408-2823 PROPER GUIDELINES Cumulative Trauma Disorders result fro

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Instruction Sheet TETRA-CRIMP* Hand Crimping Tool 59824-1
408-2823
PROPER GUIDELINES Cumulative Trauma Disorders result from prolonged manually powered hand tools. Hand tools intended occasional volume applications. wide selection powered application equipment extended-use, production operations available.
Crimping Chamber Label Crimping Chamber Places) Crimping Dies
DESCRIPTION
Each hand tool features crimping dies, spring-loaded locator assembly, ratchet handle with ratchet pawl. Figure 1.When closed, dies form three crimping chambers each labeled color BACK side tool. color indicates wire size must match insulation color terminal splice: yellow (12-10), blue (16-14), (22-16), black heavy duty (16-14 HD), green (20-16 HD). locator assembly positions terminal splice between crimping dies. ratchet handle assures full crimping. Once engaged, ratchet will release until tool handles have been FULLY closed, unless ratchet pawl depressed manually release ratchet. This feature, when depressed, prevents crimping improperly positioned terminal splice. Ratchet Pawl CAUTION crimping dies bottom before ratchet releases. This feature assures maximum electrical tensile performance crimp. re-adjust ratchet.
Back Side Tool
Locator Assembly
CRIMPING PROCEDURE
Ratchet Handle Select appropriate wire size terminal splice hand tool. wire size insulation diameter must within specified range terminal splice. Strip wire dimension provided Figure nick wire strands. Then, proceed follows: Open crimping dies squeezing tool handles together until ratchet releases.
Figure
Push locator assembly away from upper crimping slightly hold. crimping terminal, position wire barrel appropriate crimping chamber between locator assembly upper die. Make sure that flat side terminal faces Figure Detail crimping splice, position wire barrel appropriate crimping chamber. Seat splice window indent locator assembly. Refer Figure Detail Holding wire barrel place, release locator assembly. Hold tool that BACK side facing you, insert stripped wire into wire barrel until wire bottoms. Refer Figure
TOOLING ASSISTANCE CENTER 1-800-722-1111 FAX/PRODUCT INFO 1-800-522-6752 Regional Customer Service, visit website www.tycoelectronics.com
INTRODUCTION
TETRA-CRIMP Hand Crimping Tool 59824-1 (shown Figure designed crimp terminals splices listed Figure onto stranded wire sizes through AWG. Refer Catalog 82042 product part numbers. Read these instructions thoroughly before using hand tool. NOTE Dimensions this instruction sheet millimeters [with inches brackets]. Figures reference only drawn scale.
Reasons reissue provided Section REVISION SUMMARY.
E2004 Tyco Electronics Corporation, Harrisburg,
This controlled document subject change. latest revision, call FAX/PRODUCT INFO number. International Rights Reserved Tyco trademarks. *Trademark Other products, logos, company names used property their respective owners.
TETRA-CRIMP Hand Crimping Tool 59824-1
WIRE TERMINAL TERMI SPLICE SIZE (AWG) INSULATION DIAMETER RANGE STRIP LENGTH +0.397 [+.016]
408-2823
CRIMP CODE (After Crimping)
PIDG* (Pre-Insulated Diamond Grip) Ring Tongue Terminal Insulation Wire Barrel Barrel Strip Length
22-16 16-14 12-10
2.03-3.56 [.080-.140] 5.56 [.219] 2.67-4.32 [.105-.170] 3.81-6.35 [.150-.250] 8.33 [.328]
Tools with sion have code evis ater crim
5.56 [.219] 8.33 [.328] 6.75 [.266] 9.92 [.391] 7.94 [.313] 8.73 [.344] 6.75 [.266] 9.13 [.359]
Flat Side
HD16-14 3.81-6.35 [.150-.250] 22-16 16-14 12-10 2.03-3.56 [.080-.140] 2.67-4.32 [.105-.170] 3.81-6.35 [.150-.250]
PLASTI-GRIP* Ring Tongue Terminal Striped Color Code Color-Coded Insulation
HD16-14 2.67-6.35 [.105-.250] 0.97-2.79 [.038-.110] 1.17-2.79 [.046-.110] 1.42-2.79 [.056-.110] 1.60-3.30 [.063-.130] 1.98-3.30 [.078-.130] 2.41-5.08 [.095-.200] 3.02-5.08 [.119-.200] 2.67-3.56 [.105-.140] 2.92-4.32 [.115-.170] 3.81-6.35 [.150-.250] 2.03-3.18 [.080-.125] 2.67-3.81 [.105-.150] 4.32-5.59 [.170-.220]
PIDG Insulation Restriction Ring Tongue Terminal
Equally-Spaced Shaded Stripes
PIDG FASTON* Terminal
22-18 16-14 12-10
PIDG Butt Splice
22-16
Window Indent Insulation Barrel Wire Barrel
16-14 12-10
Figure
Holding wire place, squeeze tool handles together until ratchet releases. Allow tool handles open FULLY. Remove crimped terminal splice from tool. crimping splice, position uncrimped wire barrel crimping chamber. Make sure seat splice window indent locator assembly. Repeat Steps through CAUTION Damaged worn terminals must used. Terminals removed from wire, discarded, replaced with ones.
CRIMP INSPECTION
Check that crimp code color-coded insulation indicates crimping chamber used. Refer Figure Check that crimp centered wire barrel. Figure Make sure that wire insulation does enter wire barrel. Figure Check that wire flush with slightly beyond wire barrel. Figure
TETRA-CRIMP Hand Crimping Tool 59824-1
Detail Back Side Tool Upper Flat Side Terminal
408-2823
Locator Assembly Detail Stripped Wire Locator Assembly Splice Window Indent
Wire Barrel
Locator Assembly
Figure
Crimp Inspection Terminal Wire Insulation Does Enter Wire Barrel Wire Slightly Beyond Wire Barrel Splice Crimp Centered Wire Barrel
presence abnormal amounts dust dirt. degree operator skill. Your established standards. hand tool inspected before being shipped; however, recommended that tool inspected immediately upon arrival your facility ensure that tool been damaged during shipment.
5.1. Daily Maintenance
hand tool should immersed (handles partially closed) reliable commercial degreasing compound remove accumulated dirt, grease, foreign matter. When degreasing compound available, tool wiped clean with soft, lint-free cloth. hard abrasive objects that could damage tool. Make certain that retaining pins place that they secured with retaining rings. pins, pivot points, bearing surfaces should protected with THIN coat good motor oil. excessively. When tool use, keep handles closed prevent objects from becoming lodged crimping dies. Store tool clean, area.
Crimp Code Shown) (Refer Figure
Figure
MAINTENANCE INSPECTION
recommended that maintenance inspection program performed periodically ensure dependable uniform terminations. Though recommendations call least inspection month, frequency inspection depends upon following: care, amount use, handling hand tool.
5.2. Periodic Inspection Lubrication
Lubricate pins, pivot points, bearing surfaces with motor follows: Tool used daily production-lubricate daily Tool used daily (occasional)-lubricate weekly Tool used weekly-lubricate monthly
TETRA-CRIMP Hand Crimping Tool 59824-1
Wipe excess from tool, particularly from crimping area. transferred from crimping area onto certain terminations affect electrical characteristics application. Suggested Plug Gage Design 0.51 [.020]
408-2823
12.7 [.50]
Visual Inspection
Close tool handles until ratchet releases then allow them open freely. they open quickly fully, spring defective must replaced. Section REPLACEMENT REPAIR. Inspect crimping area worn, cracked, broken dies. damage evident, return tool evaluation repair. Section REPLACEMENT REPAIR.
NO-GO
Inspection Crimping Chamber
Ratchet Inspection
ratchet feature these hand tools should checked ensure that ratchet does release prematurely, allowing dies open before they have fully bottomed. Squeeze tool handles together, count number ratchet stops. Five stops, including release position, should indicated movement ratchet pawl clicking sound associated with movement. Refer Figure fewer positions indicated, ratchet pawl ratchet handle must replaced. Refer Section REPLACEMENT REPAIR. dies bottom after ratchet stops, return tool repair. Refer Section REPLACEMENT REPAIR. When tool passes ratchet inspection, lubricate with THIN coat good motor oil.
Element
element must pass completely through crimping chamber.
NO-GO element enter partially, must pass completely through crimping chamber.
Widt (Width) 4.69 [.185] 5.33 [.210] 6.85 [.270]
CRIMPING CHAMBER COLOR CODE Blue/Green Yellow/Black
GAGE ELEMENT DIAMETER 1.981-1.988 [.0780-.0783] 2.336-2.344 [.0920-.0923] 3.251-3.258 [.1280-.1283] NO-GO 2.181-2.184 [.0859-.0860] 2.537-2.540 [.0999-.1000] 3.451-3.454 [.1359-.1360]
Figure
Gaging Crimping Chamber
This inspection requires plug gage conforming dimensions provided Figure gage crimping chamber, proceed follows: Remove traces dirt from crimping chamber plug gage. order properly gage this tool, terminal must crimped crimping chamber being inspected. place terminal, soft material such brass solder used seat tooling. Close tool handles until crimping dies have bottomed; then hold this position. force dies beyond initial contact.
Hold locator assembly away from crimping dies. Carefully insert element into corresponding crimping chamber; force element must pass completely through crimping chamber. same manner, insert NO-GO element into same crimping chamber. NO-GO element start entry, must pass completely through crimping chamber. Figure crimping chambers conform crimping chamber inspection, tool considered dimensionally correct, should lubricated with THIN coat good motor oil. not, return tool further evaluation repair. Refer Section REPLACEMENT REPAIR.
Crimping Chamber
NO-GO Element
TETRA-CRIMP Hand Crimping Tool 59824-1
additional information concerning plug gage, refer instruction sheet 408-7424.
408-2823
Order replacement parts through your representative, call 1-800-526-5142, send facsimile your purchase order 717-986-7605, write CUSTOMER SERVICE (038-035) TYCO ELECTRONICS CORPORATION 3608 HARRISBURG 17105-3608 customer repair service, please contact representative 1-800-526-5136.
REPLACEMENT REPAIR
Customer-replaceable parts listed Figure complete inventory should stocked controlled prevent lost time when replacement parts necessary. Parts other than those listed should replaced ensure quality reliability.
REPLACEMENT PARTS ITEM PART NUMBER 310581-1 21018-6 1-21116-0 7-59558-9 354098-2 354266-1 7-59558-8 310575-1 DESCRIPTION STOP, Terminal Wire NUT, 8-32 RING, Retaining PIN, Jaw, Pivot FRAME, Subassembly SPRING, Extension PIN, Handle, Retaining HANDLE, Plastic TOOL
Figure (cont'd)
TETRA-CRIMP Hand Crimping Tool 59824-1
408-2823
REPLACEMENT PARTS ITEM PART NUMBER 310582-1 354256-1 310579-1 17934-1 313033-2 310578-1 1320532-1 310690-1 852980-1 18202-1 1-21113-6 1213160-1 3-21028-8 904139-1 662903-2 2-21002-4 HANDLE, Ratchet HANDLE, Plastic PAWL, Ratchet PIN, Shear-Proof, Grooved LINK, Toggle PIN, Toggle Link SPRING, Extension LABEL, Vinyl, Five-Color E-RING, Bowed E-RING, External DESCRIPTION TOOL
PIN, Slotted, .094 .630 CRIMPING DIE, Indenter CRIMPING DIE, Anvil
SCREW, Button, 8-32
Figure (end)
REVISION SUMMARY
Revisions this instruction sheet 0990-1712-03 include:
Update document corporate requirements Changed gage dimensions Figure

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