TE Connectivity 1-45216-0 Manual de usuario

Crimp Head

Mounting Holes

Typical Closed-End Splice

Crimping Head for Use with

DAHT Assembly (Ref)

DAHT Adapter 

Assembly

Retract Button

Battery Powered

Hand Tool

Battery Lock

Battery

Cartridge

1725839-1

Quick-Release Pins

*Trademark

TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners.

1of 4

Instruction Sheet

TOOLING ASSISTANCE CENTER

1-800-722-1111



PRODUCT INFORMATION

1-800-522-6752

This controlled document is subject to change.

For latest revision and Regional Customer Service,

visit our website at www.te.com LOC B

408-10032

Closed-End Splice Crimping Heads 1-45216-0

and 1-45219-2 (For Use with Battery Powered

Double Action Hand Tool Kit) 05 DEC 11 Rev B

Figure 1

1. INTRODUCTION

Crimping Heads 1-45216-0 and 1-45219-2 are

designed to crimp closed-end splices onto solid or

stranded copper wire size 22-10 AWG using Battery

Powered Double Action Hand Tool Kit 1213804-[ ] .

Refer to Figure 1 for tool components and Figure 2 for

Closed-End Splice product.

NOTE

The crimping heads can also be used with the 626

Double Action Pneumatic Tool Adapter 1213563-1.



This instruction sheet provides recommended

procedures for wire preparation, crimping head

installation, crimping, and maintenance and

inspection. For information concerning tool setup and

operation, refer to Customer Manual 409-10056

packaged with the battery tool kit.

NOTE

Dimensions are in metric units with [inches in

brackets]. Figures and illustrations are for

reference only and are not drawn to scale.

Reasons for reissue are provided in Section 7,

REVISION SUMMARY.

2. DESCRIPTION

The crimping head consists of integral jaws which

close in an arc-like motion. After an operator locates

the terminal or splice between the crimping jaws and

inserts the stripped wire, the tool is activated to crimp

the terminal or splice to the wire.

TOOL PART

NUMBER

ANDCOLOR

CODE

TOOL

MARKING

WIRE

SIZE

RANGE

(AWG)

PART NUMBER/

SPLICE TYPE COLOR

CODE SPLICE

TYPE

WIRE

COMBINATION

CHART

DOCUMENT

STRIP LENGTH

MIN. MAX.

1-45216-0 18-16

ECV-ECN 22-14

34304 Vinyl Red VS 408-1394

8.38 [.330] 9.14 [.360]

35115 NYLON Trans ECN 408-1271

36964 Vinyl Purple VS 408-1394

2-328375-3 Vinyl Purple VS 408-1394

1-45219-2 18-10

ECV-ECN 22-10 35653 NYLON Trans ECN 408-1021 10.67 [.420] 11.43 [.450]

36965 Vinyl Purple VS 408-1029

321519 Vinyl Purple ECV 408-1002 14.22 [.560] 16.00 [.630]

NOTE: In cases where twisting conductors for minimum loading is required, ensure that strip length is maintained after twisting.

408-10032

2of 4

Rev B

Figure 2

3. HEAD INSTALLATION AND REMOVAL

NOTE

Crimping heads are coated with a preservative to

prevent rust and corrosion. Wipe this preservative

from the head, particularly from the crimping

surfaces.

3.1. Installation

DANGER

STOP

To avoid personal injury, be sure to exercise

extreme caution when handling the crimp tool.

Avoid accidentally depressing the trigger control

when installing or removing crimp heads.



DANGER

STOP

DONOToperatethebatterytoolwithouttheproper

crimping head installed. After crimping head is

installed,makesurethatthequickpinsareproperly

insertedtoavoidpersonalinjuryanddamage to the

tool.

1. Remove quick pins from the adapter assembly.

Refer to Figure 1.

2. Insert crimping head into the adapter assembly.

3. After the crimping head is properly aligned, insert

the quick pins through the two holes in the adapter

and through the holes in the crimp head.

NOTE

The quick pins will "snap" into position when they

are properly inserted.



3.2. Removal

DANGER

STOP

To avoid personal injury, ALWAYS disconnect the

battery from the tool before removing crimping

head.

Remove the quick pins from the crimping head; then

remove the crimping head from the tool holder.

4. CRIMPING PROCEDURES

DANGER

STOP

To avoid personal injury, ALWAYS keep fingers

clear of crimping jaws when operating the tool.

Never place anything within the crimping jaws

except TE terminals or splices.

1. Strip wires to dimensions shown in Figure 2. DO

NOT nick wire strand or use wires with nicked or

missing conductor strands.

2. Insert stripped wires into the splice barrel.

3. Locate the splice with the wires inserted into the

crimping dies as shown in Figure 3. the skirt of the

ECN (Nylon) splice should nest against the splice

ejector. The ends of the ECV or VS (Vinyl) splices

should rest against the end of the locator.

Types

ECV and VS

Type ECN

End of Vinyl Closed-End

Splice Rests Against

Locator

Skirt of NYLON



Closed-End Splice

Rests Against Ejector

Figure 3

408-10032

3of 4

Rev B

4. Depress the trigger to advance the moving ram.

This closes the crimp jaws in order to hold the

terminal in place. DO NOT deform the wire barrel.

5. Activate the tool to complete the crimp. The crimp

tool automatically returns to the first position of the

cycle when the crimp is complete. Remove the

splice from the head.

6. Refer to Section 5 and Figures 4 and 5 for crimp

inspection.

CAUTION

Damaged product should not be used. If a

damagedspliceisevident, itshouldbecut from the

wire and replaced. Do NOT re-terminate splices.

5. MAINTENANCE AND INSPECTION

DANGER

STOP

To avoid personal injury, ALWAYS disconnect the

battery from the tool before performing

maintenance or inspection.

TE recommends that a maintenance and inspection

program be performed periodically to ensure

dependable and uniform terminations. The crimping

head should be inspected once a month. Frequency of

inspection should be adjusted to suit your

requirements through experience. Frequency of

inspection depends on:

•The care, amount of use, and handling of the

crimping head.

•The type and size of the product crimped.

•The degree of operator skill.

•The presence of abnormal amounts of dust and

dirt.

•Your own established standards.

Each crimping head is thoroughly inspected before

packaging. Since there is the possibility of crimping

head damage during shipment, new crimping heads

should be inspected immediately upon arrival at your

facility.

5.1. Daily Maintenance

TE recommends that each operator be responsible for

the following steps of daily maintenance:

1. Remove dust, moisture, and other contaminants

with a clean, soft brush, or a lint-free cloth. Do NOT

use objects that could damage the head.

2. Make sure that all pins, rings, and other

components are in place and secure.

DANGER

STOP

To avoid personal injury and damage to the tool,

make sure quick pins are properly inserted.

3. Make certain all surfaces are protected with a thin

coat of any good SAE 20 motor oil. Do NOT oil

excessively.

4. When the head assembly is not in use, store it in

a clean dry, area.

5.2. Periodic Inspection

Regular inspections should be performed by quality

control personnel. A record of scheduled inspections

should remain with the crimping heads or be supplied

to supervisory personnel responsible for the crimping

heads. Though recommendations call for at least one

inspection a month, the frequency should be based on

amount of use, working conditions, operator training

and skill, and your established company policies.

These inspections should include a visual inspection

(Paragraph 5.3) and a crimping chamber inspection

(Paragraph 5.5).

5.3. Visual Inspection

1. Remove all lubrication and accumulated film by

immersing the crimping head in a suitable

commercial degreaser that will not affect paint or

plastic.

2. Make certain all components are in place. If

replacements are necessary, contact TE.

3. Check all bearing surfaces for wear. Replace

worn parts.

4. Inspect crimp areas for flattened, chipped, or

broken parts.

5.4. Lubrication

Lubricate all pins, pivot points, and bearing surfaces

with a high quality grease. TE recommends the use of

MOLYKOTE† grease, which is a commercially

available lubricant. Lubricate according to the

following schedule:

Head used in daily production - lubricate daily

Head used daily (occasional) - lubricate weekly

Head used weekly - lubricate monthly

Wipe excess grease from crimping head, particularly

from jaw closure areas. Grease transferred from jaw

closure area onto certain terminations may affect the

electrical characteristics of an application.

† MOLYKOTE is a trademark.

408-10032

4of 4

Rev B

5.5. Gaging the Crimping Chamber

This inspection requires the use of plug gages

conforming to the dimensions shown in Figure 4. TE

does not manufacture or market these gages.

DANGER

STOP

Disconnect the battery and remove crimping head

from tool before inspecting crimping chambers.



1. Remove oil and dirt from the jaw bottoming

surfaces and plug gage element surfaces.

2. Close wire barrel crimping jaws until they are

bottomed, but not under pressure.

3. Align GO element with wire barrel crimping

section. Push element straight into crimping

chamber without using force. The GO element must

pass completely through the chamber as shown in

Figure 5.

4. Align the NO-GO element and try to insert it into

the chamber. The element may start entry, but it

must not pass completely through the crimping

chamber.

TOOL NUMBER GAGE ELEMENT DIAMETER

GO NO-GO

1-45216-0 2.311 - 2.319

[.0910 - .0913] 2.461 - 2.464

[.0969 - .0970]

1-45219-2 3.124 - 3.132

[.1230 - .1233] 3.274 - 3.277

[.1289 - .1290]

Figure 4

If the crimping chamber passes the gage inspection,

the crimping head is considered dimensionally correct

and should be lubricated with a THIN coat of any good

SAE 20 motor oil. If the crimping chamber does not

conform to the plug gage conditions, contact your local

TE representative or refer to Section 6,

REPLACEMENT AND REPAIR.

For additional information about the use of a plug

gage, see Instruction Sheet 408-7424.

Inspection of Crimping

Dies with Plug Gage JawsBottomedButNot

Under Pressure

GOmembermustpasscompletelythroughthecrimpingsurface.

NO-GO member may enter partially, but must not pass

completely through the length of the crimping surface.

Figure 5

6. REPLACEMENT AND REPAIR

Order replacement heads through your TE

representative, or call 1-800-526-5142, or send a

facsimile of your purchase order to 1-717-986-7605, or

write to:

CUSTOMER SERVICE (038-035)

TYCO ELECTRONICS CORPORATION

PO BOX 3608

HARRISBURG PA 17105-3608

For further repair and replacement information, call the

TE Tooling Assistance Center at the number at the

bottom of page 1.

7. REVISION SUMMARY

Revisions to this instruction sheet include:

•Changed company name and logo

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