBA UNO RABE RES Y No Gage No Wire Gage No Insulation 289905 002 289903 001 8 of 9 TE connectivity 5 Ep THe RRS LEE SHANE RD ECROL Ee BF FSV a TRERUORO A APODO RERALAw Tr n b Fig MNAFRLZUADOGFEBALICO NEO EXSBUAO RS PIEBLEAVTFEN 0 BY ERY Eor AEO SAE No 20 F 37474 BAGBRME SLT PF db d TEDAN ei Cit tT UPPK DOGO ERTSZL eb EB SA ARP TABA DOZNI AY FIVER TENTTEN le DIAZ UIT OBRERO TAO BR SS TAORAET RET ZA OI ELMER ITT FEU 6 1E k 7 Fig ERLER MBART ZRITET THU AARRE EREET AOK TE OLS CELO ELV EBERT EV TEOWEH WA WRB MO CEKCALT Is HOZ SEMICBHLOWIFEW gar El O DS 963 5m0 1 ess eH 2 7206666 FRY COSA Stl bY RA BHSNCHY BEIMGCRBENET Bx a1 Wal ALTIRA EERE BA ANNE PSL oP ar no Bs oy Part No on 1 Ring Retaining 4 Ring Retaining Fig
12. sible limits worn or damaged die closure surfaces are objectionable and can affect the quality of the crimp Examples of possible damaged die closure surfaces are shown in Fig 8 i connectivity RESTO 7 VRE Wire barrel jaws bottomed but not under pressure AY EVER CEE RIOR REE BRAY a SRT Sal PIHSTANE CHETS GO member must pass completely through the die closure GO 0 F VUURLESI1A NABH SCL Instruction Sheet BY tent HAS 411 5796 SEE BEBO 7 TRE INSPECTION OF INSULATION RE DIE W A p NO GO member may enter partially but must not pass through the die closure NO GO ER 0 F YOS MIS AAKASRACE SA RRIK Tl bo Fig 9 a oo JRA Fig LOM MENA LYVeAV Fit ARK ko CHUCK Sy DE Y 3 DERMBPRS TSE CAY FIVER Edo OGO 5D F IEEA BCITAL COLE Fig a RU ODETFRENTODLJE ZEY FPADBZ ET RMERLUOF En GO 9 7 INTA AABOIBLFLIADARIO LIRA Cth DXENO GO GEE9 F YREBBKACEY CEPR ULTR Ss CML A Fig 9 a MU b CMENMTHAL IR ERMA YO O BICT YRAoTOM EV ECA TLEMALTES SFA NO GO LED P LVARYA AAR MIBWEAALEAREBCT Fig 9 b 4 6 INSULATION CRIMP ADJUSTMENT The tool should be inspected for correct die closure using the gage shown below 1 Squeeze the handle until the the edges of crimp jaw touch each other 2 Make sure that GO member must pass through the die closure shown in Fig 9 a b If GO member enters less than 2 thirds of de
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