Instruction Sheet TETRA-CRIMP* 408-2823 Hand Crimping Tool 59824-1 12 JUN 14 Rev Z 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. 2. DESCRIPTION Crimping Each hand tool features two crimping dies, a spring- Crimping Chamber Label loaded locator assembly, and a ratchet handle with a Dies 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 Crimping Chamber terminal or splice: yellow (12-10), blue (16-14), red (3 Places) (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 Back Side of Tool 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 Locator manually release the ratchet. This feature, when Assembly depressed, prevents crimping of an improperly positioned terminal or splice. The crimping dies bottom before the ratchet Ratchet CAUTION releases. This feature assures maximum electrical Pawl and tensile performance of the crimp. Do NOT re-adjust the ratchet. 3. CRIMPING PROCEDURE Select the appropriate wire size and terminal or splice for the hand tool. The wire size and insulation Ratchet diameter must be within the specified range for the Handle 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 Figure 1 handles together until the ratchet releases. 2. Push the locator assembly away from the upper 1. INTRODUCTION crimping die slightly and hold. TETRA-CRIMP Hand Crimping Tool 59824-1 (shown a. If crimping a terminal, position the wire in Figure 1) is designed to crimp the terminals and barrel in the appropriate crimping chamber splices listed in Figure 2 onto stranded wire sizes 22 between the locator assembly and the upper through 10 AWG. Refer to Catalog 82042 for product die. Make sure that the flat side of the terminal part numbers. Read these instructions thoroughly faces up. See Figure 3, Detail A. before using the hand tool. b. If crimping a splice, position the wire barrel Dimensions in this instruction sheet are in NOTE in the appropriate crimping chamber. Seat the millimeters with inches in brackets . Figures and splice window indent on the locator assembly. illustrations are for reference only and are not i Refer to Figure 3, Detail B. drawn to scale. 3. Holding the wire barrel in place, release the Reasons for reissue are provided in Section 8, locator assembly. REVISION SUMMARY. 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. 2014 TE Connectivity family of companies TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. 1 of 6 All Rights Reserved PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, *Trademark visit our website at www.te.com LOC B 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 INSTRUCTIONS408-2823 Figure 2 5. Holding the wire in place, squeeze the tool 4. CRIMP INSPECTION handles together until the ratchet releases. Allow Check that the crimp dot code on the color-coded the tool handles to open FULLY. insulation indicates the crimping chamber used. Refer 6. Remove crimped terminal or splice from the tool. to Figure 2. 7. If crimping a splice, position the uncrimped wire Check that the crimp is centered on the wire barrel in the crimping chamber. Make sure to seat barrel. See Figure 4. the splice window indent on the locator assembly. Make sure that the wire insulation does not enter Repeat Steps 3 through 6. the wire barrel. See Figure 4. Damaged or worn terminals must not be used. CAUTION Check that the wire end is flush with or slightly Terminals may be removed from the wire, beyond the end of the wire barrel. See Figure 4. discarded, and replaced with new ones. Rev Z 2 of 6