Straight Action Hand Tool for Dynamic D-3 (S), D-3
Contents
1. Instruction Sheet 411 5626 Ditmensions on this sheet are in metric units U S c2. B 1 6 2 TE C FEig 6 1
3. damage in shipment new tools should be inspected when received in your plant Tools should be inspected 1 at east once a month Frequency Of inspection is depend 2 uporn 3 1 The care amount of use and handling of the tool 4 2 The type and size of the products crimped 3 The degree of operator skill do The presence of abnorimal amounts of dusts and dirt Your own established standards 4 1 4 1 Daily IMaintenance 1 Hand tool shouid be immersed handles partialty 1 ciosed in a reiiable commercial degreasing B 2 compound to remove accumulat
4. TE Connectivity Ltd Other products logos and company names might be trademarks of their respective OwnerS PROPER USE GUIDELINES Cumulatve Trauma Disorders can result from the Drolonged use of manually powered hand tools TE hand tools are intended for occasional use and low volume applications E offers a wide selection of powered applicaton equipment for extended use production operations CERTT CRIMP Rachet CERTT CRIMP Rachet Anvils Movable Dies Crimpers Fixed Dies 1 INTRODUCTION This instruction sheet covers theuseof TE Hand Crimping Tool 919600 1 919601 1 and 919602 1 which crimp AMP Dynamic D 3 loose piece tab and receptacle contacts listed in Fig 1 READ THIS INSTRUCTION MANUAL CAREFULLY BEFORE USING THE HAND TOOL 1 of 7 LOC B TE connectivity 2 8 2 2
5. 1 2 3 Fjg 4 4 5 6
6. or if the clearance between the bottorning surfaces is 0 025mm or ess c If the 0 025mm shim stock can be inserted 4 completely between the bottoming surfaces of the 0 025mm wire barrel crirnp dies the dies are considered as not bottoming Contact your local TE representative 0 025mm 6 Rev 6 of 7 connectivity 4 3 a b fig 1 cc
7. 7 Instruction Sheet 411 5626 3 CRIMPING PROCEDURE3 CRIMPING PROCEDURE Refer to Fig 2 and select wire of the specified size and insulation diameter Strip the wire to the length indicated No not cut or nick the wire strands Select an applicable loose piece contact and identify the appropriate crimp section Proceed as follows 1 Hoid tool so that BACK wire side faces you 2 Open he dies by squeezing tool handies together until CERTI CRIMP ratchet release 3 Insert contact insulation barrel from the FRONT side of he tool into the crimping chamber Position the contact on the crimpers so that the locator wire stop enters the contact locator slot 4 Holding the contact in place squeezing the tool handles together just enough to hold the contact in the crimping chamber Do NOT deform insulation barrel or wire barrel NOTE Do NOT deform the contaact insulation barrel or wire batrrel 9 Insert stripped wire through locator and into the contact wire barrel until insulation butts against locator wire stop 6 Hoiding the wire in place squeeze tool handles together until CERTI CRIMP ratchet releases 7 Allow tool handles to open FULLY and remove crimped contact from tool Locator A Good position Crimper
8. SAENo 20 d 5 Fig 5 1045 3 1045 9 Part No Descriptions Q ty Ring Retaing Instruction Sheet 411 5626 4 3 Maintenance of Hand Tool When not in use keep the tool in a clean dark place For keeping reliable performance of the tool care mast 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 cnmping terminals of the sizes other than instructed as shown Pi
9. 2 3 3 Fig 6 Fig 6 5 408 7424 Rev Instruction Sheet 411 5626 4 2 Periodic Inspection A Lubrication Lubricate all pins pivots points and bearing surfaces with a good grade S A E 20 motor oil as follows Tools used in daily production Lubricate daily Tools used in daily occasional Lubricate weekly QTools used in daily weekiy Lubricate monthly When excessive oil from tool particularly from crimping area Oil iransferred from the crimping area onto characieristics of an aDplication B Visual Inspection 1 Close tool handles until ratchet releases and then allow them to open freely Jf they do not open quickly and fully the spring is defective and must be reDlaced or repaired Return the too to TE for revaluation and repair 2 jnspect the head for worn c
10. TCSP 919602 1 25 5228 19 182 so5 Fig 6 D D CERTI CRIMP Ratchet Inspection TE The CERTI CRIMP ratchet feature on hand tools should be checked to make sure certain that the ratchet does not release prematarely allowing dies to open before they have fully bottomed 0 025mm To check ratchet feature a Make a test crimping a properly stripped 8 AWG wire and a terminal When this crimp is made 1 Squeeze handles until the ratchet is free however DO NOT RELAX PRESSURE ON TOOL 2 3 HANDLES b Bottoming is satisfactory if bottoming surfaces of the 3 wire barrel crimp dies make contact with each other
11. JFL LT Ainvil 8 Bad position Ftg 4 Rev 3 Of _ Instruction Sheet a _ TE 411 5626 connectivity Back of tool Wire side Back of tool Contact side Crimp symbol Wire size Contact support 2 6 Contact D U 4 Stripped Wire 1 0 Contact senies N Wire barrel Wire slot in iocator Contact series Locator siot In contact TooI No 7 LocatorInsulation Stop 1 gt Fig 9 4 J 4 MAINTENANCE INSPECTION TE reconnmends that a maintenance program be performed periodically to ensure dependable and 1 uniform termination Since there is a possibility of tool
12. 411 5626 22 JAN 2014 Rev E ee Instruction Sheet Straight Action Hand Tool for Dynamic D 3 S D 3 M D 3 L contacts D 3 S D 3 M D 3 L TOOL P N 919600 1 919601 1 919602 1 TE TE Front Side of Tool Crimping Chambers Figz1 AMP D 3 919600 1 919601 1 919602 1 2014 Tyco Electronics Japan G K Trademark a TE Connectivity Ltd Company All Rights Reserved TE logo is a trademark Contact Number Applicable Contact Too Number Series Size Receptacle 919600 D 3 8 175216 7527 919601 1 D 3 M 175217 18288 919602 1 D 3 L 175218 29 Fig 1
13. ed 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 3 2 Make certain that the retaining pins are in place and SAE 20 that they are secured with retaining rings 3 Ail pins pivot points and bearing surfaces should 4 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 obfects from beconning lodged in the crimping dies Store the tool in a clean dry area Rev E 4 of 7 connectivity 4 2 A SAE 20
14. g 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 forelgn Inatters from fhe tool with the nse of soft lint free cloth wiDing of gently After use wipe the die surfaces and close the handles for preventing foreign inatters from entering into the die S REPLACEMENT AND REPAIR The parts listed in Fig 9 are customer reDiaceable A complete inventory can be stocked and controlled to prevent lost time when replacernent of parts is necessary Parts other than listed should be replaced by TE to ensure quality and reliability of the tool Order replacement parts through your TE representative Send the tool with a written description of the problem to your TE representative Ring Retaing Fig 7 This TE controlled document is subject to change For latest revision call local TE representative Rev 7 of 7
15. racked or broken area Jf damaged is evident return the tool to TE for revaluation and reDar C Crimp Height Inspeciion This inspection required the use of a modified crimp height comparator with a modified anvil as shown in Fig 6 1 Refer to Fig 3 and select a contact and a wire maximum size for each crimp section listed in the chart 2 Refer to Section 3 CRIMPING PROCURE and crimp contact accordingiY 3 Using a crimp height comparator measure the wire barrel crimp height as shown in Fig 6 If the crimp height conforms to that height the tool is considered dimensionally correct If not the tool must be returned to AMP for evaluation and repair See Secton 5 REPLACEMENT AND REPAIR For additional informaHon concerning the use of the crimp height comparator refer to TE Instruction sheet 408 7424 5 Of Instruction Sheet TE 411 5626 connectivity Position point on center Of wire barrel opposite Crimp Height H mm Ins Dia mi mm Wire Banel Insulation Barrel 919600 1 D 3 S SM Ln EE 2 45 919601 1 D 3 M Wire Gi Tool Number Senes Size Symbol Te olZ8 Lg loapcoss i
16. ustormary equivalents in backets 2 DESCRIPTION The tool features two fixed dies crirmpes two movable dies anvils a contact support a locator insulation stop and a CRERI CRIMP Ratchet The FRONT side of the tool into which the contact is inserted has the tool number marked on it The locator wire stop positions the contact between the dies and aids in locating the wire in Iocator siot The ejector pulls the locator down and ejects the crimped conatct whern the tool handies are fully closed The CERTI CRIMP Ratchet assures dull crimping of the contact Once it engages the handles cannot be opened unless the handles are closed to the bottom where the correct crinnping is achieved The crimpings dies bottom before the CERTI CRIMP ratchet releases This design feature assures maXiunumt dlectrical and tensile performance of the crimp DO NOT re adjust the rachet mm Wire Stripped Leng 3 8 Rev Fig 2 2 Of 7 TE connectivity Fig 2
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