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Instruction Sheet TETRA­CRIMP Hand Crimping Tool 59824­1

05 JAN 04 Rev S

Instruction Sheet TETRA-CRIMP Hand Crimping Tool 59824-1
05 JAN 04 Rev S
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.
Crimping Chamber Label Crimping Chamber (3 Places) Crimping Dies
2. DESCRIPTION
Each hand tool features two crimping dies, a spring-loaded locator assembly, and a ratchet handle with a ratchet pawl. See Figure 1.When closed, the dies form three crimping chambers each labeled by color on the BACK side of the tool. The color indicates the wire size and must match the insulation color of the terminal or splice: yellow (12-10), blue (16-14), red (22-16), black heavy duty (16-14 HD), and green (20-16 HD). The locator assembly positions the terminal or splice between the crimping dies. The ratchet handle assures full crimping. Once engaged, the ratchet will not release until the tool handles have been FULLY closed, unless the ratchet pawl is depressed to manually release the ratchet. This feature, when depressed, prevents crimping of an improperly positioned terminal or splice. Ratchet Pawl CAUTION The crimping dies bottom before the ratchet releases. This feature assures maximum electrical and tensile performance of the crimp. Do NOT re-adjust the ratchet.
Back Side of Tool
Locator Assembly
3. CRIMPING PROCEDURE
Ratchet Handle Select the appropriate wire size and terminal or splice for the hand tool. The wire size and insulation diameter must be within the specified range for the terminal or splice. Strip the wire to the dimension provided in Figure 2. Do NOT nick or cut the wire strands. Then, proceed as follows: 1. Open the crimping dies by squeezing the tool handles together until the ratchet releases.
Figure 1
2. Push the locator assembly away from the upper crimping die slightly and hold. a. If crimping a terminal, position the wire barrel in the appropriate crimping chamber between the locator assembly and the upper die. Make sure that the flat side of the terminal faces up. See Figure 3, Detail A. b. If crimping a splice, position the wire barrel in the appropriate crimping chamber. Seat the splice window indent on the locator assembly. Refer to Figure 3, Detail B. 3. Holding the wire barrel in place, release the locator assembly. 4. Hold the tool so that the BACK side is facing you, and insert the stripped wire into wire barrel until the wire bottoms. Refer to Figure 3.
TOOLING ASSISTANCE CENTER 1-800-722-1111 FAX / PRODUCT INFO 1-800-522-6752 For Regional Customer Service, visit our website at www.tycoelectronics.com
1. INTRODUCTION
TETRA-CRIMP Hand Crimping Tool 59824-1 (shown in Figure 1) is designed to crimp the terminals and splices listed in Figure 2 onto stranded wire sizes 22 through 10 AWG. Refer to Catalog 82042 for product part numbers. Read these instructions thoroughly before using the hand tool. NOTE Dimensions in this instruction sheet are in millimeters with inches in brackets. Figures are for reference only and are not drawn to scale.
Reasons for reissue are provided in Section 7, REVISION SUMMARY.
E2004 Tyco Electronics Corporation, Harrisburg, PA
This controlled document is subject to change. For latest revision, call the FAX / PRODUCT INFO number. All International Rights Reserved AMP and Tyco are trademarks. Trademark Other products, logos, and company names used are the property of their respective owners.
TETRA-CRIMP Hand Crimping Tool 59824-1
WIRE TERMINAL TERMI A OR SPLICE P ICE SIZE (AWG) INSULATION DIAMETER RANGE STRIP LENGTH +0.397 +.016
CRIMP DOT CODE OT CO E (After Crimping)
PIDG (Pre-Insulated Diamond Grip) Ring Tongue Terminal Insulation Wire Barrel Barrel Strip Length
Tools with Re sion AA and lat d n have c mp do code To s evis n A d ater do not crim dot c es.
Flat Side
HD16-14 HD 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 for HD Color-Coded Insulation
HD16-14 HD 2.67-6.35 .105-.250 22 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 G Ring Tongue Terminal
Equally-Spaced Shaded Stripes
PIDG FA G FASTON Terminal N
PIDG Butt G Splice
Window Indent W Insulation Barrel Wire W Barrel
Figure 2
5. Holding the wire in place, squeeze the tool handles together until the ratchet releases. Allow the tool handles to open FULLY. 6. Remove crimped terminal or splice from the tool. 7. If crimping a splice, position the uncrimped wire barrel in the crimping chamber. Make sure to seat the splice window indent on the locator assembly. Repeat Steps 3 through 6. CAUTION Damaged or worn terminals must not be used. Terminals may be removed from the wire, discarded, and replaced with new ones.
4. CRIMP INSPECTION
- Check that the crimp dot code on the color-coded insulation indicates the crimping chamber used. Refer to Figure 2. - Check that the crimp is centered on the wire barrel. See Figure 4. - Make sure that the wire insulation does not enter the wire barrel. See Figure 4. - Check that the wire end is flush with or slightly beyond the end of the wire barrel. See Figure 4.
TETRA-CRIMP Hand Crimping Tool 59824-1
Detail A Back Side of Tool Upper Die Flat Side of Terminal
Locator Assembly Detail B Stripped Wire Locator Assembly Splice Window Indent
Wire Barrel
Locator Assembly
Figure 3
Crimp Inspection Terminal Wire Insulation Does Not Enter Wire Barrel Wire End Slightly Beyond End of Wire Barrel Splice Crimp Centered on Wire Barrel
2. The presence of abnormal amounts of dust and dirt. 3. The degree of operator skill. 4. Your own established standards. The hand tool is inspected before being shipped however, it is recommended that the tool be inspected immediately upon arrival at your facility to ensure that the tool has not been damaged during shipment.
5.1. Daily Maintenance
1. The hand tool should be immersed (handles partially closed) in a reliable commercial degreasing compound to remove accumulated dirt, grease, and foreign matter. When degreasing compound is not available, tool may be wiped clean with a soft, lint-free cloth. Do NOT use hard or abrasive objects that could damage the tool. 2. Make certain that the retaining pins are in place and that they are secured with retaining rings. 3. All pins, pivot points, and bearing surfaces should be protected with a THIN coat of any good SAE 20 motor oil. Do NOT oil excessively. 4. When the tool is not in use, keep handles closed to prevent objects from becoming lodged in the crimping dies. Store the tool in a clean, dry area.
Crimp Code (1 Dot Shown) (Refer to Figure 2)
Figure 4
5. MAINTENANCE AND INSPECTION
It is recommended that a maintenance and inspection program be performed periodically to ensure dependable and uniform terminations. Though recommendations call for at least one inspection a month, frequency of inspection depends upon the following: 1. The care, amount of use, and handling of the hand tool.
5.2. Periodic Inspection A. Lubrication
Lubricate all pins, pivot points, and bearing surfaces with SAE 20 motor oil as follows: Tool used in daily production-lubricate daily Tool used daily (occasional)-lubricate weekly Tool used weekly-lubricate monthly
TETRA-CRIMP Hand Crimping Tool 59824-1
12.7 .50 Typ
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 spring is defective and must be replaced. See Section 6, REPLACEMENT AND REPAIR. 2. Inspect crimping area for worn, cracked, or broken dies. If damage is evident, return the tool for evaluation and repair. See Section 6, REPLACEMENT AND REPAIR. GO Dia
W NO-GO Dia
Inspection of Crimping Chamber
C. Ratchet Inspection
The ratchet feature on these hand tools should be checked to ensure that the ratchet does not release prematurely, allowing the dies to open before they have fully bottomed. 1. Squeeze the tool handles together, and count the number of ratchet stops. Five stops, including the release position, should be indicated by the movement of the ratchet pawl and the clicking sound associated with its movement. Refer to Figure 1. 2. If fewer positions are indicated, the ratchet pawl and ratchet handle must be replaced. Refer to Section 6, REPLACEMENT AND REPAIR. 3. If dies do not bottom after 5 ratchet stops, return tool for repair. Refer to Section 6, REPLACEMENT AND REPAIR. When the tool passes the ratchet inspection, lubricate it with a THIN coat of any good SAE 20 motor oil.
GO Element
GO element must pass completely through the crimping chamber.
NO-GO element may enter partially, but must not pass completely through the crimping chamber.
"W" Widt (Width) Max 4.69 .185 5.33 .210 6.85 .270
CRIMPING CHAMBER COLOR CODE Red Blue / Green Yellow / Black
GAGE ELEMENT DIAMETER GO 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 5
D. Gaging the Crimping Chamber
This inspection requires the use of a plug gage conforming to the dimensions provided in Figure 5. To gage the crimping chamber, proceed as follows: 1. Remove traces of oil or dirt from the crimping chamber and plug gage. 2. In order to properly gage this tool, a terminal must be crimped in the crimping chamber being inspected. In place of a terminal, a soft material such as brass or solder may be used to seat the tooling. 3. Close the tool handles until the crimping dies have bottomed then hold in this position. DO NOT force the dies beyond initial contact.
4. Hold locator assembly away from crimping dies. Carefully insert GO element into the corresponding crimping chamber do not force it. The GO element must pass completely through the crimping chamber. 5. In the same manner, try to insert the NO-GO element into the same crimping chamber. The NO-GO element may start entry, but must not pass completely through the crimping chamber. See Figure 5. If the crimping chambers conform to the crimping chamber inspection, the tool is considered dimensionally correct, and should be lubricated with a THIN coat of any good SAE 20 motor oil. If not, return the tool for further evaluation and repair. Refer to Section 6, REPLACEMENT AND REPAIR.
Crimping Chamber
NO-GO Element
TETRA-CRIMP Hand Crimping Tool 59824-1
For additional information concerning the use of a plug gage, refer to instruction sheet 408-7424.
Order replacement parts through your representative, or call 1-800-526-5142, or send a facsimile of your purchase order to 717-986-7605, or write to: CUSTOMER SERVICE (038-035) TYCO ELECTRONICS CORPORATION PO BOX 3608 HARRISBURG PA 17105-3608 For customer repair service, please contact a representative at 1-800-526-5136.
6. REPLACEMENT AND REPAIR
Customer-replaceable parts are listed in Figure 6. A complete inventory should be stocked and controlled to prevent lost time when replacement of parts is necessary. Parts other than those listed should be replaced to ensure quality and reliability.
REPLACEMENT PARTS ITEM 1 2 3 4 5 6 7 8 PART NUMBER 310581-1 21018-6 1-21116-0 7-59558-9 354098-2 354266-1 7-59558-8 310575-1 DESCRIPTION STOP, Terminal and Wire NUT, 8-32 RING, Retaining PIN, Jaw, Pivot FRAME, Subassembly SPRING, Extension PIN, Handle, Retaining HANDLE, Plastic QTY PER TOOL 1 2 2 1 1 1 1 1
TETRA-CRIMP Hand Crimping Tool 59824-1
REPLACEMENT PARTS ITEM 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 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 PIN LINK, Toggle PIN, Toggle Link SPRING, Extension LABEL, Vinyl, Five-Color E-RING, Bowed E-RING, External PIN DESCRIPTION QTY PER TOOL 1 1 2 1 1 2 2 1 1 1 1
PIN, Slotted, .094 D .630 L CRIMPING DIE, Indenter CRIMPING DIE, Anvil
SCREW, Button, 8-32 .75 L
Figure 6 (end)
7. REVISION SUMMARY
Revisions to this instruction sheet per EC 0990-1712-03 include:
S Update document to corporate requirements S Changed gage dimensions in Figure 5