TE Connectivity TETRA-CRIMP 59824-1 Bedienungsanleitung

Instruction Sheet

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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.

408-2823

22 JUN 2022 Rev AB

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 is available for extended-use production operations.

Figure 1: TETRA-CRIMP Hand Crimping Tool PN 59824-1

Back side of tool

Ratchet pawl

Crimping chamber (3 places)

Locator assembly

Crimping chamber label

Crimping dies

Ratchet handle

TETRA-CRIMP™Hand Crimping Tool

PN 59824-1

408-2823

Rev AB

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1. INTRODUCTION

The TETRA-CRIMP Hand Crimping Tool 59824-1 (Figure 1) is designed to crimp the terminals and splices

shown in Figure 2 onto stranded wire sizes 22 through 10 AWG (Table 1). For product part numbers, refer to

AMP Terminals & Splices on the TE Connectivity website.

NOTE

Dimensions in this instruction sheet are in millimeters with [inches in brackets]. Figures are for reference only and are not

drawn to scale.

Read these instructions thoroughly before crimping connectors.

Figure 2: Terminals and splices

PIDG™ring tongue terminal

Flat side

PLASTI-GRIP™ring tongue terminal

Strip length

PIDG insulation restriction ring tongue terminal

Color-coded insulation

PIDG FASTON™terminal

Striped color code for HD

PIDG butt splice

Equally-spaced shaded stripes

Wire barrel

Window indent

Insulation barrel

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Table 1: Crimping specifications

Terminal or splice

Wire size

Insulation diameter

Strip length

±0.397 [±.016]

Crimp dot

code* (after

crimping)

PIDG ring tongue terminal

22-16

2.03-3.56 [.080-.140]

5.56 [.219]

16-14

2.67-4.32 [.105-.170]

12-10

3.81-6.35 [.150-.250]

8.33 [.328]

16-14 HD

3.81-6.35 [.150-.250]

PLASTI-GRIP ring tongue terminal

22-16

2.03-3.56 [.080-.140]

5.56 [.219]

16-14

2.67-4.32 [.105-.170]

12-10

3.81-6.35 [.150-.250]

8.33 [.328]

16-14 HD

2.67-6.35 [.105-.250]

PIDG insulation restriction ring tongue terminal

0.97-2.79 [.038-.110]

6.75 [.266]

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]

9.92 [.391]

3.02-5.08 [.119-.200]

PIDG FASTON terminal

22-18

2.67-3.56 [.105-.140]

7.94 [.313]

16-14

2.92-4.32 [.115-.170]

12-10

3.81-6.35 [.150-.250]

8.73 [.344]

PIDG butt splice

22-16

2.03-3.18 [.080-.125]

6.75 [.266]

16-14

2.67-3.81 [.105-.150]

12-10

4.32-5.59 [.170-.220]

9.13 [.359]

*Tools with revision AA and later do not have crimp dot codes.

2. DESCRIPTION

Each hand tool features two crimping dies, a spring-loaded locator assembly, and a ratchet handle with a

ratchet pawl (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 (Table 2).

Table 2: Wire sizes

Color

Wire size

Yellow

12-10

Blue

16-14

Red

22-16

Black heavy duty

16-14 HD

Green

20-16 HD

The locator assembly positions the terminal or splice between the crimping dies. The ratchet handle assures

full crimping. When engaged, the ratchet does not release until the tool handles have been fully closed, unless

the ratchet pawl is depressed to manually release the ratchet. This feature prevents crimping of an improperly

positioned terminal or splice.

CAUTION

The dies bottom before the ratchet releases. This feature ensures maximum electrical and tensile performance of the crimp.

Do not re-adjust the ratchet.

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3. CRIMPING

1. 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.

2. Strip the wire to the dimension provided in Table 1. Do not nick or cut the wire strands.

3. Open the crimping dies by squeezing the tool handles together until the ratchet releases.

4. Push the locator assembly away from the upper crimping die slightly and hold.

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 (Figure 3).

If crimping a splice, position the wire barrel in the appropriate crimping chamber. Seat the splice

window indent on the locator assembly (Figure 3).

Figure 3: Positioning the wire barrel

Terminal

Splice

Flat side of terminal

Locator assembly

Splice window indent

5. While holding the wire barrel in place, release the locator assembly.

408-2823

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6. While holding the tool so that the back side is facing you, insert the stripped wire into the wire barrel

until the wire bottoms (Figure 4).

Figure 4: Inserting the wire

Stripped wire

Back side of tool

Upper die

Locator assembly

Wire barrel

7. While holding the wire in place, squeeze the tool handles together until the ratchet releases. Allow the

tool handles to open fully.

8. Remove crimped terminal or splice from the tool.

9. 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 5 through 7.

CAUTION

Do not use damaged or worn terminals. Terminals can be removed from the wire, discarded, and replaced with new ones.

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4. INSPECTING THE CRIMP

Verify that the crimp dot code on the color-coded insulation indicates the crimping chamber used (see

Table 1).

Verify that the crimp is centered on the wire barrel (Figure 5).

Make sure that the wire insulation does not enter the wire barrel (Figure 5).

Verify that the wire end is flush with or slightly beyond the end of the wire barrel (Figure 5).

Figure 5: Inspecting the crimp

Terminal

Splice

Wire insulation does not enter wire barrel

Wire end extends slightly beyond end of wire barrel

Crimp is centered on wire barrel

Crimp dot code (one dot shown)

5. MAINTENANCE AND INSPECTION

The hand tool is inspected before it is shipped. Inspect it immediately upon arrival at your facility to ensure that

the tool has not been damaged during shipment.

Perform a maintenance and inspection program at least once a month to ensure dependable and uniform

terminations. Base your frequency of inspection on the following:

The care, amount of use, and handling of the hand tool.

The presence of abnormal amounts of dust and dirt.

The degree of operator skill.

Your own established standards.

408-2823

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5.1. Daily maintenance

1. Immerse the hand tool (with handles partially closed) in a reliable commercial degreasing compound

to remove accumulated dirt, grease, and foreign matter. If no degreasing compound is available, the

tool can be wiped clean with a soft, lint-free cloth. Do not use hard or abrasive objects that could

damage the tool.

2. Ensure that the retaining pins are in place and 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 the handles closed to prevent objects from becoming lodged in the

dies.

5. Store the tool in a clean, dry area.

5.2. Periodic inspection

Lubrication

Lubricate all pins, pivot points, and bearing surfaces with SAE 20 motor oil as indicated in Table 3. Wipe

excess oil from the tool, particularly from the crimping area. Oil transferred from the crimping area onto

terminations can affect the electrical characteristics of an application.

Table 3: Lubrication schedule

Tool is used . . .

Lubricate . . .

Daily (production)

Daily

Daily (occasional)

Weekly

Monthly

Visual inspection

1. Close the tool handles until the 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 7, REPLACEMENT

AND REPAIR.

2. Inspect the crimping area for worn, cracked, or broken dies. If damage is evident, return the tool for

evaluation and repair. See section 7, REPLACEMENT AND REPAIR.

Ratchet inspection

Check the ratchet feature on these hand tools to ensure that the ratchet does not release prematurely,

allowing the dies to open before they have fully bottomed.

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.

If fewer than five positions are indicated, the ratchet pawl and ratchet handle must be replaced. Refer

to section 7, REPLACEMENT AND REPAIR.

If dies do not bottom after five ratchet stops, return the tool for repair. Refer to section 7,

REPLACEMENT AND REPAIR.

If the tool passes the ratchet inspection, lubricate it with a thin coat of any good SAE 20 motor oil.

408-2823

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Gaging the crimping chamber

Figure 6 shows a recommended plug gage design for the wire crimping chamber.

Figure 6: Recommended plug gage design

0.51 [.020] x 45º (typical)

12.7 [.50] (typical)

Width (Table 4)

GO diameter (Table 4)

NO-GO diameter (Table 4)

Table 4: Plug gage specifications

Crimping

chamber

color code

Gage element diameter

Width

(maximum)

NO-GO

Red

1.981-1.988 [.0780-.0783]

2.181-2.184 [.0859-.0860]

4.69 [.185]

Blue/green

2.336-2.344 [.0920-.0923]

2.537-2.540 [.0999-.1000]

5.33 [.210]

Yellow/black

3.251-3.258 [.1280-.1283]

3.451-3.454 [.1359-.1360]

6.85 [.270]

1. Remove any traces of oil or dirt from the crimping chamber and plug gage.

2. Close the tool handles until the crimping dies have bottomed and hold in this position. Do not force

the dies beyond initial contact.

3. Carefully insert the GO element into the the corresponding crimping chamber. Do not force it. The GO

element must pass completely through the crimping chamber. See Figure 7.

408-2823

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4. Try to insert the NO-GO element into the same crimping chamber. The NO-GO elemen can start

entry, but must not pass completely through the crimping chamber. See Figure 7.

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. See section 7, REPLACEMENT AND

REPAIR.

Figure 7: Gaging the crimping chamber

6. CONVERTING OLD TOOLS TO SINGLE RATCHET PAWL

To convert an existing tool to single ratchet pawl, use the retrofit kit that corresponds to the frame type of

your tool (Table 5). Refer to instruction sheet 408-10339.

Table 5: Retrofit kits

Frame type

Retrofit kit

Stamped

2119486-1

Solid

2119486-2

7. REPLACEMENT AND REPAIR

Customer-replaceable parts (

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Figure 8) are listed in See Table 6 on page 11 for part numbers and descriptions.

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