MACOM 5767154-3

Instruction Sheet
408-10040
PIDG* STRATO-THERM*
Terminal Crimping Tools
04 MAR 09
Rev C
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.
Stationary
Locator
Crimping Dies
(Anvils)
CERTI-CRIMP*
Hand Crimping Tool
Ratchet Control
Insulation Crimping
Adjustment Pin
Movable Crimping
Dies (Indenters)
Figure 1
1. INTRODUCTION
This instruction sheet covers hand crimping tools
576778, 576779, 576780, 576781, 576782, 576783,
and 576784 which are used to crimp PIDG
STRATO–THERM Terminals to the wire sizes listed in
Figure 2.
NOTE
i
Dimensions on this instruction sheet are in
millimeters [with inches in brackets]. Figures and
illustrations are for identification only and are not
drawn to scale.
2. DESCRIPTION
Each tool features a head containing two stationary
crimping dies (anvils) and two movable crimping dies
(indenters), a locator, an insulation crimping
adjustment pin, and a CERTI–CRIMP hand crimping
tool ratchet control. See Figure 1.
E
2009 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
When closed, the crimping dies form one crimping
chamber with two sections: an insulation barrel
section and a wire barrel section. The insulation barrel
section crimps the terminal onto the wire insulation
and, simultaneously, the wire barrel section crimps
the terminal wire barrel onto the stripped wire. The
locator positions the terminal in the crimping chamber.
The insulation crimping adjustment pin is used to
regulate the height of the insulation crimp.
The CERTI–CRIMP hand crimping tool ratchet control
ensures full crimping of the terminal. Once engaged,
the ratchet will not release until the tool handles have
been FULLY closed.
CAUTION
!
The crimping dies bottom before the
CERTI-CRIMP hand crimping tool ratchet control
releases. This design feature ensures maximum
electrical and tensile performance of the crimp.
Do NOT re-adjust the ratchet.
TOOLING ASSISTANCE CENTER 1-800-722-1111
This controlled document is subject to change.
PRODUCT INFORMATION 1-800-522-6752
For latest revision and Regional Customer Service,
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
visit our website at www.tycoelectronics.com
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LOC B
408-10040
PIDG STRATO-THERM Terminal Crimping Tools
HAND TOOL
WIRE
TERMINAL COLOR CODE
DOT
HANDLE COLOR
CODE
CODE
PART
SIZE
NUMBER
(AWG)
576778
24-22
2 Dots
576779
20
1 Dot
576780
18
2 Dots
576781
16
1 Dot
576782
14
2 Dots
576783
12
1 Dot
2 Handles White
White
576784
10
1 Dot
2 Handles Black
Black
HIGH
TEMP.
1 Handle Black
Brown
1 Handle Brown
1 Handle Gray
1 Handle Orange
2 Handles Orange
Black
5.56 [.219]
6.35 [.250]
5.56 [.219]
6.35 [.250]
5.56 [.219]
6.35 [.250]
5.56 [.219]
6.35 [.250]
5.56 [.219]
6.35 [.250]
5.56 [.219]
6.35 [.250]
7.62 [.300]
8.38 [.330]
Orange
Orange
(With Black Stripe)
White
White
1 Handle Black
Max.
(With Black Stripe)
Orange
1 Handle White
Min.
(With Black Stripe)
Orange
1 Handle Black
LOW TEMP.
Purple
Gray
1 Handle Purple
STRIP LENGTH
(With Black Stripe)
White
(With Black Stripe)
---
Figure 2
3. CRIMPING PROCEDURE
CAUTION
Do NOT use wire with nicked or missing
conductors.
NOTE
Refer to Section 5 for information on the
insulation crimp adjustment.
!
i
NOTE
Refer to Figure 3 and the following steps for terminal
crimping procedures.
PIDG STRATO-THERM Terminals
Insulation Barrel
Make sure terminal insulation color code matches
tool handle color.
i
2. Open the tool jaws by closing the tool handles
until the ratchet releases, then allow the handles to
open fully.
Wire Barrel
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
until the end of the conductor butts against the
locator.
End of Conductor
Butts Against
Locator
Locator
CAUTION
Do NOT allow wire insulation to enter the
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
open fully, and remove the crimped terminal.
Wire Barrel Butts
Against Locator
Figure 3
1. Strip the wire to the dimension provided in
Figure 2, being careful to avoid nicking or
damaging the conductor(s).
2 of 7
8. Observe the dot code on the finished crimp to
ensure that the correct terminal and tool
combination was used. See Figure 2.
9. Refer to Section 4 and Figure 4 for terminal
crimp inspection procedure.
Tyco Electronics Corporation
Rev C
408-10040
PIDG STRATO-THERM Terminal Crimping Tools
4. CRIMP INSPECTION
4. Close the tool handles to complete the crimp.
Inspect crimped terminals by checking the features
described in Figure 4. Terminals, not meeting the
described conditions should NOT Be used.
5. Removed the crimped terminal and check the
insulation crimp by bending the wire back and forth
once. The terminal should retain its grip on the wire
insulation. If the wire pulls out, set the insulation
crimp adjustment pins to the next higher position
(No. 2).
5. INSULATION CRIMP ADJUSTMENTS
The insulation crimping section of the hand tool has
three positions: 1 (tight), 2 (medium), and 3 (loose).
To adjust the section:
6. Perform another crimp and repeat the
adjustment as necessary until the correct insulation
grip is attained. Do not use a tighter setting than
required.
1. Insert the insulation crimp adjustment pins into
the No. 3 position. Refer to Figure 1.
2. Place the terminal into the crimping jaws as
shown in Figure 3.
CAUTION
3. Insert the UNSTRIPPED wire into ONLY the
insulation barrel (refer to Figure 3) portion of the
terminal.
ACCEPT
Make sure that both insulation crimp adjustment
pins are in the same position.
!
REJECT
1
2
4
4
5
5
7
1
2
3
Wire Range
Stamped Here
3
Wire Range
5
Stamped Here
6
6
7
1
1
Insulation barrel is in firm contact with wire insulation.
2
Correct color code, dot code, and tool combination.
3
Wire size is within wire range stamped under terminal tongue.
4
Crimp centered on wire barrel.
5
End of conductor is flush with, or extends beyond end of
Wire insulation does not enter wire barrel.
7
No nicked or missing conductor strands.
5
Wire insulation extruded. (Insulation crimp too tight on terminals.)
See Paragraph 5.1.
2
Wrong dot code and color code combination. See Figure 2.
3
Wire size is not within wire range stamped on terminal tongue.
4
Crimp not centered on wire barrel. (Terminal was not butted
against locator. See Figure 4.)
5
End of conductor is not flush with or extending beyond end of wire
barrel. (Check for correct strip length.)
terminal wire barrel.
6
7
6
Wire insulation entered wire barrel.
7
Nicked or missing conductor strands.
Figure 4
Rev
C
Tyco Electronics Corporation
3 of 7
408-10040
PIDG STRATO-THERM Terminal Crimping Tools
6. MAINTENANCE AND INSPECTION PROCEDURE
Tyco Electronics recommends 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 on:
1. The care, amount of use, and handling of the
hand tool.
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, Tyco Electronics recommends that the tool
be inspected immediately upon arrival to ensure that
the tool has not been damaged during shipment.
6.1. Daily Maintenance
1. 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 jaws. Store the tool in a clean, dry area.
6.2. 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
Wipe excess oil from tool, particularly from crimping
area. Oil transferred from the crimping area onto
certain terminations may affect the electrical
characteristics of an application.
B. Visual Inspection
1. Close tool handles until ratchet releases and
then allow them to open freely. If they do not open
4 of 7
quickly and fully, the spring is defective and must
be replaced. See Section 7, REPLACEMENT AND
REPAIR.
2. Inspect head assembly for worn, cracked, or
broken jaws. If damage is evident, return the tool
to Tyco Electronics for evaluation and repair. See
Section 7, REPLACEMENT AND REPAIR.
C. Crimping Die Closure Inspections
Each tool is inspected for proper die closure before
shipment. However, inspection of die closure for
excessive wear is required periodically.
This inspection requires the use of plug gages
conforming to the dimension shown in Figure 5. Tyco
Electronics does not manufacture or market these
gages.
To gage die closure, refer to Figure 6 and proceed as
follows:
1. Remove traces of oil or dirt from the crimping
chamber and plug gage.
2. Close the tool handles until the wire barrel dies
are bottomed. Do not apply additional pressure to
the tool handles.
3. With wire barrel dies bottomed, inspect the wire
barrel crimp die closure using the proper plug
gage. Press the spring–loaded locator down and
hold gage in alignment with the die closure.
4. Align the GO element with the wire barrel
section of the crimping chamber. Push element
straight into the crimping chamber without using
force. The GO element must pass completely
through the crimping chamber. See Figure 6.
5. Align the NO–GO element and try to insert it
straight into the same section of the crimping
chamber. The NO–GO element may start entry,
but must not pass completely through the crimping
chamber. See Figure 6.
6. Insert tool insulation crimping adjustment pin
into Position 1.
7. With crimping dies bottomed, check the
insulation barrel section of the crimping chamber
as described in Steps 4 and 5.
If the crimping chamber conforms to the gage
inspection, the tool is considered dimensionally
correct, and should be lubricated with a THIN coat of
any good SAE 20 motor oil. If not, the tool must be
returned to Tyco Electronics for further evaluation and
repair. Refer to Section 7, REPLACEMENT AND
REPAIR.
For additional information regarding the use of plug
gages, refer to Instruction Sheet 408–7424.
Tyco Electronics Corporation
Rev C
408-10040
PIDG STRATO-THERM Terminal Crimping Tools
Suggested Plug Gage Design for
Suggested Plug Gage Design for
Wire Barrel Section of Crimping Chamber
Insulation Barrel Section of Crimping Chamber
GO Dim.
GO Dim.
NO-GO Dim.
NO-GO Dim.
NO
GO
GO
W"
50.8 [2]
Die Closure
Configuration
Die Closure
Configuration
Min Typ
WIRE BARREL CRIMP CHAMBER
HAND
W"
6.35 [.250]
Min Typ
INSULATION BARREL CRIMP CHAMBER
TOOL
GO
NO-GO
GO
NO-GO
WIDTH (W)
576778
2.591-2.598 [.1020-.1023]
2.690-2.692 [.1059-.1060]
0.813-0.820 [.0320-.0323]
1.217-1.219 [.0479-.0480]
4.06 [.160]
576779
2.591-2.598 [.1020-.1023]
2.690-2.692 [.1059-.1060]
1.067-1.074 [.0420-.0423]
1.471-1.473 [.0579-.0580]
4.39 [.173]
576780
3.048-3.056 [.1200-.1203]
3.147-3.150 [.1239-.1240]
0.940-0.947 [.0370-.0373]
1.344-1.346 [.0529-.0530]
5.89 [.232]
576781
3.124-3.132 [.1230-.1233]
3.223-3.226 [.1269-.1270]
0.940-0.947 [.0370-.0373]
1.344-1.346 [.0529-.0530]
5.89 [.232]
576782
3.327-3.335 [.1310-.1313]
3.426-3.429 [.1349-.1350]
1.067-1.074 [.0420-.0423]
1.471-1.473 [.0579-.0580]
6.63 [.261]
576783
3.683-3.691 [.1450-.1453]
3.782-3.785 [.1489-.1490]
1.067-1.074 [.0420-.0423]
1.471-1.473 [.0579-.0580]
6.63 [.261]
576784
4.775-4.783 [.1880-.1883]
4.874-4.877 [.1919-.1920]
1.676-1.684 [.0660-.0663]
2.080-2.083 [.0819-.0820]
8.43 [.332]
Figure 5
(Detail A) Inspection of Wire Barrel Crimping Dies
(Detail B) Inspection of Insulation Crimping Dies
Wire Barrel Dies
Wire Barrel Dies
Bottomed But Not
Bottomed But
Under Pressure
Not Under Pressure
Gage
Gage
Insert 0.025 mm
[.001 In.] Shim Here
Adjustment Pin
When Checking
in No. 1
CERTI-CRIMP Hand
Position
Crimping Tool Ratchet
Control
GO gage must pass completely
through the die closure.
NO-GO gage may enter partially,
but must not pass completely
through the die closure.
Figure 6
Rev C
Tyco Electronics Corporation
5 of 7
408-10040
PIDG STRATO-THERM Terminal Crimping Tools
D. CERTI-CRIMP Hand Crimping Tool Ratchet
Control Inspection
The CERTI–CRIMP hand crimping tool ratchet control
feature on Tyco Electronics hand tools should be
checked to ensure that the ratchet does not release
prematurely, allowing the dies to open before they
have fully bottomed. Obtain a 0.025 mm [.001 in.]
shim that is suitable for checking the clearance
between the bottoming surfaces of the crimping dies.
Proceed as follows:
1. Select the maximum size wire for the tool and a
terminal.
2. Position the terminal and wire between the
crimping dies as described in Section 3.
3. Hold wire in place and squeeze tool handles
until the CERTI–CRIMP hand crimping tool ratchet
control releases. Hold the handles in this position,
maintaining just enough tension to keep the dies
closed.
4. Check the clearance between the bottoming
surfaces of the crimping dies with the 0.025 mm
[.001 in.] shim. If the clearance is 0.025 mm
[.001 in.] or less, the ratchet is considered
6 of 7
satisfactory. If the clearance exceeds 0.025 mm
[.001 in.], the ratchet is out of adjustment and must
be repaired.
7. REPLACEMENT AND REPAIR
Replaceable parts are listed in Figure 7. Parts other
than those listed in Figure 7 should be replaced by
Tyco Electronics to ensure quality and reliability of the
tool. Order replacement parts through your Tyco
Electronics Representative, or call 1–800–526–5142,
or send a facsimile of your purchase order to
1–717–986–7605, or write to:
CUSTOMER SERVICE (38–35)
TYCO ELECTRONICS CORPORATION
P.O. BOX 3608
HARRISBURG, PA 17105–3608
For tool repair service, please contact an Tyco
Electronics Representative at 1–800–526–5136.
8. REVISION SUMMARY
S Updated document to corporate requirements
S Changed item 6 part number in table in
Figure 7
Tyco Electronics Corporation
Rev C
408-10040
PIDG STRATO-THERM Terminal Crimping Tools
Approx.
Approx.
76.2
304.8
[3.00]
[12.00]
8
1
9
2
6
4
11
3
12
10
5
7
ITEM
NO.
DESCRIPTION
PIDG STRATO-THERM TERMINAL CRIMPING TOOL REPLACEMENT PARTS
QTY
PER
TOOL
576778
576779
576780
576781
576782
576783
576784
1
PIN, Retaining
2
300388
300388
300388
300388
300388
300388
300388
2
RING, Retaining
4
525108
525108
525108
525108
525108
525108
525108
3
PIN, Retaining
1
300389
300389
300389
300389
300389
300389
300389
4
RING, Retaining
2
21045-6
21045-6
21045-6
21045-6
21045-6
21045-6
21045-6
5
PIN, Adjustment
1
1752891-1
1752891-1
1752891-1
1752891-1
1752891-1
1752891-1
1752891-1
6
LOCATOR, Stop
1
1901238-1
1901238-1
1901238-2
1901238-2
1901238-2
1901238-2
1901238-3
7
PIN
1
5-21028-7
5-21028-7
5-21028-7
5-21028-7
5-21028-7
5-21028-7
5-21028-7
8
SPRING
1
7-59683-6
7-59683-6
7-59683-6
7-59683-6
7-59683-6
7-59683-6
7-59683-6
9
SCREW
2
59580-6
59580-6
59580-6
59580-6
59580-6
59580-6
59580-6
10
STATIONARY DIE, Insulation
1
576788
576788-1
576788-2
576788-2
576788-3
576788-3
576788-4
11
MOVING DIE, Insulation
1
576785
576785-1
576785-2
576785-2
576785-3
576785-3
576785-4
12
PIN
1
21028-4
21028-4
21028-4
21028-4
21028-4
21028-4
21028-4
Figure 7
Rev
C
Tyco Electronics Corporation
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