TE Connectivity PIDG PEEK STRATO-THERM User manual

Instruction Sheet
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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.
408-10040
9 SEP 2022 Rev G
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 is available for extended-use production operations.
Figure 1: PIDG PEEK STRATO-THERM terminal crimping tool
1
Stationary crimping dies (anvils)
2
Locator
3
Movable crimping dies (indenters)
4
Insulation crimping adjustment pin
5
Ratchet control
6
304.8 mm [12.0 in.] (approximate)
7
76.2 mm [3.0 in.] (approximate)
PIDG™PEEK STRATO-THERM™
Terminal Crimping Tools

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1. INTRODUCTION
This instruction sheet covers hand crimping tools 576778, 576779, 576780, 576781, 576782, 576783, and
576784, which are used to crimp PIDG PEEK STRATO-THERM Terminals to the wire sizes listed in Table 1.
Table 1: Crimping specifications
NOTE
Dimensions in this instruction sheet are in millimeters with [inches in brackets]. Figures are for reference only and are not
drawn to scale.
Read these instructions thoroughly before crimping connectors.
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 the handles are 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. 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. After it is engaged,
the ratchet does not release until the tool handles are fully closed.
CAUTION
The dies bottom before the ratchet releases. This feature ensures maximum tensile performance of the crimp. This design
feature ensures maximum electrical and tensile performance of the crimp Do not re-adjust the ratchet.
Hand tool
part number
Wire size
(AWG)
Dot code
Handle
colors
Terminal color code
Strip length
High
temp
Low temp
Min
Max
576778
24-22
2 dots
1 brown
Brown
Black
5.56 [.219]
6.35 [.250]
576779
20
1 dot
1 gray
1 purple
Gray
Purple (black stripe)
576780
18
2 dots
1 orange
Orange
Orange (black stripe)
576781
16
1 dot
2 orange
576782
14
2 dots
1 white
White
White (black stripe)
576783
12
1 dot
2 white
576784
10
1 dot
----
Black
----
7.62 [.300]
8.38 [.330]

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3. CRIMPING
NOTE
Refer to section 5 for information on insulation crimp adjustment.
1. Verify that the terminal insulation color code matches the tool handle color.
2. Select a wire of the correct size and insulation diameter for the terminal (see Table 1). Do not use wire
with nicked or missing conductors.
3. Strip the wire to the length listed in Table 1. Do not nick or cut wire strands.
4. Select an applicable contact and identify the appropriate crimp section according to the wire size
markings on the tool.
5. Squeeze the tool handles together until the ratchet releases and allow them to open fully.
6. Place the terminal in the dies so the wire barrel butts against the locator (Figure 2).
7. Close the handles of the tool until the contact is lightly held by the die set, but is not deformed to the
point where the wire cannot enter freely.
8. Insert the wire into the crimp barrel of the contact until it butts against the locator.
CAUTION
Do not allow wire insulation to enter the terminal wire barrel.
9. While holding the wire in place, fully cycle the tool until the ratchet releases and allows the handle to
open.
10. Remove the crimped terminal.
11. Examine the dot code on the finished crimp to ensure that the correct terminal and tool combination
was used (Table 1).
12. Inspect the crimp as described in section 4.
Figure 2: Crimping
1
Insulation barrel
2
Wire barrel
3
Wire barrel butts against locator
4
End of conductor butts against locator
5
Locator

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4. INSPECTING THE CRIMP
Inspect crimped terminals by checking the features shown in Figure 3. Poor crimps (Figure 4) can be avoided
by carefully following the procedures provided in section 3, and by following the tool maintenance procedures
provided in section 6.
Figure 3: Features of a good crimp
1
Insulation barrel is in firm contact with wire insulation.
2
Correct color code, dot code, and tool combination.
3
Wire size matches wire range or size stamped under tongue.
4
Crimp is centered on wire barrel.
5
Bare wire ends are flush with (or extend slightly beyond) end of wire barrel.
6
Wire insulation does not enter wire barrel.
7
No nicked or missing wire strands.
Figure 4: Features of a poor crimp
1
Wire insulation is extruded.
2
Incorrect color code, dot code, and tool combination.
3
Wire size does not match wire range or size stamped under tongue.
4
Crimp is not centered on wire barrel.
5
Wire not inserted far enough to reach end of wire barrel.
6
Wire insulation enters wire barrel. Check for incorrect strip length.
7
Nicked or missing wire strands.

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5. ADJUSTING THE INSULATION CRIMP
The insulation crimping section of the hand tool has an adjustment pin that controls the tightness of the crimp.
This pin has three positions (Figure 5).
Figure 5: Insulation crimp adjustment pin
1
Tight
2
Medium
3
Loose
To adjust the crimp tightness, complete the following steps.
1. Insert the insulation crimp adjustment pin into the number 3 (loose) position.
2. Place the terminal into the crimping jaws (Figure 2).
3. Insert the unstripped wire into only the insulation barrel of the terminal (Figure 2).
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.
6. If the wire pulls out, tighten the crimping section by setting the insulation crimp adjustment pin to the
number 2 (medium) position.
7. Perform another crimp and repeat the adjustment as needed until the correct insulation grip is
achieved. Do not use a tighter setting than necessary.

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6. MAINTENANCE AND INSPECTION
The hand tool is inspected before being shipped. Inspect it immediately upon arrival to ensure that it was not
damaged during shipment.
6.1. Daily maintenance
Make each operator of the power unit aware of, and responsible for, the following daily maintenance
requirements:
Remove dust, moisture, and other contaminants with a clean, soft brush or soft, lint-free cloth. Do not
use objects that could damage the dies.
Remove all lubrication and accumulated film by immersing the tool (with the handles partially closed) in
a suitable commercial degreaser.
Ensure that the retaining pins are in place and secured with retaining rings.
Protect all pins, pivot points, and bearing surfaces with a thin coat of any good SAE 20 motor oil. Do
not oil excessively.
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. Lubrication
Lubricate all pins, pivot points, and bearing surfaces with SAE 20 motor oil as indicated in Table 2. Wipe
excess oil from the tool, particularly from the crimping area. Oil transferred from the crimping area onto
terminations can affect the electrical characteristics of an application.
Table 2: Lubrication schedule
How tool is used
When to lubricate
In daily production
Daily
Daily (occasional)
Weekly
Weekly
Monthly
6.3. Visual inspection
Regular inspections should be performed at least once per month by quality control personnel. A record of
scheduled inspections should remain with the dies or be supplied to personnel responsible for the dies. Base
your inspection frequency on the amount of use, ambient working conditions, operator training and skill, and
established company standards. Perform the inspection as follows:
Close the tool handles until the ratchet releases and then allow them to open freely. If they do not open
quickly and fully, the spring is defective and must be replaced. See section 7, REPLACEMENT AND
REPAIR.
Inspect head assembly for worn, cracked, or broken jaws. If damage is evident, return the tool to TE for
evaluation and repair. See section 7, REPLACEMENT AND REPAIR.

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6.4. Crimping die closure inspection
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 dimensions shown in Table 3 and Table 4.
Figure 6: Recommended plug gage design for wire barrel section of crimping chamber
1
GO dimension
2
NO GO dimension
3
50.8 [2] minimum (typical)
4
Die closure configuration
Table 3: Plug gage dimensions for wire barrel crimping chamber
Hand tool
GO
NO GO
576778
2.591-2.598 [.1020-.1023]
2.690-2.692 [.1059-.1060]
576779
2.591-2.598 [.1020-.1023]
2.690-2.692 [.1059-.1060]
576780
3.048-3.056 [.1200-.1203]
3.147-3.150 [.1239-.1240]
576781
3.124-3.132 [.1230-.1233]
3.223-3.226 [.1269-.1270]
576782
3.327-3.335 [.1310-.1313]
3.426-3.429 [.1349-.1350]
576783
3.683-3.691 [.1450-.1453]
3.782-3.785 [.1489-.1490]
576784
4.775-4.783 [.1880-.1883]
4.874-4.877 [.1919-.1920]

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Figure 7: Recommended plug gage design for insulation barrel section of crimping chamber
1
Width
2
GO dimension
3
NO GO dimension
4
6.35 [.250] minimum (typical)
5
Die closure configuration
Table 4: Plug gage dimensions for insulation barrel crimping chamber
Hand tool
GO
NO GO
Width (W)
576778
0.813-0.820 [.0320-.0323]
1.217-1.219 [.0479-.0480]
4.06 [.160]
576779
1.067-1.074 [.0420-.0423]
1.471-1.473 [.0579-.0580]
4.39 [.173]
576780
0.940-0.947 [.0370-.0373]
1.344-1.346 [.0529-.0530]
5.89 [.232]
576781
0.940-0.947 [.0370-.0373]
1.344-1.346 [.0529-.0530]
5.89 [.232]
576782
1.067-1.074 [.0420-.0423]
1.471-1.473 [.0579-.0580]
6.63 [.261]
576783
1.067-1.074 [.0420-.0423]
1.471-1.473 [.0579-.0580]
6.63 [.261]
576784
1.676-1.684 [.0660-.0663]
2.080-2.083 [.0819-.0820]
8.43 [.332]

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To gage die closure, complete the following steps.
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 the gage in alignment with the die closure.
4. Align the GO element with the wire barrel section of the crimping chamber (Figure 8). Push the element
straight into the crimping chamber without using force. The GO element must pass completely through
the crimping chamber.
5. Align the NO-GO element and try to insert it straight into the same section of the crimping chamber.
The NO-GO element can start entry, but must not pass completely through the crimping chamber
(Figure 8).
Figure 8: Inspecting the wire barrel crimping dies
1
Wire barrel dies are bottomed, but not under pressure
2
Insert 0.025 mm [.001 in.] shim
3
Gage
4
GO gage must pass completely through the die closure
5
NO GO gage can enter partially, but must not pass completely through the die closure

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1. Insert the insulation crimping adjustment pin in position 1 (Figure 9).
2. With the crimping dies bottomed, check the insulation barrel section of the crimping chamber (Figure 9)
as described in steps 4 and 5.
If the crimping chamber conforms to the gage inspection, the tool is considered dimensionally
correct. Lubricate it with a thin coat of any good SAE 20 motor oil.
If not, the tool must be returned to TE for further evaluation and repair. Refer to section 7,
REPLACEMENT AND REPAIR.
Figure 9: Inspecting the insulation barrel crimping dies
1
Gage
2
Adjustment pin in position 1
3
Wire barrel dies are bottomed, but not under pressure
4
GO gage must pass completely through the die closure
5
NO GO gage can enter partially, but must not pass completely through the die closure
For additional information regarding the use of plug gages, refer to instruction sheet 408-7424.
6.5. Inspecting the ratchet control
The CERTI-CRIMP hand crimping tool ratchet control feature on TE hand tools must be checked to ensure that
the ratchet does not release prematurely, allowing the dies to open before they have fully bottomed.
1. Obtain a 0.025 mm [.001 in.] shim that is suitable for checking the clearance between the bottoming
surfaces of the crimping dies.
2. Select the maximum size wire for the tool and a terminal.
3. Position the terminal and wire between the crimping dies as described in section 3.
4. While holding the wire in place, squeeze the 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.
5. 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 satisfactory.
If the clearance exceeds 0.025 mm [.001 in.], the ratchet is out of adjustment and must be
repaired.

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7. REPLACEMENT AND REPAIR
Replaceable parts are listed in Figure 7. Parts other than those listed in Figure 7 should be replaced by TE to
ensure quality and reliability of the tool. Order replacement parts through your TE representative. You can also
order parts by any of the following methods:
Go to TE.com and click the Shop TE link at the top of the page.
Call 800-522-6752.
Write to:
CUSTOMER SERVICE (038-035)
TE CONNECTIVITY CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
For customer repair services, call 800-522-6752.
Figure 10: Replaceable parts
Table 5: Part numbers
Item
Description
Quantity
per tool
576778
576779
576780
576781
576782
576783
576784
1
Stationary insulation die
1
576788
576788-1
576788-2
576788-3
576788-4
2
Moving insulation die
1
576785
576785-1
576785-2
576785-3
576785-4
3
Stop locator
1
1901238-1
1901238-2
1901238-3
4
Screw
2
59580-6
5
Spring
1
7-59683-6
6
Retaining ring
4
525108
7
Retaining pin
2
300388
8
Retaining ring
2
21045-6
9
Retaining pin
1
300389
10
Pin
1
5-21028-7
11
Pin
1
21028-4
12
Adjustment pin
1
1752891-1

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8. REVISION SUMMARY
Revisions to this instruction sheet include:
Reformatted to current standard for instruction sheets
Updated handle colors in Table 1