Instruction Sheet
1 of 8
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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
23 JAN 18 Rev F
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 PEEK STRATO-THERM Terminals to the wire sizes listed in Figure 2.
Figure 2
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.
Hand Tool
Part Number
Wire Size
(AWG)
Dot Code
Color Code
Terminal Color Code
Strip Length
High Temp
Low Temp
Min
Max
576778
24-22
2 Dots
1 Handle Brown
Brown
Black
5.56 [.219]
6.35 [.250]
576779
20
1 Dot
1 Handle Purple
Gray
Purple
(w/Black Stripe)
5.56 [.219]
6.35 [.250]
576780
18
2 Dots
1 Handle Black
Orange
Orange
(w/Black Stripe)
5.56 [.219]
6.35 [.250]
576781
16
1 Dot
2 Handles Orange
Orange
Orange
(w/Black Stripe)
5.56 [.219]
6.35 [.250]
576782
14
2 Dots
1 Handle Black
White
White
(w/Black Stripe)
5.56 [.219]
6.35 [.250]
576783
12
1 Dot
2 Handles White
White
White
(w/Black Stripe)
5.56 [.219]
6.35 [.250]
576784
10
1 Dot
2 Handles Black
Black
----
7.62 [.300]
8.38 [.330]
PIDG* PEEK STRATO-THERM*
Terminal Crimping Tools
Insulation Crimping Adjustment Pin
(Shown in No. 3 Position - reference)
408-10040
Rev F
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NOTE
Dimensions in this instruction sheet are in millimeters [with inches in brackets]. Figures are not drawn to scale.
Reasons for re-issue of this instruction sheet are provided in Section 8, REVISION SUMMARY.
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.
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.
3. CRIMPING PROCEDURE
NOTE
Refer to Section 5 for information on the insulation crimp adjustment.
Refer to Figure 3 for terminal crimping procedures.
1. Strip the wire to the length indicated in Figure 2; being careful not to nick or cut wire strands.
CAUTION
DO NOT use wire with nicked or missing conductors.
NOTE
Make sure terminal insulation color code matches tool handle color.
2. Open the tool jaws by closing the handles until the ratchet releases; then allow handles to open fully.
3. Place the terminal in the dies so 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.
Figure 3
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Rev F
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5. Insert properly stripped wire into the terminal until the end of the conductor butts against the 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.
8. Observe the dot code on the finished crimp to ensure that the correct terminal and tool combination
was used (reference Figure 2).
9. Refer to Section 4 and Figure 4 for crimp inspection procedure.
4. CRIMP INSPECTION
Inspect crimped terminals by checking the features described in Figure 4. Terminals not meeting the described
conditions should NOT be used.
Figure 4
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Rev F
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5. INSULATION CRIMP ADJUSTMENTS
The insulation crimping section of the hand tool has three positions: No. 1 (tight), No. 2 (medium), and No. 3
(loose).
To adjust the section:
1. Insert the insulation crimp adjustment pin into the No. 3 position (reference 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 pin 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.
6. MAINTENANCE AND INSPECTION PROCEDURE
TE Connectivity recommends that a maintenance and inspection program be performed periodically to ensure
dependable and uniform terminations. Though recommendations call for at least one inspection per month,
frequency of inspection depends on:
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.
The hand tool is inspected before being shipped; however, TE recommends that the tool be inspected
immediately upon arrival to ensure it 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
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.
408-10040
Rev F
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Visual Inspection
1. Close tool handles until 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 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.
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 dimensions shown in Figure 5.
NOTE
TE Connectivity does not manufacture or market these gages.
Hand Tool
Wire Barrel Crimp Chamber
Insulation barrel Crimp Chamber
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
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 insulation crimping adjustment pin into the No. 1 position.
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Rev F
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7. With crimping dies bottomed, check the insulation barrel section of the crimping chamber using the
same procedure 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
TE 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.
Figure 6
CERTI- CRIMP Hand Crimping Tool Ratchet Control Inspection
The CERTI-CRIMP hand crimping tool ratchet control feature on TE 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 satisfactory. If the
clearance exceeds 0.025 mm [.001 in.], the ratchet is out of adjustment and must be repaired.
408-10040
Rev F
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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, or call 1-800-
526-5142, or send a facsimile of your purchase order to 1-717-986-7605, or write to:
CUSTOMER SERVICE (038-035)
TE CONNECTIVITY CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
For tool repair service, please contact a TE Representative at 1-800-526-5136.
Figure 7
PIDG PEEK STRATO-THERM Terminal Crimping Tool Replacement Parts
408-10040
Rev F
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8. REVISION SUMMARY
Revisions to this instruction sheet include:
Changed terminal name from PIDG STRATO-THERM to PIDG PEEK STRATO-THERM (3 places).
Updated format, logo and enterprise name
Moved some figures due to formatting changes (figures were not re-numbered).
In Figure 1 added text identifying insulation crimping adjustment pin position for reference
Removed “Detail A” and “Detail B” text in Figure 6
Mouser Electronics
Authorized Distributor
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