AMP* Double Action Hand Tool for PIDG FASTON
Contents
1. Fig 4t an FO IKK VRT Ve HAL AFO FIX HE CREST oT RAL LAY EFVRAEFZF ay bARRT SAE CHL INY FLAEN BAX ET PAAR FE M4T47 VeAM Ces tHE ZORRO Bk AAS ABUT AVS PAU 2274 ARMOR EE KATA ryk CmceaemNes EPTUT AABCHL LIF CP 5 GO G80 F VYRHLUTAE Fig 6 Big TP et GO 0 7 Lite lt SRILA ZED RO ARIZ EEA FE COMMHA AA 802 30 LMA SRWE XARRAT 3 RICNO GO EEU F VERAAKMT 4y NO GO OED SDi SATAY ETA BOR TIRI EEA ZERA ZAABOI LELASZBREKAK TT Instruction Sheet 411 5860 4 Close tool handles until ratchet releases and then allow them to open freely If they do not open quickly and fully the spring is defective and must be replaced or repaired Return the tool to your local TE for revaluation and repair C Crimping Die Gaging Inspection This inspection requires the use of plug gages conforming to dimensions To gage the crimping area s refer to Fig 4 and proceed as follows 1 Close the crimping area by squeezing the tool handles together until the crimping dies have bottomed and then HOLD the too handles in this position Do not force the dies beyond initial contact 2 Align the GO element of the gage with the appropriate crimping area to be checked Refer to Fig 6 And Push the element carefully without forcing The GO member must pass completely through the die closure If GO member enters less than 2 thirds of depth on die closure it is reject 3 Align the GO element of the gage with the ap2. HOT UPET oA ERTALL Bll EBA A ABC CAMASHWEDR NY FILA PAU Tita T PKL LRERUEO Nyv RbdK UT REO EHEJ 4 OER LATT Fig IR L 22 Db Ova amp H LL 7 0 UROL AL Cit amp ES LOTT 52 Ae A ras tH CO CyY theo BEM E lt UTP X13 ASAE 4 OF Ae EAU FEE IME CHE L TP S43 Og HARBIN EAL THI SRE fe AE OHARTRERALTHSRA mia OA IAREBALTOSRA HEW RAO Mo CHE RERA AROMAS UTS CHAR BEER EFTLRBHOET B ERE lL FT RAT IAF y JPN KZL Z OAU amp BU CRL HEALT PPE FRRAUTHALY 2 SCOR MAY AIP HS TCL eH YD TRA MmORRR MEBs Z Him OFig 7e BleL TP KL 3 Hao 4 ABA AIK CBRE A OUR A ERE DPRAL TEE Rev B Instruction Sheet 411 5860 All tools are inspected before being shipped However Since there is a possibility of tool damage in shipment new tools should be inspected in accordance with Section 5 when received in your plant Due to the precision design it is important that no parts of the tool be modified after receiving 5 1 Daily Maintenance 1 Remove dust moisture and other contaminant from the tool with a clean brush or a soft lint free cloth Do NOT use objects that damage the tool 2 Make sure that the proper retaining pins are in place and secured with the proper retaining ring 3 Make certain that all pins pivot points and bearing surfaces are protected with a THIN coat of any good SAE 20 motor oil Do NOT ail excessively 4 When the tool is not in use keep the handles closed to prevent obje
3. MP EA LLR SMOWMLEF 3 TERR BI EIS ipl CA KIRE KGS CSET amp UARARI SEIS HUIF MEY 207 ELA T lal CARVE L CHB LET EAI BRO AR TEL GB Ft Flo OE REL TUITE FUT EAA LNY FLARE L KE Emr eRe EHS PREC Ho TP Ka TT CHF ON LIL ET XE CIEL ECA 5 RE ARES TROBE lt JEL ARR IK MERE TS D CE PETAR REFRE SHMSKD CAMS LT RTEHSILEFBBORLET CRZ HA HA ERS LL LAO PARE L ZTR I kA RIFAU LD CIES ARBRE LT Feb OPA HHAOHRAU TRON AK QHET Stat OTE EA OfFRGORBORNO BG ESRI BIROTIEO Ae O21 F Mlasme T SALE Rev B AR YT AE 2H 3k OF MEBI ES Instruction Sheet 411 5860 5 Position terminal so insulating sleeve butts against locator and is centered on crimping jaws 6 Insert properly stripped wire s into the terminal until wire insulation begins to wedge against terminal insulation barrel or until wire insulation butts against terminal wire barrel Wire end should be approximately flush with wire barrel end 7 Hold wire in place squeeze tool handles together until the CERTI CRIMP ratchet releases 8 Allow tool handles to open FULLY Raise locator and remove crimped terminal 4 INSULATION CRIMP ADJUSTMENT The insulation barrel crimp height is regulated by placing the insulation adjustment pins in one of three positions 1 small 2 medium or 3 large Determine the proper insulation crimp setting as follows 1 Place adjustment pins in No 3 position Insert terminal into according to Paragraph 3 Crimping p
4. gt TE Instruction Sheet BY tent HAS connectivity 411 5860 18 NOV 2013 Rev B AMP Double Action Hand Tool for P I D G FASTON P I D G FASTON AMP 47 L 7 ov av FIR TOOL P N 90009 8 1 ET EEO EFS FLAS RGM Kid REOTA LAR BES LSCTEMSOVEF TE OFMLBI RT BME DRVEROBWIBAULTRAL TEld BEROMMAIAS KSI IB HDR t mL THOET PROPER USE GUIDELINES Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools TE hand tools are intended for occasional use and low volume applications TE offers a wide selection of powered application equipment for extended use production operations urA Locator gt Wire Size Stamp Here TEAR POH AIEN Y F4AAYVYVTRHAHBEE CERTI CRIMP Ratchet EGA Crimp dies RBA tem x PARE V Insulation crimp height adjustment pins Fig 1 L RCA Z OBR HAS td Figl ER n SAMP P LD G Faston SEA TLR A 7590009 8 4 Favs CFig 2t DX HS Mat eB ST ARRO CHAT 4 EO TT PASS tk lt HEH 2013 Tyco Electronics Japan G K Trademark a TE Connectivity Ltd Company All Rights Reserved TE logo is a trademark ARII bA jVA SNARARE TE Connectivity Ltd 77 7 Other products logos and company names might be trademarks of their respective owners 1 INTRODUCTION This instruction sheet covers the use of TE Hand Crimping Tool listed in Fig 1 P N 90009 8 which crimps AMP P D G FASTON terminals listed in Fig 2 READ THIS INSTRUCTION MANUAL CAR
5. to the bottom where the correct crimping is achieved The crimping dies bottom before the CERTI CRIMP ratchet releases This design feature assures maximum electrical and tensile performance of the crimp DO NOT re adjust the ratchet Receptacle Opened Portion Insulating sleeve Mae AY T Note Not to scale ERHI Wire Size AWG mm YRARA Raps Cron SS PE oe G Ric gt RATEI NTO OREA A Lf Wire strip length WA Aby TRE eT ES Terminal No Wire barrel DIRE A EB Insulation barrel ERA A PB insert wires in terminal as shown above Mant OAR IIA amp h A ERR hmoeRS Wire strip length mm 14 16 1 25 2 27 170604 Fig 2 Rev B 2of9 TE connectivity BY tent HAS JESFINODSHL ABD Opened portion of receptacle GyJ p Slot in locator Wye INA Locator base COL tos yku Press here to raise locator Instruction Sheet 411 5860 TEORA EAA FRONT of Tool RREA TERN 7 y LERTA Insulating sleeve butts against locator Fig 3 3 FeO FR FG CANCER X UEI OH Aaaa yrn TEX EHTA ZOS E RES BLO BRUNT F X KRESE Om GBR AEC I lt BU At EBIBLT EE HU Ze Ha T amp A CFig 2 amp Fig 34 BRL MUF DFR o TEET o TP ELS l Fig 2c STS PHI BRO MB amp wT oT RA RIK E DI KE OUR RIFLES T HP St WO db SRBRRBO ARIS AEE EHU OF Xba 2 TADHKWaFaticm lt SHOT EX LO BRAM ARIZA kI ANET 3 TAO F47UV VSR IRE EAD Po
6. EFULLY BEFORE USING THE HAND TOOL 1 of 9 LOC B TE connectivity PWS S Y A A RECS RI RlISHPS LING ELOROC TA SKIL Bie ENMANE Pat ORs Bas amp fit tC CBT Sha 114 1002 BY tent HAS 2 LEHE YY ZICAMPOWM AS ZARETE EK ERT 4 AOE AHS DARET E A RA FAM wo Tnt AREN TFL e a A O WARRE Zhrict F4 7VVYAHRDH Heat EBOISATTOIEF ay BILAPYVAIACH IFUATEAOE HOMECA REC KA KG Ao TIAET Gi ET EE VIE iT ORG RR A ABE mo HET SZOIMBLET Y F4 AVVIR DMA Be lite EI Eat SZEOILSO EMRA S LERRET TATO Y FUISMRVESC ED TOET EHZ AIRY HF AAV TI F Foy bART ARNETHA KT IRIE EAI WN ERORE A A kagit INTOJ ATF FFx y hls L CER CHE LAO OTF Ee Instruction Sheet 411 5860 Dimensions on this sheet are in metric units Figures are not dimension Also refer to the application specification below 114 1002 2 DESCRIPTION The BACK of tool has AMP marking on the link The FRONT of tool Wire Side into which the wire is inserted has the wire size marked on the link This tool features a terminal locator two insulation adjustment pins and CERTIi CRIMP ratchet The locator is spring loaded to position and hold the terminai in the tool The insulation adjustment pins are used to regulate the crimp height of the terminal insulation barrel A CERTI CRIMP Ratchet on the crimping tool ensures full crimping of terminals Once it engages the handles cannot be opened unless the handles are closed
7. TwWS4Rh5H H vy FLEE CH REAM AL Fav b BAKA TA YF Lea eES 4 RAY TRaIT RICRE4KO E PRM A kmr AET Rev B 3 CRIMPING PROCEDURE NOTE Each hand tool is coated with a preservative to prevent rust or corrosion Wipe this preservative from the tool particularly from crimping jaws before using the tool NOTE Refer to Section 4 for information on the insulation crimp adjustment Select the appropriate terminal and refer to Fig 2 and Fig 3 and proceed as follows t Strip the wire to the dimension provided in Fig 2 being careful to avoid nicking or damaging the conductor NOTE Do NOT use wire with nicked or missing conductors 2 Hold tool so FRONT Wire side is facing you 3 Make sure ratchet is released squeeze tool handles together and allow them to open FULLY 4 Raise locator and insert terminal into slot making sure opened portion of receptacle is turned away from locator base 3of9 TE connectivity BY tent HAS 5 KRAI R30 4 BILE EGY ERZI AOR SED HEE A mx ks 6 BERR OR BE EB A Mah BEE HI zB TAVEDO wD ERROR Ot TO FE SUBIR ZEAE CIEL lt BBS SULABRETA LET ERO FGI ERR Oa amp fe CES LUT EAA S offi Ti eit dus 7 WREAK RN LABS PFay hk DPI AHA HE CVY EN ARMIK D ot BAY ELERE OT wya pZ LERS Hic fe ROWE TP EL BIER A BOB Xli ZINA A CARLE T L MEEVORICZULMAAET JHI p Aw WG 22 55 TOFI iT CAEI VELTTO 2 Bt LTO ARE ET ORB WMA RMILA LED
8. cts from becoming lodged in the crimping are and store the tool in a clean dry area DANGER IDo not throw nor drop the tool onto the floor nor strike things with tools NOTE Avoid crimping terminals of the sizes except Fig 2 and crimping are which does not meet spec 5 2 Periodic Inspection A Lubrication Lubricate all pins pivots points and bearing surfaces with a good grade S A E 20 motor oil as follows Tools used in daily production Lubricate daily Tools used in daily occasional Lubricate weekly Tools used in daily weekly Lubricate monthly When excessive oil from tool particularly from crimping area Oil transferred from the crimping area onto characteristics of an application B Visual Inspection 1 Remove all lubrication and accumulated film by immersing the tool handles partially closed in a suitable commercial degrease that will not effect paint or plastic material 2 Make certain that all retaining pins are in place and are secured with retaining lf replacements are necessary refer to the parts list in Fig 7 3 Inspect the crimping area for pitted or chipped surfaces 5 of 9 TE connectivity BY tent HAS 4 NYZ FLeETF oy b BMA SE CHU INY FA III ADT FN BUFF a y hBRBEDOLAIAR EBA RM fHIBL TASZOC XH E IH O DBAS HoT ABU TIAR BAH iF EE OMMOARL BSA KKB ETLE Ao TT C 21 ABA OR FER ERZA ADAMO RIL Mya AI IE tx a MUCH OETA STEBER SAVETE E HENTAR L TRR Ald amp O EAA
9. into space between insulation barrel die and wire barrel die WALABA A LR BBY A aaa RRT Y DA Wire barrel die RARER MZA Z Fig 5 D F420 YTF 3 rybk o TED HLA OT oA FIZ yT Faxy kiA AEREA A h A KOTE ZRES NAIME ECA TAZ Dibar Faov7FAZKEMOIRU002mmOYA F lary tml TUTOFIETRELTT aL Y FAAYYVYT MCAT oT PEL IFz yt ORBIILWFOR 1 TROMME RY 4 KORAO BRL PIDGE OE fig TP Xa 2 3380 EA FMR FIEPESI RNAF ECEAMICPIDGe BRE ty LTT Rev B D CERTI CRIMP Ratchet Inspection Obtain a 025 mm shim that is suitable for checking the clearance between the bottoming surfaces of the crimping dies To inspect the CERTI CRIMP ratchet 1 Refer to Fig 2 and select a terminal and wire maximum size 2 Position the terminal in the appropriate crimping area according to the method described in Section 3 through 2 to 5 70f9 TE connectivity BY tent HAS GAGE MAY NOT BE INSERTED IN EITHER SIDE OF TOOL WHEN GAGING WIRE BARREL DIE PRESB BVY Cr VEZA ZAABOL DBO ETA KN PLUG GAGE FVIAF Y Instruction Sheet 411 5860 Toot TE Wire Barrel Jaws Bottomed But Not Under Pressure INY ELERU E KROVY 3 A TUBA RICH EANEVYCHETS RE BEBO oF DRE OF WIRE BARREL INSPECT GO GAD V V BEATA AD Aas MTSE NO GO E 0 7 7 OAs a ARIASRAUCHE AA ZERO AR Titt IMPING DIE WITH GAGE Go element may enter completely through the die closure No Go element may enter partially but m
10. propriate crimping area nd try to insert the NO GO member The NO GO member may enter partially but must pass through the die closure completely If NO GO member enters less than 1 thirds of depth on die closure it is reject SUGGESTED PLUG GAGE NO HET ZPIAPSF Y WIRE BARREL CRIMPING CHAMBER GO ELEMENT BF Tool Number 90009 8 2 781 ER Ta ab S EIE Plug Gage Diameter Dimension mm ia 7 Y Go 1E E t F Y No Go 0 006 0 001 NO GO 0 010 2 908 9 015 Fig 4 Rev B 6 of 9 gt TE connectivity BY tent HAS ATELY EA CREE OTIS ChLeMMLU EAS THFHOKSRBILE OT SREDA oT T n HO GO IEX V NO GO F VETRA ZAOEGEX ARA UER ETANE DTN COTREABEUTHHATS CeEMBMBRET LEER Z1 ZO ARESKETA OZ LAD POEHLER VOIO R IE ZE HBS E CME HP XV PIP PF VOMAARIIOI Too OT HERE ORRER AAAS 4087424 4 BARU TP UA Instruction Sheet 411 5860 4 Repeat the gage inspection procedure for each crimping area making sure the correct plug gage for each inspection f both wire barrel and insulation crimp die closure meet the GO NO GO gage conditions the die closure may be considered dimensionally correct If you find that the die closure do not confirm with GO NO GO gage conditions Contact your TE representative For additional information concerning the use of the plug gage refer to instruction sheet 408 7424 Insulation barrel die REIL SEBS A Insert end of gage
11. replacement of parts is necessary Parts other than listed should be replaced by TE to ensure quality and reliability of the tool Order replacement parts through your TE representative Send the tool with a written description of the problem to your TE representative 8of9 D Instruction Sheet L D i E Byte sit BAS connectivity 411 5860 ae oom as t Closed o PAn FA TOR a 4 it amp Dimension mm Weight g a B c TOOL NUMBERS DETAIL REF AND PART NUMBERS LESS RARU RS Hn Part No Descriptions 720666 3 VFAAVA YVYA Ring Retaing 720666 6 FIZY YY Ring Retaing Fig 7 FEF lt ei AAAA REVISION SUMMARY Rev A 6X Fig 4 F VBRTHIAESIEM Rev A Sheet 6 of 9 Fig 4 Added tolerances Rev B Fig 3 RMA EZ AKIR Rev B Fig 3 Remove minimum force COSBRILSAICAY RR SHEN THY DRCECEESNET ROAT ALTRAKAZE BAET This TE controlled document is subject to change For latest revision call local TE representative Rev B 9of9
12. rocedure Steps 2 through 5 2 Insert UNSTRIPPED wire into terminal insulation barrel Crimp terminal and remove from tool 3 Check insulation crimp by bending wire back and forth once time If wire pulls out place adjustment pins in next smaller position and repeat these procedures Crimp should hold wire insulation firmly without cutting into it 4 Close the tool handles until the terminal is firmly in place Do NOT deform insulation barre or wire barrel 5 MAINTENANCE INSPECTION PROCEDURE AMP recommends that a maintenance inspection program be performed periodically to ensure dependable and uniform terminations Tool should be inspected at least once a month Frequency of inspection may be adjusted to suit your requirement through experience Frequency of inspection is depend upon The care amount of use and handling of the hand tool The presence of abnormal amounts of dust and dirt The degree of operator The presence of abnormal amounts of dusts and dirt Your own established standard 4of9 TE connectivity BY tent HAS wEDREEARBILAMZOREVWOELED I Rica At EBERLE Tani TD fit IFAs SU SZBAMSOETOC Vi ROR LTP O KERR aT CM at ROE RHTWETH SG AEE LEW EO FAL 5 1 OS ake LESPOoeNOVABPCLIAPS TT Ewo Meo OTTU EZLR O AOT PUY 2UT4UYVAFEY MBM ANMBI SO UFAY YFUYAFRLAAMYIEDS NTS DEEL T FEU LEY ERY b SOPRMRBWNIIISEBO SAE No 20 RA zme XU TEAL 4 TAO MARIS BSBt Rick KNB
13. ust not pass completely through the die closure 3 FERRE E XA IRB CG FPF y b AEB Hna ETY FLETT CHAZ DIRRRTI L FEA EIEN Se Ro CHA AMS UPARKBIZ UT PF XA 4 FA ADH aT ARAOT EAE Fay LOR Xt F E A0 025mmW F T amp F VARADI Fay b REL BUTE FX M 20 025mm amp V K OR AREH L AINELE ZONT 5 HO EH Bh UCRAOOMAOAR M5 ERASE KE CMM PS EERFOL BAZHS OMBRE amp We L ZIBA SAE20 HAS gt SHES EREBOMD lt S THM te tii CLARE RVC T FEA 6 3ci8ebin amp tees Fig 7 oa U eB inid bo BRICK CT ASAT RECT SBA ARIK TAL MICE m Aik TE MAIC CHEAP Xia ZAAO m mA fe HAM amp HERR T AkO TC RHEL E To TAO BH HWE ZRH MOH AICBAL Tid MELOACL MME BAECS LOITF AL Rev B 3 While holding the wire in place squeeze the tool handles until the CERTI CRIMP ratchet releases Hold the tool in this position maintaining just enough pressure to keep the dies closed 4 Check the clearance the bottoming surfaces of the crimping dies If the 0 025mm shim stock can be inserted completely between the bottoming surfaces of the wire barrel crimp dies the dies are considered as not bottoming Refer to Section 5 Repair and Replacement Contact your local TE representative if the tool conforms to these inspection procedures lubricate ti with a THIN coat of any good SAE 20 motor oil 6 REPLACEMENT AND REPAIR The parts listed in Fig 7 are customer replaceable A complete inventory can be stocked and controlled to prevent lost time when
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