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.
CERTI-CRIMP* Hand
Crimping Tool Ratchet
Control
Color Code for PIDG* and
PLASTI-GRIP* Products
Wire Size Range
Stamped Here
Color Code for
Sealed Splices
HAND CRIMPING TOOL PART NUMBERS
Insulation Crimp Adjustment
Pins in No. 3 Position
46121
47304
47386
47386-5
47387
47907-1
48518-2
69151-1
69454
169485
Figure 1
1. INTRODUCTION
This instruction sheet covers the Hand Crimping Tools
listed in Figure 1, which are used to crimp the
terminal types listed in Figure 2.
NOTE
Dimensions on this sheet are in millimeters
[with inch-equivalent dimensions in brackets].
Figures and illustrations are for identification only
and are not drawn to scale.
connectors to be applied, as listed in Figure 3. The
crimping tools may show more than one color code.
Check Figure 3 to be sure that the correct tool/
connector combination is being used.
For example, tool 47386 can be used to apply PIDG
terminals and splices with a yellow color code, as well
as spare wire caps with a red color code.
Figure 3 lists the number of dots (or rib) that appear
embossed on a crimped item when the connector is
crimped in the correct tooling.
The CERTI–CRIMP hand crimping tool ratchet control
ensures full crimping of terminals and splices. Once
engaged, the ratchet will not release until the tool
handles have been FULLY closed.
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
i
Reasons for reissue are provided in Section 9,
REVISION SUMMARY.
2. DESCRIPTION
(Figure 1)
The handles and label (if applicable) of the crimping
tools are color–coded to match the color coding of the
E
2007 Tyco Electronics Corporation, Harrisburg, PA
TOOLING ASSISTANCE CENTER 1-800-722-1111
PRODUCT INFORMATION 1-800-522-6752
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
1
of 10
LOC B
www.tycoelectronics.com
*Trademark. Other products, logos, and company names used are the property of their respective owners.
Hand Crimping Tools
CONNECTOR
TYPE
PIDG Terminals and
Splices
PIDG Insulation
Restricting Nylon Termi
nals
PIDG Radiation
Resistant Terminals
and Splices
PIDG FASTON*
Receptacles,
Part Nos 641321-1
(.187 Series) and
641324-1 (.110 Series)
PLASTI-GRIP
Terminals
PLASTI-GRIP
Butt Splices
Spare Wire Caps
Solid or Stranded
Copper
Solid or Stranded
Copper
Stranded Copper
Stranded Copper
26-24
Stranded Copper
27-14
Stranded Copper
26-14
408-1559
5. Insert properly stripped wire(s) into the terminal
or splice, as shown in Figure 4 or Figure 5.
CAUTION
Do NOT allow wire insulation to enter the
terminal or splice wire barrel.
WIRE
TYPE
Solid or Stranded
Copper
WIRE SIZE
[AWG]
30-14
!
6. Complete the crimp by closing the tool handles
until the ratchet releases.
7. Release the tool handles, allow the handles to
open fully, and remove the crimped terminal or
splice.
8. To crimp the other half of a splice, re–position
the uncrimped half of the splice in the tool as
shown in Figure 5. Follow the procedure used to
crimp the first splice half.
9. Refer to Section 4 and Figure 7 for terminal and
splice crimp inspection procedure.
22-14
26-22
3.2. For Spare Wire Caps
1. Strip the wire to the dimensions provided in
Figure 3.
CAUTION
Do NOT use wire with nicked or missing
conductors.
22-14
Figure 2
CAUTION
The crimping areas bottom before the crimping
tool ratchet releases. This is a design feature that
assures maximum tensile performance of the
crimp. Do NOT re-adjust the ratchet.
!
!
NOTE
Make sure that the color coding on the spare wire
cap and the tool match.
3. CRIMPING PROCEDURE
NOTE
Refer to Section 5 for information on the
insulation crimp adjustment.
i
2. Place the crimping tool’s insulation adjustment
pins in the No. 3 position.
3. Close the tool handles until the crimping jaws
partially close, but leave enough space for the cap
to be inserted between the dies.
4. Raise the locator so that the end of the cap
rests against the recessed surface of the locator,
as shown in Figure 6.
5. Close the tool handles until the cap is held firmly
in place. Do NOT deform the cap wire barrel.
6. Insert the properly stripped wire into the cap
until the wire bottoms.
7. Hold the wire in position and complete the crimp
by closing the tool handles until the ratchet
releases.
8. Release the tool handles, allow the handles to
open fully, and remove the crimped spare wire cap.
9. Refer to Section 4 and Figure 7 for spare wire
cap crimp inspection procedure.
i
3.1. For PIDG and PLASTI-GRIP Terminals and Splices
1. Strip the wire to the dimension provided in
Figure 3, being careful to avoid nicking or
damaging the conductor(s).
CAUTION
Do NOT use wire with nicked or missing
conductors.
!
2. Open the tool jaws by closing the tool handles
until the ratchet releases, then allow the handles to
open fully.
3. Place the terminal or splice in the dies as shown
in Figure 4 or Figure 5.
4. Close the tool handles until the terminal or splice
is held firmly in place. Do NOT deform the terminal
or splice wire barrel.
2
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Tyco Electronics Corporation
Rev
P
Hand Crimping Tools
408-1559
PLASTI-GRIP
Terminal
PIDG Butt Splice
Spare Wire Cap
Color Stripe on
Radiation Resistant
PIDG Type
Terminals
3 Equally Spaced Color
Stripes on Insulation
Restricting
PLASTI-GRIP
Butt Splice
FASTON
Receptacle
Color Stripe on
Radiation Resistant
TOOL NUMBER
AND
DESCRIPTION
WIRE
RANGE
(AWG)
TOOL
COLOR
AND DOT
CODE
PRODUCT
PRODUCT
INSULATION COLOR
CODE
WIRE STRIP LENGTH
TERMINALS
MIN.
MAX.
SPLICES
MIN.
MAX.
46121
169485
47304
D
47907-1
26-22
RED
AND
YELLOW
ONE DOT
YELLOW
BLUE AND
WHITE
TWO DOTS
PIDG TERMS. SPLICES
AND PLASTI-GRIP
BUTT SPLICES
PIDG TERMINALS
PIDG TERMS. & SPLICES
PIDG RADIATION
RESISTANT
TERMINALS & SPLICES
PIDG TERMINALS
MS 25036-143 THRU -147
YELLOW
4
[5/32]
4.8
[3/16]
4.4
[11/64]
5.2
[13/64]
24-20
NATURAL COLOR
TRANSLUCENT
(RADIATION RESISTANT
HAS WHITE STRIPE)
YELLOW
NATURAL COLOR
WITH YELLOW STRIPE
RED
(RADIATION
RESISTANT
NATURAL COLOR
TRANSLUCENT WIRED
STRIPE)
1.04-2.62 [16-14] BLUE
0.41-1.65 [20-16 HD]
GREEN (RADIATION
RESISTANT NATURAL
COLOR TRANSLUCENT
W/BLUE STRIPE)
4.8
[3/16]
5.6
[7/32]
5.6
[7/32]
6.4
[1/4]
47386
47386-5
26-24
47386
47386-5
69151-1
D
69454
YELLOW
AND
RED
ONE
DOT
PIDG RADIATION
RESISTANT TERMINALS
MS 7928/4-143 THRU -147
PIDG TERMS. & SPLICES
& PLASTI-GRIP
TERMINALS
5.2
[13/64]
6
[15/64]
22-16
RED
22-18
RED 1 DOT
AND 1 RIB
BLUE AND
GREEN
TWO
DOTS
47387
16-14
20-16HD
PIDG RADIATION
RESISTANT
TERMINALS
AND SPLICES
5.2
[13/64]
6
[15/64]
6.4
[1/4]
7.1
[9/32]
D
TIGHT INSULATION SUPPORT FOR WIRES WITH THIN WALL INSULATION
Figure 3 (cont’d)
Rev
P
Tyco Electronics Corporation
3
of 10
Hand Crimping Tools
408-1559
TOOL NUMBER
AND
DESCRIPTION
WIRE
RANGE
(AWG)
INSUL
DIA.
RANGE
mm [in.]
0.66-1.40
[.026-.055]
0.79-1.40
[.031-.055]
0.66-1.40
[.026-.055]
0.79-1.40
[.031-.055]
0.97-2.79
[.038-.055]
1.17-2.79
[.046-.110]
1.42-2.79
[.056-.110]
TOOL
COLOR
AND DOT
CODE
PIDG
INSULATION
RESTRICTING
NYLON
RED
AND
YELLOW
ONE DOT
TERMINALS
PIDG INSULATION
RESTRICTING
NYLON TERMINALS
MS 7928/1-1
THRU -10
PRODUCT
PRODUCT
INSULATION COLOR
CODE
WIRE STRIP
LENGTH
MIN.
MAX.
46121
169485
47304
26
YELLOW W/3
BLACK STRIPES
YELLOW W/3
BLUE STRIPES
YELLOW W/3
BLACK STRIPES
YELLOW W/3
BLUE STRIPES
RED W/3
4.8
[3/16]
5.6
[7/32]
D
24
26
47386
47386-5
24
22
47386
47386-5
69151-1
YELLOW AND RED
ONE DOT (TOOL NO.
69151-1
MOD. F IS CODED
RED ONLY)
PIDG
INSULATION
RESTRICTING
NYLON
TERMINALS
BLUE AND
GREEN
TWO DOTS
GREEN STRIPES
6.4
RED W/3
RED STRIPES
RED W/3
WHITE STRIPES
[1/4]
7.1
9/32
D
20
18
47387
16
1.60-3.30
[.063-.130]
BLUE W/3
BLUE STRIPES
D
TIGHT INSULATION SUPPORT FOR WIRES WITH THIN WALL INSULATION
TOOL NUMBER
AND
DESCRIPTION
WIRE
RANGE
(AWG)
TOOL
COLOR
AND DOT
CODE
YELLOW
22-18
AND RED
ONE DOT
BLUE AND
47387
16-14
GREEN
TWO DOTS
PRODUCT
PRODUCT
INSULATION COLOR
CODE
MIN.
WIRE STRIP
LENGTH
MAX.
47386
47386-5
SPARE WIRE CAP
NO. 328307
RED
8
[5/16]
8.7
[11/32]
SPARE WIRE CAP
NO. 328308
BLUE
TOOL NUMBER
AND
DESCRIPTION
WIRE
RANGE
(AWG)
PRODUCT
PRODUCT
INSULATION COLOR
CODE
WIRE STRIP
LENGTH
MIN.
MAX.
YELLOW
PIDG FASTON RECEPTACLES
48518-2
26-24
P/N 641321-1 (187 SERIES) AND P/N
641324-1 (110 SERIES)
NOTE: Color code is for
reference only. Always order correct
tool by supplying part numbers of
receptacles being crimped.
4.8
[3/16]
5.6
[7/32]
Figure 3 (end)
PIDG and PLASTI-GRIP Terminals
“C”
“B”
“C”
“B”
PIDG
Terminal
PIDG
Insulation
Restricting
Terminal
Terminal Wire Barrel
Butts Against Locator
End of Wire Conductor
“C”
“B”
Wire Stop
Butts Against Tool Locator
“C” “B”
(Note: Wire Butts Against
FASTON Receptacle Wire
Stop)
B" Equals
Wire Barrel
C" Equals
PIDG FASTON Receptacle
PLASTI-GRIP Terminal
Insulation
Figure 4
Barrel
4 of 10
Tyco Electronics Corporation
Rev P
Hand Crimping Tools
408-1559
Butt Splices
C"
B"
Spare Wire Caps
Insulation
Adjustment
Pins in No. 3
PIDG Splice
Window Indent
Locator
Position
PLASTI-GRIP Splice
Wire Stop
Wire Barrel
C"
B"
Window
Indent
Raise Locator so
that End of Cap
Rests Against
Recessed Surface
Wire Bottoms
in Cap
B" Equals Wire Barrel
C" Equals Insulation Barrel
Locator Seats in
Window Indent
of Splice
Insulation Crimp Adjustment
Pins in No. 3 Position
First
Crimp
Wire Stop
of Locator
Figure 6
1. Insert the insulation crimp adjustment pins into
the No. 3 position. Refer to Figure 1 or Figure 5.
2. Place the terminal or splice into the crimping
jaws as shown in Figure 4 or Figure 5.
3. Insert the UNSTRIPPED wire into ONLY the
insulation barrel (refer to Figure 4 or Figure 5)
portion of the terminal or splice.
4. Close the tool handles to complete the crimp.
5. Remove the crimped terminal or splice and
check the insulation crimp by bending the wire
back and forth once. The terminal or splice should
retain its grip on the wire insulation. If the wire pulls
out, set the insulation crimp adjustment pins to the
next higher position (No. 2).
6. Perform another crimp and repeat the
adjustment as necessary until the correct insulation
grip is attained. Do not use a tighter setting than
required.
Locator Seats in Window
Indent of Splice
End of Wire Conductor Butts
Against Splice Wire Stop
Second
Crimp
End of Wire Conductor Butts
Against Splice Wire Stop
CAUTION
Make sure that both insulation crimp adjustment
pins are in the same position.
Figure 5
4. CRIMP INSPECTION
!
5.2. For PLASTI-GRIP Terminals and Splices
NOTE
PLASTI-GRIP terminals and splices feature a
wire insulation support" only. The terminal or
Inspect crimped terminals and splices by checking the
features described in Figure 7. Terminals and splices
not meeting these conditions should NOT be used.
5. INSULATION CRIMP ADJUSTMENTS
5.1. For PIDG Terminals and Splices
NOTE
PIDG terminals and splices feature a wire
insulation grip."
i
splice insulation should ideally be in contact with
the wire insulation.
1. Set adjustment pins in position No. 3 for wire
having a large insulation diameter.
2. Set adjustment pins in position No. 2 for wire
having a medium insulation diameter.
3. Set adjustment pins in position No. 1 for wire
having a small insulation diameter.
CAUTION
Make sure that both insulation crimp adjustment
pins are in the same position.
i
The insulation crimping section of the hand tool has
three positions: 1 (tight), 2 (medium), and 3 (loose).
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