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576778

P1-P3P4-P6P7-P7
Instruction Sheet
PIDG* STRATO- THERM*
408--10040
LOC B
1 of 7
E2012 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
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.
TOO LING ASSISTANCE CENTER 1- -800- - 722- - 1111
PRODUCT INFORMA TION 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
04 JAN 12 Rev ETerminal Crimping Tools
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
Stationary
Crimping Dies
(Anvils)
Locator
CERTI--CRIMP*
Hand Crimping Tool
Ratchet Control
Insulation Crimping
Adjustment Pin
Movable Crimping
Dies (Indenters)
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.
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.
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.
The crimping dies bottom before the
CERTI--CRIMP hand cr imping tool ratchet control
releases. This design feature ensur es maximum
electrical and tensile performance of the crimp.
Do NOT re--adjust the ratchet.
ORIGINAL INSTRUCTI O NS
NOTE
i
CAUTION
!
408- 10040
Rev E2 of 7
HAND TOOL WIRE
D
O
T
H
A
N
D
L
E
C
O
L
O
R
TERMINAL COLOR CODE STRIP LENGTH
H
A
N
D
T
O
O
L
PART
NUMBER
W
I
R
E
SIZE
(AWG)
D
O
T
CODE
H
A
N
D
L
E
C
O
L
O
R
CODE
HIGH
TEMP.
LOW TEMP. Min. Max.
576778 24--22 2Dots
1 Handle Black
1 Handle Brown
Brown Black 5.56 [.219] 6.35 [.250]
576779 20 1Dot
1 Handle Gray
1 Handle Purple
Gray
Purple
(With Black Stripe)
5.56 [.219] 6.35 [.250]
576780 18 2Dots
1 Handle Orange
1 Handle Black
Orange
Orange
(With Black Stripe)
5.56 [.219] 6.35 [.250]
576781 16 1Dot 2 Handles Orange Orange
Orange
(With Black Stripe)
5.56 [.219] 6.35 [.250]
576782 14 2Dots
1 Handle White
1 Handle Black
White
White
(With Black Stripe)
5.56 [.219] 6.35 [.250]
576783 12 1Dot 2 Handles White White
White
(With Black Stripe)
5.56 [.219] 6.35 [.250]
576784 10 1Dot 2 Handles Black Black -- -- -- 7.62 [.300] 8.38 [.330]
Figure 2
3. CRIMPING PROCEDURE
RefertoSection5forinformationonthe
insulation crimp adjustment.
Refer to Figure 3 and the following steps for terminal
crimping procedures.
Figure 3
PIDG STRATO-THERM Terminals
Locator
Wire Barrel Butts
Against Locator
End of Conductor
Butts Against
Locator
Insulation Barrel Wire Barrel
1. Strip the wire to the dimension provided in
Figure 2, being careful to avoid nicking or
damaging the conductor(s).
Do NOT use wire with nicked or missing
conductors.
Make sure terminal insulation color code matches
tool handle color.
2. Open the tool jaws by closing the tool handles
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
until the end of the conductor butts against the
locator.
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.
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.
NOTE
i
CAUTION
!
NOTE
i
CAUTION
!
408- 10040
3 of 7Rev E
4. CRIMP INSPECTION
Inspect crimped terminals by checking the features
described in Figure 4. Terminals, not meeting the
described conditions should NOT Be used.
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:
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.
3. Insert the UNSTRIPPED wire into ONLY the
insulation barrel (refer to Figure 3) portion of the
terminal.
4. Close the tool handles to complete the crimp.
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).
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.
Make sure that both insulation crimp adjustment
pins are in the same position.
Figure 4
1
Insulation barrel is in firm contact with wire i nsulation.
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
terminal wire barrel.
6
Wire insulation does not enter wire barrel.
7
No nicked or missing conductor strands.
1
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.)
6
Wire insulation entered wire barrel.
7
Nicked or missing conductor strands.
ACCEPT REJECT
Wire Range
Stamped Here
Wire Range
Stamped Here
1
2
4
5
3
5
6 7
4
5
1 2
3
6 7 5
7
CAUTION
!
P1-P3P4-P6P7-P7

576778

Mfr. #:
Buy 576778
Manufacturer:
TE Connectivity
Description:
General Hand Tool Used In The Aircraft And Military Industries
Lifecycle:
New from this manufacturer.
Delivery:
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