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©2014 TE Connectivity family of companies All Rights Reserved *Trademark TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners. 1 of 6 Instruction Sheet TOOLING ASSISTANCE CENTER 1-800-722-1111 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 LOC B 408-2823TETRA-CRIMP* 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. Figure 1 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. Dimensions in this instruction sheet are in millimeters [with inches in brackets]. Figures and illustrations are for reference only and are not drawn to scale. Reasons for reissue are provided in Section 8, REVISION SUMMARY. 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. 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. 3. CRIMPING PROCEDURE 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. 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. Crimping Chamber Label Crimping Chamber (3 Places) Back Side of Tool Locator Assembly Crimping Dies Ratchet Pawl Ratchet Handle NOTE i CAUTION ORIGINAL INSTRUCTIONS
- 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. Damaged or worn terminals must not be used. T erminals 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. CAUTION
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. 6. REVISING OLD TOOLS TO SINGLE RATCHET PAWL Use retrofit kit 2119486-1 for old revision tools with stamped frames. Use retrofit kit 2119486-2 for old revision tools with solid frames. Reference Instruction Sheet 408-10339. 7. 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. Order replacement parts through your TE Connectivity 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 TE Representative at 1-800-526-5136. 8. REVISION SUMMARY
- Updated document to corporate requirements
- Updated table in Figure 6 Figure 6 (Cont’d) 12 20 2011 12 20
Figure 6 (End) REPLACEMENT PARTS ITEM PART NUMBER DESCRIPTION QTY PER TOOL 1 310581-1 STOP, Terminal and Wire 1 2 21018-6 NUT, 8-32 2 3 1-21116-0 RING, Retaining 2 4 7-59558-9 PIN, Jaw, Pivot 1 5 --- FRAME, Subassembly 1 6 354266-1 SPRING, Extension 1 7 7-59558-8 PIN, Handle, Retaining 1 8 2217549-1 HANDLE, Plastic 1 9 --- HANDLE, Ratchet 1 10 2217548-1 HANDLE, Plastic 1 11 1583388-1 PAWL, Ratchet 1 12 9-59558-0 PIN, Grooved 1 13 --- PIN 1 14 --- LINK, Toggle 2 15 --- PIN, Toggle Link 2 16 310690-1 SPRING, Extension 1 17 852980-1 LABEL, Vinyl, Five-Color 1 18 18202-1 E-Ring, Bowed 1 19 1-21113-6 E-RING, External 1 20 21045-1 RING, Retaining 2 21 3-21028-8 PIN, Slotted, .094 D.630 L 1 22 --- CRIMPING DIE, Indenter 1 23 --- CRIMPING DIE, Anvil 1 24 2-21002-4 SCREW, Button, 8-32.75 L 2