Instruction Sheet PIDG*STRATO-THERM* 408--10040 TerminalCrimpingTools 04 JAN 12 Rev E PROPERUSEGUIDELINES CumulativeTraumaDisorderscanresultfromtheprolongeduseofmanuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume applications.Awide selection ofpowered application equipmentforextended--use,production operationsisavailable. Locator Stationary Crimping Dies (Anvils) CERTI--CRIMP* Hand Crimping Tool Ratchet Control Insulation Crimping Adjustment Pin Movable Crimping Dies (Indenters) Figure 1 When closed, the crimping dies form one crimping 1. INTRODUCTION chamber with two sections: an insulation barrel This instruction sheet covers hand crimping tools section and a wire barrel section. The insulation barrel 576778, 576779, 576780, 576781, 576782, 576783, section crimps the terminal onto the wire insulation and 576784 which are used to crimp PIDG and, simultaneously, the wire barrel section crimps STRATO--THERM Terminals to the wire sizes listed in the terminal wire barrel onto the stripped wire. The Figure 2. locator positions the terminal in the crimping chamber. The insulation crimping adjustment pin is used to Dimensions on this instruction sheet are in NOTE regulate the height of the insulation crimp. millimeters with inches in brackets . Figures and illustrations are for identification only and are not The CERTI--CRIMP hand crimping tool ratchet control i drawn to scale. ensures full crimping of the terminal. Once engaged, the ratchet will not release until the tool handles have been FULLY closed. 2. DESCRIPTION Each tool features a head containing two stationary The crimping dies bottom before the CAUTION crimping dies (anvils) and two movable crimping dies CERTI--CRIMP hand crimping tool ratchet control (indenters), a locator, an insulation crimping releases. This design feature ensures maximum adjustment pin, and a CERTI--CRIMP hand crimping electrical and tensile performance of the crimp. tool ratchet control. See Figure 1. Do NOT re--adjust the ratchet. E2012 Tyco Electronics Corporation, a TE Connectivity Ltd. Company TOOLING ASSISTANCE CENTER 1--800--722--1111 This controlled document is subject to change. 1 of 7 All Rights Reserved PRODUCT INFORMATION 1--800--522--6752 For latest revision and Regional Customer Service, *Trademark visit our website at www.te.com LOCB TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners. ORIGINAL INSTRUCTIONS408-10040 TERMINALCOLORCODE STRIPLENGTH HHANDANDTTOOOLOL WWIRIREE DDOOTT HHAANNDDLLEECCOOLLOORR PART SIZE HIGH CODE CODE LOWTEMP. Min. Max. NUMBER (AWG) TEMP. 1 Handle Black 576778 24--22 2Dots Brown Black 5.56 .219 6.35 .250 1 Handle Brown 1 Handle Gray Purple 576779 20 1Dot Gray 5.56 .219 6.35 .250 1 Handle Purple (With Black Stripe) 1 Handle Orange Orange 576780 18 2Dots Orange 5.56 .219 6.35 .250 1 Handle Black (With Black Stripe) Orange 576781 16 1Dot 2 Handles Orange Orange 5.56 .219 6.35 .250 (With Black Stripe) 1 Handle White White 576782 14 2Dots White 5.56 .219 6.35 .250 1 Handle Black (With Black Stripe) White 576783 12 1Dot 2 Handles White White 5.56 .219 6.35 .250 (With Black Stripe) 576784 10 1Dot 2 Handles Black Black ------ 7.62 .300 8.38 .330 Figure 2 Do NOT use wire with nicked or missing 3. CRIMPINGPROCEDURE CAUTION conductors. RefertoSection5forinformationonthe NOTE insulation crimp adjustment. i Make sure terminal insulation color code matches NOTE tool handle color. Refer to Figure 3 and the following steps for terminal crimping procedures. i PIDG STRATO-THERM Terminals 2. Open the tool jaws by closing the tool handles Insulation Barrel Wire Barrel until the ratchet releases, then allow the handles to open fully. 3. Place the terminal in the dies so that the wire barrel butts against the locator. 4. Close the tool handles until the terminal is held firmly in place. Do NOT deform the terminal. 5. Insert properly stripped wire into the terminal End of Conductor until the end of the conductor butts against the Butts Against locator. Locator Locator Do NOT allow wire insulation to enter the CAUTION terminal wire barrel. 6. Complete the crimp by closing the tool handles until the ratchet releases. 7. Release the tool handles, allow the handles to Wire Barrel Butts open fully, and remove the crimped terminal. Against Locator 8. Observe the dot code on the finished crimp to ensure that the correct terminal and tool Figure 3 combination was used. See Figure 2. 1. Strip the wire to the dimension provided in Figure 2, being careful to avoid nicking or 9. Refer to Section 4 and Figure 4 for terminal damaging the conductor(s). crimp inspection procedure. 2 of 7 Rev E