TE Connectivity 607949-1 Bedienungsanleitung

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*Trademark. Other products, logos, and company names might betrademarks of their respective owners.

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.tycoelectronics.com

1of 5

LOC B

Hand Crimping Tool 607949-1

(For Insulated Heat Shrink Splices) 408-4087

23 JAN 12 Rev C

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.

Figure 1

1. INTRODUCTION

Hand Crimping Tool 607949-1, a three-cavity, two-jaw

crimping tool is designed to crimp the conductor

portion of insulated heat-shrink splices in the following

range of wire sizes:

•RED - Wire sizes 22 to 16 AWG, outer cavity.

•BLUE - Wire sizes 16 to 14 AWG, middle cavity.

•YELLOW - Wire sizes 12 to 10 AWG, inner cavity.

Read these instructions thoroughly before crimping

any contacts.

All dimensions on this document are in metric units

[withU.S.customaryunitsinbrackets]. Illustrations

and figures are for reference only and are not

drawn to scale

Reasons for reissue of this instruction sheet are

provided in Section 7, REVISION SUMMARY.

2. DESCRIPTION

The tool features crimper and anvil jaws, color coded

wire size marking, spring actuated handles with

cushioned hand grips, and a ratchet mechanism which

will not release until the tool handles have been

FULLY closed, thus ensuring a reliable crimp

termination.

If the ratchet should need adjustment, refer to

Paragraph 4.2.C.

3. CRIMPING PROCEDURES (Figure 2)

1. Close the tool handles until the ratchet releases,

then allow the tool handles to open fully.

2. Select the appropriate cavity for the splice being

crimped.

3. Align conductor portion of terminal in the cavity

as shown in Figure 2.

4. Close the tool carefully until the jaws grip the

terminal lightly and hold it in place without distortion.

5. Insert a properly stripped wire (Figure 2) into the

terminal until it bottoms.

6. To crimp, hold the wire in place, squeeze the

handles until the ratchet releases, allow the jaws to

open FULLY, and remove crimped splice.

4. MAINTENANCE/INSPECTION

4.1. Daily Maintenance

Maintenance and inspection should be performed

regularly. Tool should be wiped clean with special

emphasis on the crimping cavities.

Front of

Tool

Crimper

Jaws

Ratchet

Anvil

Jaws

Cushioned

Hand Grips

NOTE

ORIGINAL INSTRUCTIONS

408-4087

2of 5

Rev C

Figure 2

4.2. Periodic Inspection

Hand tool should be immersed (handles partially

closed) in a reliable commercial degreasing

compound which does not attack paint or plastic

material, to remove accumulated dirt, grease, and

foreign matter. The tool should be re-lubricated after

cleaning. The tool may then be wiped clean with a

soft, lint-free cloth. Do NOT use hard or abrasive

objects that could damage the tool. Ensure that the

tool conforms to the information in Figure 6.

A. Lubrication

Lubricate all pins, pivot points, and bearing surfaces

with SAE† 20 motor oil as follows:

•Tools used in daily production - lubricate daily

•Tools used daily (occasionally) - lubricate weekly

•Tools used weekly - lubricate monthly

Wipe excess oil from tool, particularly from crimping

area. Oil transferred from the crimping area onto

certain terminations may affect the electrical

characteristics of an application.

B. Visual Inspection

1. Close tool handles until ratchet releases and then

allow them to open freely. If they do not open

quickly and fully, the tool is defective and must be

replaced. See Section 6, REPLACEMENT.

2. Inspect jaws for worn, cracked, or broken areas.

If damage is evident, the toolmust be replaced. See

Section 6, REPLACEMENT.

C. Gaging the Crimping Chamber

This inspection requires the use of plug gages

conforming to the dimensions in Figure 3.

TE Connectivity does not manufacture or market these

gages. To gage the crimping chamber, proceed as

follows:

1. Remove traces of oil or dirt from crimping

chamber and plug gages.

2. Close the tool handles until it is evident that the

jaws have bottomed, then HOLD in this position. Do

NOT force the jaws beyond initial contact.

3. Align the GO element with the crimping chamber.

Push element straight into the crimping chamber

without using force. The GO element must pass

completely through. Refer to Figure 3.

4. Now align the NO-GO element and try to insert it

straight into the same crimping chamber. The NO-

GO element may start entry but must not pass

completely through as shown in Figure 3.

If the crimping chamber conforms to the gage

inspection, it is considered dimensionally correct and

should be lubricated with a THIN coat of any good

SAE 20 motor oil. If not, the tool must be replaced.

See Section 6, REPLACEMENT.

D. Ratchet Inspection

Obtain a .025 mm [.001 in.] shim that is suitable for

checking the clearance between the bottoming

surfaces of the crimping jaws. (See Figure 3).

Proceed as follows:

1. Select a contact and wire (maximum size) for the

tool (see Figure 3).

Conductor

Crimp

Area

Stripped Wire

Crimping

Jaws

L = 7.14 [.281] 22-16-14 AWG

L= 9.53 [.375] 12-10 AWG Splice

† SAE is a trademark.

408-4087

3of 5

Rev C

Figure 3

2. Position the contact and wire between the

crimping jaws, according to Section 3, CRIMPING

PROCEDURE (Steps 1 through 6). Holding the wire

in place, squeeze the tool handles together until the

ratchet releases. Hold the tool handles in this

position, maintaining just enough pressure to keep

the jaws closed.

3. Check the clearance between the bottoming

surfaces of the crimping jaws. If the clearance is

025 mm [.001 in.], or less, the ratchet is satisfactory.

If clearance exceeds .025 mm [.001 in.] the ratchet

is out of adjustment and must be adjusted (see

Section 5, TOOL ADJUSTMENT).

E. Tool Force Values

1. Apply force as shown until ratchet releases. The

force at a point 44.45 mm [1.75 in.] from handle

ends should be 35 to 45 pounds. See Figure 4.

Figure 4

25.4 [1.00]

Min Typ

“GO” Element Must

Pass Completely

Through the Section

“”NO-GO”ElementMay

EnterPartiallyButMust

Not Pass Completely

Through the Section

Bottoming Surfaces

Gage dimension “G” with the handles closed to ratchet stop.

GO Element

NO-GO Element

NEST DIMENSION “G”

WIRE SIZE (AWG) GO DIAMETER NO-GO-DIAMETER

22 - 16 2.29 [.090] 2.39 [.094]

16 - 14 2.65 [.1045] 2.78 [.1095]

12 - 10 3.68 [.145] 3.84 [.151]

44.45

[1.75]

Apply Force as Shown Until Ratchet Releases.

The force at Point 44.45 mm [1.75 in.] from the

Handle Ends Should Be 1.88-2.42 kg [35-45 lb.]

408-4087

4of 5

Rev C

Figure 5

2. To adjust the tool to obtain the proper force

values, open the handles and loosen the locknut

with Spanner Wrench 127298-1 (availablefrom TE).

See Section 5, TOOL ADJUSTMENT.

3. On the opposite side of the tool, turn the eccentric

stud CLOCKWISE to increase the handle load; or

COUNTERCLOCKWISE to decrease the handle

load. Tighten locknut, measure force and continue

to adjust if necessary.

5. TOOL ADJUSTMENT (Figure 5)

If the ratchet must be adjusted, use the spanner

wrench, and proceed as follows:

1. Loosen the ratchet locknut on the back of the tool

(side with wire size markings).

2. Check bottoming of tool jaws according to

Paragraph 4.2.C. Turn screw on front of tool

CLOCKWISE to tighten ratchet (must reduce crimp

height) or COUNTERCLOCKWISE to loosen

ratchet (may increase crimp height).

3. When tool jaws bottom properly, retighten the nut.

Itmaybenecessarytoholdtheratchetscrewwhile

securing the ratchet locknut.

6. REPLACEMENT

This tool is not repairable and a spare should be

stocked to prevent lost timewhen replacement of tools

is necessary. Order replacement tools through your

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

7. REVISION SUMMARY

•Updated document to corporate requirements

•Removed “AMPLIVERSAL” in all instances in

document

Ratchet Locknut

Adjustment Screw

Clockwise to tighten;

Counterclockwise to Loosen

NOTE

408-4087

5of 5

Rev C

Figure 6

4.95 [.195] Weight: 340 kg [.75 lb.]

228.6 [9.00]

57.15 [2.25]

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