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ORIGINAL INSTRUCTIONS
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.
408-32129
The flip locator prevents the contact from bending during the crimping procedure.
The ratchet release lever enables the user to open the partially closed tool handles when necessary.
The ratchet is used to control the crimp height of the terminal’s wire barrel and ensures full crimping of the
terminal.
The ratchet is used to control the crimp height of the terminal’s wire barrel and ensures full crimping of the
terminal.
Wire Strip Length 2.9 to 3.9
[.114 to .153]
WIRE
SIZE
(AWG)
28-26
24
22-20
18
S
M
CRIMP
SECTION
(WIRE SIZE
MARKING)
28-26
24
22-20
18
CONTACT
1318108-1
1318112-1
1318107-1
1318111-1
HAND TOOL
2255143-1
2255144-1
Figure 2
3. CRIMPING PROCEDURE
Refer to the table in Figure 2 and ensure compatibility between the wire, contact, and crimping tool. Wire size
must be within the specified range for the contact. Strip the wire to the length indicated.
CAUTION
Do NOT cut or nick the wire strands.
The hand crimping tool must be the one designed for crimping the wire and contact. Identify the appropriate
crimp section (according to the wire size markings on the BACK of the tool).
Refer to Figure 3 and proceed as follows:
1. Hold tool so BACK (wire side) is facing you.
2. Make sure the ratchet is released by squeezing the tool handles and allowing them to open FULLY.
3. Open flip locator. Insert contact into the flip locator (make sure contact is inserted properly).
4. Close flip locator.
5. Pre-close the handles slightly, and insert the wire into the contact.
6. Close the handles until the automatic ratchet releases.
7. Open flip locator. Take wire with contact out of locator.
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408-32129
Flip Locator
Figure 3
4. TOOL CERTIFICATION
These instructions have been approved by TE Design, Production, and Quality Control Engineers to provide
documented maintenance and inspection procedures.
Through TE test laboratories and the inspection of production assembly, the procedures described herein have
been established to ensure quality and reliability of TE hand crimping tools.
5. INSPECTION PROCEDURES
5.1. Daily Maintenance
It is recommended that each operator of the tool be made aware of, and responsible for, the following four
steps of daily maintenance:
1. Remove dust, moisture, and other contaminants with a clean brush, or a soft lint-free cloth. Do NOT
use objects that could damage the tool.
2. Make sure the proper retaining pins are in place and secured with the proper retaining rings.
3. Make certain all pins, pivot points, and bearing surfaces are protected with a THIN coat of any good
SAE No. 20 motor oil. Do NOT oil excessively.
4. When the tool is not is use, keep the handles closed to prevent objects from becoming lodged in the
crimping dies and store the tool 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 tool and/or be supplied to supervisory personnel responsible for the tool. Through
recommendations call for at least one inspection a month, the inspection frequency should be based on the
amount of use, ambient working conditions, operator training and skill, and established company standards.
These inspections should be performed in the following sequence:
Visual Inspection
1. Remove all lubrication and accumulated film by immersing the tool (handles partially closed) in a
suitable commercial degreaser that will not affect paint or plastic material.
2. Make certain all retaining pins are in place and secured with retaining ring.
3. Close the tool handles until the ratchet releases, then allow handles to open freely. If they do not open
quickly and fully, return the tool to TE for evaluation and repair.
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408-32129
Inspect the head assembly with special emphasis on checking for worn, cracked, or broken die. If damage
to any part of the head assembly is evident, return the tool to TE for evaluation and repair.
Crimp Height Inspection
This inspection requires the use of a micrometer with a modified anvil as shown in Figure 4.
Proceed as follows:
Refer
to the table in Figure 4 and select a contact and a wire (maximum size) for each crimp section listed
in the table.
1. Refer to Section 3, CRIMPING PROCEDURE and crimp the contact(s) accordingly.
2. Using a crimp height comparator, measure the wire barrel height as shown in Figure 4. If the crimp
height conforms to that shown in the table, the tool is considered dimensionally correct. If not, return
the tool to TE for evaluation and repair.
TE does not market crimp height comparators. Refer to Instruction Sheet 408-7424 for detailed
information on obtaining and using a crimp height comparator.
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