TE Connectivity TETRA-CRIMP 59824-1 User manual

Instruction Sheet
1 of 13
© 2022 TE Connectivity Ltd. family of companies.
All Rights Reserved.
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners.
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.
408-2823
22 JUN 2022 Rev AB
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: TETRA-CRIMP Hand Crimping Tool PN 59824-1
1
Back side of tool
5
Ratchet pawl
2
Crimping chamber (3 places)
6
Locator assembly
3
Crimping chamber label
7
Crimping dies
4
Ratchet handle
TETRA-CRIMP™Hand Crimping Tool
PN 59824-1

408-2823
Rev AB
2 of 13
1. INTRODUCTION
The TETRA-CRIMP Hand Crimping Tool 59824-1 (Figure 1) is designed to crimp the terminals and splices
shown in Figure 2 onto stranded wire sizes 22 through 10 AWG (Table 1). For product part numbers, refer to
AMP Terminals & Splices on the TE Connectivity website.
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.
Figure 2: Terminals and splices
1
PIDG™ring tongue terminal
8
Flat side
2
PLASTI-GRIP™ring tongue terminal
9
Strip length
3
PIDG insulation restriction ring tongue terminal
10
Color-coded insulation
4
PIDG FASTON™terminal
11
Striped color code for HD
5
PIDG butt splice
12
Equally-spaced shaded stripes
6
Wire barrel
13
Window indent
7
Insulation barrel

408-2823
Rev AB
3 of 13
Table 1: Crimping specifications
Terminal or splice
Wire size
Insulation diameter
Strip length
±0.397 [±.016]
Crimp dot
code* (after
crimping)
PIDG ring tongue terminal
22-16
2.03-3.56 [.080-.140]
5.56 [.219]
1
16-14
2.67-4.32 [.105-.170]
2
12-10
3.81-6.35 [.150-.250]
8.33 [.328]
1
16-14 HD
3.81-6.35 [.150-.250]
1
PLASTI-GRIP ring tongue terminal
22-16
2.03-3.56 [.080-.140]
5.56 [.219]
1
16-14
2.67-4.32 [.105-.170]
2
12-10
3.81-6.35 [.150-.250]
8.33 [.328]
1
16-14 HD
2.67-6.35 [.105-.250]
1
PIDG insulation restriction ring tongue terminal
22
0.97-2.79 [.038-.110]
6.75 [.266]
1
20
1.17-2.79 [.046-.110]
1
18
1.42-2.79 [.056-.110]
1
16
1.60-3.30 [.063-.130]
2
14
1.98-3.30 [.078-.130]
2
12
2.41-5.08 [.095-.200]
9.92 [.391]
1
10
3.02-5.08 [.119-.200]
1
PIDG FASTON terminal
22-18
2.67-3.56 [.105-.140]
7.94 [.313]
1
16-14
2.92-4.32 [.115-.170]
2
12-10
3.81-6.35 [.150-.250]
8.73 [.344]
1
PIDG butt splice
22-16
2.03-3.18 [.080-.125]
6.75 [.266]
1
16-14
2.67-3.81 [.105-.150]
2
12-10
4.32-5.59 [.170-.220]
9.13 [.359]
1
*Tools with revision AA and later do not have crimp dot codes.
2. DESCRIPTION
Each hand tool features two crimping dies, a spring-loaded locator assembly, and a ratchet handle with a
ratchet pawl (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 (Table 2).
Table 2: Wire sizes
Color
Wire size
Yellow
12-10
Blue
16-14
Red
22-16
Black heavy duty
16-14 HD
Green
20-16 HD
The locator assembly positions the terminal or splice between the crimping dies. The ratchet handle assures
full crimping. When engaged, the ratchet does not release until the tool handles have been fully closed, unless
the ratchet pawl is depressed to manually release the ratchet. This feature prevents crimping of an improperly
positioned terminal or splice.
CAUTION
The dies bottom before the ratchet releases. This feature ensures maximum electrical and tensile performance of the crimp.
Do not re-adjust the ratchet.

408-2823
Rev AB
4 of 13
3. CRIMPING
1. 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.
2. Strip the wire to the dimension provided in Table 1. Do not nick or cut the wire strands.
3. Open the crimping dies by squeezing the tool handles together until the ratchet releases.
4. Push the locator assembly away from the upper crimping die slightly and hold.
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 (Figure 3).
If crimping a splice, position the wire barrel in the appropriate crimping chamber. Seat the splice
window indent on the locator assembly (Figure 3).
Figure 3: Positioning the wire barrel
Terminal
Splice
1
Flat side of terminal
2
Locator assembly
3
Splice window indent
5. While holding the wire barrel in place, release the locator assembly.

408-2823
Rev AB
5 of 13
6. While holding the tool so that the back side is facing you, insert the stripped wire into the wire barrel
until the wire bottoms (Figure 4).
Figure 4: Inserting the wire
1
Stripped wire
2
Back side of tool
3
Upper die
4
Locator assembly
5
Wire barrel
7. While holding the wire in place, squeeze the tool handles together until the ratchet releases. Allow the
tool handles to open fully.
8. Remove crimped terminal or splice from the tool.
9. 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 5 through 7.
CAUTION
Do not use damaged or worn terminals. Terminals can be removed from the wire, discarded, and replaced with new ones.

408-2823
Rev AB
6 of 13
4. INSPECTING THE CRIMP
Verify that the crimp dot code on the color-coded insulation indicates the crimping chamber used (see
Table 1).
Verify that the crimp is centered on the wire barrel (Figure 5).
Make sure that the wire insulation does not enter the wire barrel (Figure 5).
Verify that the wire end is flush with or slightly beyond the end of the wire barrel (Figure 5).
Figure 5: Inspecting the crimp
1
Terminal
2
Splice
3
Wire insulation does not enter wire barrel
4
Wire end extends slightly beyond end of wire barrel
5
Crimp is centered on wire barrel
6
Crimp dot code (one dot shown)
5. MAINTENANCE AND INSPECTION
The hand tool is inspected before it is shipped. Inspect it immediately upon arrival at your facility to ensure that
the tool has not been damaged during shipment.
Perform a maintenance and inspection program at least once a month to ensure dependable and uniform
terminations. Base your frequency of inspection on the following:
The care, amount of use, and handling of the hand tool.
The presence of abnormal amounts of dust and dirt.
The degree of operator skill.
Your own established standards.

408-2823
Rev AB
7 of 13
5.1. Daily maintenance
1. Immerse the hand tool (with handles partially closed) in a reliable commercial degreasing compound
to remove accumulated dirt, grease, and foreign matter. If no degreasing compound is available, the
tool can be wiped clean with a soft, lint-free cloth. Do not use hard or abrasive objects that could
damage the tool.
2. Ensure that the retaining pins are in place and 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 the handles closed to prevent objects from becoming lodged in the
dies.
5. Store the tool in a clean, dry area.
5.2. Periodic inspection
Lubrication
Lubricate all pins, pivot points, and bearing surfaces with SAE 20 motor oil as indicated in Table 3. 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 3: Lubrication schedule
Tool is used . . .
Lubricate . . .
Daily (production)
Daily
Daily (occasional)
Weekly
Weekly
Monthly
Visual inspection
1. 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.
2. Inspect the crimping area for worn, cracked, or broken dies. If damage is evident, return the tool for
evaluation and repair. See section 7, REPLACEMENT AND REPAIR.
Ratchet inspection
Check the ratchet feature on these hand tools to ensure that the ratchet does not release prematurely,
allowing the dies to open before they have fully bottomed.
Squeeze the tool handles together and count the number of ratchet stops. Five stops, including the
release position, should be indicated by the movement of the ratchet pawl and the clicking sound
associated with its movement. Refer to Figure 1.
If fewer than five positions are indicated, the ratchet pawl and ratchet handle must be replaced. Refer
to section 7, REPLACEMENT AND REPAIR.
If dies do not bottom after five ratchet stops, return the tool for repair. Refer to section 7,
REPLACEMENT AND REPAIR.
If the tool passes the ratchet inspection, lubricate it with a thin coat of any good SAE 20 motor oil.

408-2823
Rev AB
8 of 13
Gaging the crimping chamber
Figure 6 shows a recommended plug gage design for the wire crimping chamber.
Figure 6: Recommended plug gage design
1
0.51 [.020] x 45º (typical)
2
12.7 [.50] (typical)
3
Width (Table 4)
4
GO diameter (Table 4)
5
NO-GO diameter (Table 4)
Table 4: Plug gage specifications
Crimping
chamber
color code
Gage element diameter
Width
(maximum)
GO
NO-GO
Red
1.981-1.988 [.0780-.0783]
2.181-2.184 [.0859-.0860]
4.69 [.185]
Blue/green
2.336-2.344 [.0920-.0923]
2.537-2.540 [.0999-.1000]
5.33 [.210]
Yellow/black
3.251-3.258 [.1280-.1283]
3.451-3.454 [.1359-.1360]
6.85 [.270]
1. Remove any traces of oil or dirt from the crimping chamber and plug gage.
2. Close the tool handles until the crimping dies have bottomed and hold in this position. Do not force
the dies beyond initial contact.
3. Carefully insert the GO element into the the corresponding crimping chamber. Do not force it. The GO
element must pass completely through the crimping chamber. See Figure 7.

408-2823
Rev AB
9 of 13
4. Try to insert the NO-GO element into the same crimping chamber. The NO-GO elemen can start
entry, but must not pass completely through the crimping chamber. See Figure 7.
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. See section 7, REPLACEMENT AND
REPAIR.
Figure 7: Gaging the crimping chamber
6. CONVERTING OLD TOOLS TO SINGLE RATCHET PAWL
To convert an existing tool to single ratchet pawl, use the retrofit kit that corresponds to the frame type of
your tool (Table 5). Refer to instruction sheet 408-10339.
Table 5: Retrofit kits
Frame type
Retrofit kit
Stamped
2119486-1
Solid
2119486-2
7. REPLACEMENT AND REPAIR
Customer-replaceable parts (

408-2823
Rev AB
10 of 13
Figure 8) are listed in See Table 6 on page 11 for part numbers and descriptions.