59239-4 [TE]
Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools;
| 型号： | 59239-4 |
| 厂家： | 
TE CONNECTIVITY |
| 描述： | Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools |
| 文件： | 总9页 (文件大小：680K) |
| 中文： | 中文翻译 | 下载： | 下载PDF数据表文档文件 |
Instruction Sheet
Heavy Head Hand Tools 59239-4,
59239-8, 59287-2, and 525692
408-1261
27 AUG 15 Rev K
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.
Handles
Locator
StationaryCrimpingDies
(Anvils)
Ratchet
Head
Insulation Crimping
Adjustment Pin
Movable Crimping Dies
(Indenters)
Tool Color Code: Yellow
Tool Dot Code: 1
PRODUCT
INSULATION COLOR
WIRE
INSULATION
DIAMETER
(mm [in.])
TOOL
TYPE
TYPE
SIZE (AWG)
CODE
PIDG* Vinyl and
Nylon Terminal and
Splice and
PLASTI-GRIP*
Terminal
Yellow
12 - 10
Solid or Stranded
Copper
5.84-6.35
[.230-.250]
Yellow w/ Black stripes
16 - 14 ‡
2.41-5.08
[.095-.200]
Yellow w/ 3 Yellow Stripes
Yellow w/ 3 Brown Stripes
12
10
PIDG Insulation
Restring Nylon
Terminal
59239-4
59239-8
525692
Stranded Copper
3.02 - 5.08
[.119 - .200]
PIDG Radiation
Resistant
Terminal and Splice
Natural with Yellow Stripe
Natural with Yellow Stripe
12 - 10
Stranded Copper
Stranded Copper
6.60 [.260] Max
5.33 [.210] Max
16 - 14 ‡
Spare Wire Cap
328309
Yellow
Yellow
12 - 10
12 - 10
PIDG Vinyl and
Nylon Terminal and
Splice and
PLASTI-GRIP
Terminal
Solid or Standed
Copper
6.99-7.62
[.275-.300]
59287-2
Yellow w/ Black Stripe
16 - 14 ‡
‡ Heavy Duty
Figure 1
©2015 TE Connectivity family of companies
All Rights Reserved
*Trademark
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
1 of 9
LOC B
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners.
408-1261
The locator positions the product in the crimping
chamber. The insulation crimping adjustment pin is
used to regulate the height of the insulation crimp.
1. INTRODUCTION
Heavy Head Hand Tools (HHHT) 525692, 59239-4,
59239-8, and 59287-2 are designed to crimp the
product listed in Figure 1 onto the wire also listed.
Each tool handles are color coded (yellow) to
correspond to the color code of the product. Each tool
produces a dot code (one dot) on the crimp to
correspond to the given wire size range. Refer to
Figure 2.
Dimensions are in metric units [with U.S. customary
units in brackets]. Figures and illustrations are for
NOTE
reference only and are not drawn to scale.
i
3. CRIMPING PROCEDURE
3.1. Wire Preparation
For other tools accompanied by this instruction sheet,
follow the instructions for the tool used to crimp the
same wire size.
Strip the wire within the dimensions given in Figure 3,
being careful to avoid nicking or damaging the wire
conductor(s).
Reasons for reissue of this instruction sheet are
provided in Section 7, REVISION SUMMARY.
2. DESCRIPTION
DO NOT use wire with nicked or missing
conductor(s).
CAUTION
Each tool consists of a head containing two stationary
crimping dies (anvils) and two movable crimping dies
(indenters), a locator, an insulation crimping
adjustment pin, and handles with a ratchet. See
Figure 1.
!
3.2. Crimping
Make sure that the insulation color code of the product
matches the color of the tool handles. Refer to
Figure 1.
These tools are members of the CERTI-CRIMP* hand
crimping tool family. The ratchet on these tools
ensures full crimping of the product. Once engaged,
the ratchet will not release until the handles have been
FULLY closed.
A. Terminals
1. Insert the insulation crimp adjustment pin in the
proper position according to Section 4.
When closed, the crimping dies form a crimping
chamber with two sections: an insulation barrel section
and a wire barrel section. The insulation barrel section
crimps the insulation barrel of the product onto the
wire insulation and, simultaneously, the wire barrel
section crimps the wire barrel of the product onto the
wire conductor(s).
2. Open the crimping dies by closing the tool
handles until the ratchet releases, then allow the
handles to open FULLY.
3. Place the terminal in the crimping chamber so
that the wire barrel butts against the locator. Refer
to Figure 4.
The crimping dies bottom before the ratchet releases.
This design ensures maximum electrical and tensile
performance of the crimp. DO NOT re-adjust the
ratchet.
Product Color Code
PIDG Terminals
PLASTI-GRIP Terminal
PIDG Butt Splice
Spare Wire Cap
Color Stripe on
Heavy Duty and
Radiation Resistant
Color of
Insulation
Color Stripe on
Heavy Duty
Color Stripe on
Radiation Resistant
Three Equally Spaced
Color Stripes on
Insulation Restricting
Figure 2
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Rev K
408-1261
4. Close the tool handles until the terminal is held
firmly in place. DO NOT deform the terminal.
5. Insert a properly stripped wire into the terminal
wire barrel until the end of the wire conductor(s)
butts against the locator.
DO NOT allow the wire insulation to enter the
terminal wire barrel.
CAUTION
!
WIRE STRIP
PRODUCT
LENGTH
PIDG Vinyl and Nylon Terminal, PLASTI-GRIP
7.94-8.73
Terminal, and PIDG Radiation Resistant
[.312-.344]
Terminal
9.65-10.4
PIDG Insulation Restricting Nylon Terminal
[.380-.410]
PIDG Vinyl and Nylon Splice and PIDG
Radiation Resistant Splice
8.64-9.65
[.340-.380]
8.64-9.65
[.340-.380]
Spare Wire Cap
Figure 4
Figure 3
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. Inspect the crimp to make sure that it conforms to
Figures 7 and 8. Terminals not meeting the
described conditions should NOT be used.
B. Butt Splices
1. Open the crimping dies by closing the tool
handles until the ratchet releases, then allow the
handles to open FULLY.
2. Depress the locator. Position the splice in the
crimping chamber so that window indent of the
splice seats over the locator. See Figure 5.
3. Close the tool handles until the splice is held
firmly in place. DO NOT deform the splice.
4. Insert a properly stripped wire into the wire barrel
of the splice until the end of the wire conductor(s)
butts against the splice wire stop.
Figure 5
3 of 9
Rev K
408-1261
DO NOT allow wire insulation to enter the splice
wire barrel.
5. Insert a properly stripped wire into the spare wire
cap until the wire conductor(s) bottoms.
CAUTION
6. Hold the wire in position, and complete the crimp
by closing the tool handles until the ratchet
releases.
!
5. 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 spare wire
cap.
6. Release the tool handles, allow the handles to
open FULLY, and remove the crimped splice.
8. Inspect the crimp to make sure that it conforms to
Figures 7 and 8. Spare wire caps not meeting the
described conditions should NOT be used.
7. Turn the splice around, depress the locator, and
position the splice in the crimping chamber so that
the window indent of the splice seats over the
locator. Follow Steps 3 through 6.
4. INSULATION CRIMP ADJUSTMENT
8. Inspect the crimp to make sure that it conforms to
Figures 7 and 8. Splices not meeting the described
conditions should NOT be used.
The insulation crimping section of the hand tool has
three positions: 1 (tight), 2 (medium), and 3 (loose).
To adjust the grip resulting from the crimp of the
insulation barrel, proceed as follows:
C. Spare Wire Cap
1. Place the tool insulation adjustment pins in the
Position 3.
4.1. PIDG Terminal and Splice
PIDG terminals and splices feature a wire
insulation grip.
NOTE
2. Close the tool handles until the crimping dies
partially close, but leave enough space for the spare
wire cap to be inserted in the crimping chamber.
i
3. Depress the locator so that the end of the spare
wire cap rests against the recessed surface of the
locator. See Figure 6.
1. Insert each insulation crimp adjustment pin into
Position 3. Refer to Figure 1.
4. Close the tool handles until the spare wire cap is
held firmly in place. Do NOT deform the spare wire
cap.
Make sure that both insulation crimp adjustment
pins are in the same position.
CAUTION
!
2. Place the terminal or splice into the crimping
chamber as described in Section 3.
3. Insert an UNSTRIPPED wire into ONLY the
insulation barrel of the terminal or splice.
4. Close the tool handles until the ratchet releases.
Wire Conductor(s)
Bottomed in Spare
Wire Cap
5. Release the tool handles, and allow the handles
to open FULLY. Remove the crimped terminal or
splice.
6. Check the insulation barrel crimp by bending the
wire back and forth once. The terminal or splice
should retain its grip on the wire insulation. If it does
not, insert each insulation crimp adjustment pin into
the next position (Position 2).
End of Spare Wire
Cap Against
Recessed Surface
of Locator
7. Repeat Steps 2 through 6 until the correct
insulation barrel grip is attained. DO NOT use a
tighter position than is necessary.
Locator
Depressed
4.2. PLASTI-GRIP Terminal
PLASTI-GRIP terminals and splices feature a wire
"insulation support" only. Ideally, the terminal or splice
insulation should be in contact with the wire insulation.
Insulation Pin in Position 3
Figure 6
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Rev K
408-1261
Figure 7
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Rev K
408-1261
Figure 8
dependable and uniform terminations. Though
Insert each insulation crimp adjustment pin into
position according to the following:
recommendations call for at least one inspection a
month, frequency of inspection depends on:
Make sure that both insulation crimp adjustment
CAUTION
pins are in the same position.
1. The care, amount of use, and handling of the tool.
!
2. The presence of abnormal amounts of dust and
dirt.
• Position 3 for wire having a large insulation
3. The degree of operator skill.
diameter.
4. Your own established standards.
• Position 2 for wire having a medium insulation
The tool is inspected before being shipped; however, it
is recommended that the tool be inspected
immediately upon arrival to ensure that the tool has
not been damaged during shipment.
diameter.
• Position 1 for wire having a small insulation
diameter.
5. MAINTENANCE AND INSPECTION
It is recommended that a maintenance and inspection
program be performed periodically to ensure
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Rev K
408-1261
If gaging the crimping chamber is not required,
5.1. Daily Maintenance
NOTE
inspect the die closure using an alternate
procedure, i.e., the "Insulation Crimp Adjustment"
(see Section 4) and "Visual Inspection" (see
Paragraph 5.2.B).
1. Immerse the tool (handles partially closed) in a
reliable commercial degreasing compound to
remove accumulated dirt, grease, and foreign
matter. When degreasing compound is not
available, the tool may be wiped clean with a soft,
lint-free cloth. DO NOT use hard or abrasive objects
that could damage the tool.
i
1. Remove traces of oil or dirt from the crimping
chamber and plug gage.
2. Insert each insulation crimp adjustment pin into
Position 1. See Figure 10.
2. Make certain that the retaining pins are in place
and that they are secured with retaining rings.
3. Close the tool handles until the crimping dies
bottom, and hold in this position. DO NOT force
beyond initial contact.
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. Press and hold the locator down.
4. When the tool is not in use, keep the handles
closed to prevent objects from becoming lodged in
the crimping dies. Store the tool in a clean, dry area.
5. Carefully insert the GO element into the crimping
chamber as shown in Figure 10; DO NOT force it.
For the wire barrel section of the crimping chamber,
the GO element must pass completely through the
crimping chamber. For the insulation barrel section,
the GO element must pass through the length of the
section but will stop against the wire barrel section.
5.2. Periodic Inspection
A. Lubrication
Lubricate all pins, pivot points, and bearing surfaces
with any good SAE† 20 motor oil as follows:
6. In the same manner, try to insert the NO-GO
element into the crimping chamber as shown in
Figure 10. The NO-GO element may begin entry,
but may not pass through the crimping chamber.
• Tool used in daily production - daily
• Tool used daily (occasional) - weekly
• Tool used weekly - monthly
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, return the tool for
evaluation and repair. See Section 6, REPLACEMENT
AND REPAIR.
Wipe excess oil from the tool, particularly from the
crimping area. Oil transferred from the crimping area
onto certain terminations may affect the electrical
characteristics of an application.
B. Visual Inspection
5.3. Ratchet 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 6, REPLACEMENT
AND REPAIR.
Check the ratchet to ensure that the ratchet does not
release prematurely, allowing the dies to open before
they have fully bottomed. Proceed as follows:
1. Remove traces of oil or dirt from the bottoming
surfaces of the dies.
Some tools do not have handle return springs. This
inspection does not apply to those tools.
NOTE
2. Obtain a 0.025 mm [.001 in.] shim that is suitable
for checking the clearance between the bottoming
surfaces of the dies.
i
2. Inspect the head for worn, cracked, or broken
crimping dies. If damage is evident, return the tool
for evaluation and repair. See Section 6,
REPLACEMENT AND REPAIR.
3. Select a terminal or splice and maximum size
wire for the terminal or splice.
4. Position the terminal or splice in the crimping
chamber according to Section 3, CRIMPING
PROCEDURE. Holding the wire in place, squeeze
the tool handles together until the ratchet releases.
Hold the tool handles in this position, maintaining
just enough pressure to keep the dies closed.
C. Gaging the Crimping Chamber
This inspection requires the use of plug gages
conforming to the dimensions provided in Figure 9.
To gage the crimping chamber, proceed as follows:
5. Check the clearance between the bottoming
surfaces of the dies. If the clearance is 0.025 mm
[.001 in.] or less, the ratchet is satisfactory. If
clearance exceeds 0.025 mm [.001 in.], the ratchet
is out of adjustment and must be repaired. See
Section 6, REPLACEMENT AND REPAIR.
†SAE is a trademark.
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Rev K
408-1261
“W” = 6.35 +/-0.13 [.250 +/-.005]
GAGE ELEMENT DIAMETER
GAGE ELEMENT DIAMETER
GO
4.293-4.300 [.1690-.1693]
NO-GO
GO
NO-GO
4.442-4.445 [.1749-.1750]
1.626-1.633 [.0640-.0643]
2.131-2.134 [.0839-.0840]
Figure 9
Detail A
Inspection of Wire Barrel
Section of Crimping Chamber
Detail B
Inspection of Insulation Barrel
Section of Crimping Chamber
Insulation Crimp
Adjustment Pin
In Position 1
Crimping Dies
Bottomed But Not
Under Pressure
Crimping Dies Bottomed
But Not Under Pressure
Plug Gage
Plug Gage
GO Element Must Pass Completely Through Length of Insulation
Barrel Crimping Chamber But Stop on Wire Barrel Section
GO Element Must Pass Completely
Through Crimping Chamber
NO-GO Element May Start Entry, But Must Not Pass Completely Through Crimping Chamber
Figure 10
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Rev K
408-1261
6. REPLACEMENT AND REPAIR
CUSTOMER SERVICE (038-035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
Customer-replaceable parts are listed in
Figure 11.
HARRISBURG PA 17105-3608
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 by TE Connectivity to ensure quality and
reliability. Order replacement parts through your
representative, or call 1-800-526-5142, or send a
facsimile of your purchase order to 717-986-7605, or
write to:
For customer repair service, call 1-800-526-5136.
7. REVISION SUMMARY
• Updated document to corporate requirements
• Added new information to Figures 9 and 10
REPLACEMENT PARTS
PART NUMBER FOR TOOL 306110-9
QTY PER
TOOL
ITEM
DESCRIPTION
PIN, Retaining
59239-4, 59239-8
59287-2
300388
525692
300388
1
2
300388
21045-3
2
4
1
2
1
1
1
1
2
1
1
1
21045-3
300389
525108
RING, Retaining
PIN, Retaining
RING, Retaining
PIN ASSEMBLY, Adjustment
LOCATOR, Stop
PIN
3
300389
300389
4
21045-6
21045-6
303848-2
306110-4
5-21028-7
7-59683-6
6-306131-4
45891-8
45888-7
21028-5
21045-6
5
303848-2
306110-9
5-21028-7
7-59683-6
6-306131-4
306106-2
306107-2
21028-4
303848-2
306110-9
5-21028-7
7-59683-6
6-306131-4
306106-2
306107-2
21028-4
6
7
8
SPRING
9
SCREW
10
11
12
STATIONARY DIE, Insulation
MOVING DIE, Insulation
PIN
Figure 11
9 of 9
Rev K
相关型号：
59239-8
Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools
TE
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