Instruction Sheet CERTI- LOK* Hand Tool Frame Assembly

Instruction Sheet
408-- 6764
CERTI- LOK* Hand Tool
Frame Assembly 169400
07 APR 11
Rev D
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.
Stabilizer
Screw
Terminal
Stabilizer
NOTE
i
169406
Dimensions are in millimeters, with [inches in
brackets]. Figures and illustrations are for
reference only and are not drawn to scale.
Reasons for reissue of this sheet are provided in
Section 8, REVISION SUMMARY.
Locator
Screws
2. DESCRIPTION (Figure 1)
Locator/
Wire Stop
Ratchet
(Crimp Height)
Adjuster
The tool features a ratchet, ratchet release lever,
ratchet adjuster, locator/wire stop (hereafter referred
to as “locator”), and a terminal stabilizer (hereafter
referred to as “stabilizer”).
NOTE
Ratchet
Release
Lever
i
The stabilizer and locator are specific to each die
assembly used in the hand tool. When installing
a die assembly, the accompanying stabilizer and
locator must be installed on the tool for proper
functioning.
The ratchet release lever enables the tool operator to
open the partially closed tool handles when
necessary. During crimping, the locator correctly
positions wire and product (terminal, splice, or
contact), while the stabilizer (when used) prevents the
product from bending.
Figure 1
1. INTRODUCTION
CERTI--LOK Hand Tool Frame Assembly 169400 is
designed to accept crimping die assemblies which
crimp PIDG* and PLASTI--GRIP* terminals, PIDG
“window” splices, SOLISTRAND* terminals and
splices, and Multimate Type III(+). Refer to the
instructions packaged with the die sets for installation,
selection data, crimping procedure, and die
maintenance.
Documentation for the die sets includes the
instruction sheets listed in Figure 2.
The locator and product insulation are color--coded for
a given wire range as listed in the instructions
accompanying the die assembly. The product bearing
the color--coded insulation is crimped in the matching
color--coded crimping closure of the dies.
The ratchet adjuster is used to control the crimp
height of the product’s wire/insulation barrel when a
certain amount of wear has taken place on the ratchet
mechanism or other internal parts of the tool. See
Section 6, RATCHET INSPECTION AND
ADJUSTMENT.
DIE ASSEMBLY PART NUMBER
PRODUCT APPLIED
INSTRUCTION SHEET
169404
PIDG and PLASTI--GRIP terminals, and PIDG “window” splices
408--6765D
169409
SOLISTRAND terminals and splices
408--6801
169414
Multimate Type III(+) contacts
408--6858
D CAUTION: This die set (169404) is not designed for “red” and “yellow” FASTON* PIDG and PLASTI--GRIP receptacles. Attempts to use
these products in this die set will break the stabilizer.
Figure 2
E2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
*Trademark
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
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners.
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LOC B
ORIGINAL INSTRUCTIONS
PROPER USE GUIDELINES
408- 6764
Typical Dies
(Upper and Lower)
Blade-- Tip
of Screwdriver
View from
Rear of
Tool Head
Figure 3
3. LOCATOR, STABILIZER, AND DIE ASSEMBLY
INSTALLATION AND REMOVAL
When changing dies, first remove the locator and/or
stabilizer and then remove the existing dies before
installing the new dies by performing the following:
3.1. Locator (Figure 1)
4. CRIMPING PROCEDURE
Refer to the instructions packaged with the die
assemblies for product selection, wire strip lengths,
and correct positioning of product in the crimping
dies. Crimping procedure is as follows:
1. Squeeze tool handles until the ratchet releases
and allow them to open fully.
3.2. Stabilizer (Figure 1)
2. Place the product (terminal, splice, or contact)
into the lower die and squeeze the tool handles
together until the product is held by the dies but the
wire barrel is not deformed.
Remove the stabilizer by removing the stabilizer
screw with the hex wrench supplied with the tool kit.
3. Insert the stripped wire into the wire barrel of the
product.
3.3. Die Removal (Figure 3)
4. Squeeze the tool handles until the ratchet
releases to complete the crimp.
Loosen each of the locator screws (alternately, one
turn at a time) until the locator can be removed.
1. Remove upper die by positioning the blade tip of
a screwdriver behind and under the die. Push die
outward and apply a rocking action to the die while
pushing it out of the tool frame head. See inset,
Figure 3.
2. Remove lower die by pushing upwards with
thumb and prying out of tool frame using
screwdriver tip.
3.4. Die Insertion (Figure 3)
1. Slide each die into the tool frame head as
shown in Figure 3 until it “clicks” into position.
2. After installing dies, install locator and/ or
stabilizer (as required) according to the instructions
packaged with the die set.
2 of 3
NOTE
i
In the event that the product is improperly
positioned in the dies, or if the wrong die position
was selected, release the ratchet by squeezing
the tool handles slightly and turning the ratchet
release counterclockwise (see Figure 1). Allow
handles to open and then reposition product
properly.
5. MAINTENANCE/INSPECTION
5.1. Maintenance
1. Remove dust, moisture, and other contaminants
with a clean brush, or a clean, soft, lint--free cloth.
Do not use objects that could damage the tool.
2. Make certain that all screws are in place and
secured.
Rev D
408- 6764
3. Lubricate all pins, pivot points, and bearing
surfaces with a thin coat of SAE 20 motor oil.
4. When the tool is not in use, keep it in the tool kit
and store in a clean, dry area.
5.2. Inspection
5. To adjust the ratchet, refer to Figure 4 and
perform the following:
a. Remove the screw on the adjuster wheel
from each side of the tool head.
b. With pliers, grip the knob on the locator and
advance the wheel clockwise one notch.
Regular inspections should be performed to ensure
the quality and reliability of the tool. Though
recommendations call for at least one inspection a
month, the inspection frequency should be based
upon amount of use, working conditions, operator
training and skill, and established company
standards. Inspect the tool as follows:
Tool Head
(Locator Side)
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 that all screws are in place and
secured.
Locator
Screw
Notch
Knob
3. Close tool handles until ratchet releases, then
allow them to open freely. If they do not open
quickly and fully, the spring is defective.
4. Inspect the head assembly for worn or broken
components.
6. RATCHET INSPECTION AND ADJUSTMENT
NOTE
i
A die set must be installed in the tool for this
procedure.
Obtain a 0.025 mm [.001 in.]--thick shim that is
suitable for checking the clearance between the
bottoming surfaces of the crimping dies, and proceed
as follows:
1. Select a product and wire (maximum size)
appropriate for the dies.
2. Position the product and wire between the
crimping dies, according to Section 4, CRIMPING
PROCEDURE.
3. Squeeze the tool handles together until the
ratchet releases. Hold the tool handles in this
position, maintaining sufficient pressure to keep the
dies closed.
4. Check the clearance between the bottoming
surfaces of the crimping dies. If the clearance is
0.025 mm [.001 in.] or less, the ratchet is
satisfactory. If the clearance exceeds 0.025 mm
[.001 in.], the ratchet is out of adjustment and must
be adjusted.
Rev D
Wheel
Figure 4
c. Replace screws on adjuster wheel and repeat
Steps 1 through 4. Repeat ratchet adjustment if
necessary.
7. REPLACEMENT
Order replacement tools through your TE Connectivity
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 (38--35)
TYCO ELECTRONICS CORPORATION
P.O. BOX 3608
HARRISBURG, PA 17105--3608
For further replacement information, contact a
TE Representative at 1--800--526--5136.
8. REVISION SUMMARY
Since the previous release of this sheet, the following
changes were made:
S Updated document to corporate requirements
S New format
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