TE Connectivity 59239-4 User manual

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*Trademark
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Instruction Sheet
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 LOC B
408-1261
Heavy Head Hand Tools 59239-4,
59239-8, 59287-2, and 525692 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.
Figure 1
Handles
Locator
StationaryCrimpingDies
(Anvils)
Movable Crimping Dies
(Indenters)
Tool Color Code: Yellow
Tool Dot Code: 1
Insulation Crimping
Adjustment Pin
Ratchet
Head
TOOL
PRODUCT WIRE
TYPE INSULATION COLOR
CODE TYPE SIZE (AWG) INSULATION
DIAMETER
(mm [in.])
59239-4
59239-8
525692
PIDG* Vinyl and
NylonTerminaland
Splice and
PLASTI-GRIP*
Terminal
Yellow Solid or Stranded
Copper
12 - 10 5.84-6.35
[.230-.250]
Yellow w/ Black stripes 16 - 14 ‡
PIDG Insulation
Restring Nylon
Terminal
Yellow w/ 3 Yellow Stripes Stranded Copper 12 2.41-5.08
[.095-.200]
Yellow w/ 3 Brown Stripes 10 3.02 - 5.08
[.119 - .200]
PIDG Radiation
Resistant
Terminal and Splice
Natural with Yellow Stripe Stranded Copper 12 - 10 6.60 [.260] Max
Natural with Yellow Stripe 16 - 14 ‡
Spare Wire Cap
328309 Yellow Stranded Copper 12 - 10 5.33 [.210] Max
59287-2
PIDG Vinyl and
NylonTerminaland
Splice and
PLASTI-GRIP
Terminal
Yellow Solid or Standed
Copper
12 - 10 6.99-7.62
[.275-.300]
Yellow w/ Black Stripe 16 - 14 ‡
‡ Heavy Duty
ORIGINAL INSTRUCTIONS

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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.
Dimensionsareinmetricunits[withU.S.customary
units in brackets]. Figures and illustrations are for
reference only and are not drawn to scale.
For other tools accompanied by this instruction sheet,
follow the instructions for the tool used to crimp the
same wire size.
Reasons for reissue of this instruction sheet are
provided in Section 7, REVISION SUMMARY.
2. DESCRIPTION
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.
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.
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).
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.
The locator positions the product in the crimping
chamber. The insulation crimping adjustment pin is
used to regulate the height of the insulation crimp.
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.
3. CRIMPING PROCEDURE
3.1. Wire Preparation
Strip the wire within the dimensions given in Figure 3,
being careful to avoid nicking or damaging the wire
conductor(s).
DO NOT use wire with nicked or missing
conductor(s).
3.2. Crimping
Make sure that the insulation colorcode of the product
matches the color of the tool handles. Refer to
Figure 1.
A. Terminals
1. Insert the insulation crimp adjustment pin in the
proper position according to Section 4.
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.
Figure 2
NOTE
i
CAUTION
!
ProductColorCode
PIDG Terminals PLASTI-GRIP Terminal PIDG Butt Splice Spare Wire Cap
Color Stripe on
Heavy Duty and
Radiation Resistant
Three Equally Spaced
Color Stripes on
Insulation Restricting
Color Stripe on
Radiation Resistant Color of
Insulation
Color Stripe on
Heavy Duty

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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.
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 4
Figure 5
PRODUCT WIRE STRIP
LENGTH
PIDG Vinyl and Nylon Terminal, PLASTI-GRIP
Terminal, and PIDG Radiation Resistant
Terminal 7.94-8.73
[.312-.344]
PIDG Insulation Restricting Nylon Terminal 9.65-10.4
[.380-.410]
PIDG Vinyl and Nylon Splice and PIDG
Radiation Resistant Splice 8.64-9.65 [.340-.380]
Spare Wire Cap 8.64-9.65
[.340-.380]
CAUTION
!

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DO NOT allow wire insulation to enter the splice
wire barrel.
5. Complete the crimp by closing the tool handles
until the ratchet releases.
6. Release the tool handles, allow the handles to
open FULLY, and remove the crimped splice.
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.
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.
C. Spare Wire Cap
1. Place the tool insulation adjustment pins in the
Position 3.
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.
3. Depress the locator so that the end of the spare
wire cap rests against the recessed surface of the
locator. See Figure 6.
4. Close the tool handles until the spare wire cap is
held firmly in place. Do NOT deform the spare wire
cap.
Figure 6
5. Insert a properly stripped wire into the spare wire
cap until the wire conductor(s) bottoms.
6. Hold the wire in position, and 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.
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.
4. INSULATION CRIMP ADJUSTMENT
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:
4.1. PIDG Terminal and Splice
PIDG terminals and splices feature a wire
insulation grip.
1. Insert each insulation crimp adjustment pin into
Position 3. Refer to Figure 1.
Make sure that both insulation crimp adjustment
pins are in the same position.
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.
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).
7. Repeat Steps 2 through 6 until the correct
insulation barrel grip is attained. DO NOT use a
tighter position than is necessary.
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.
CAUTION
!
Wire Conductor(s)
BottomedinSpare
Wire Cap
EndofSpareWire
Cap Against
RecessedSurface
of Locator
Locator
Depressed
Insulation Pin in Position 3
NOTE
i
CAUTION
!

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Figure 7

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Figure 8
Insert each insulation crimp adjustment pin into
position according to the following:
Make sure that both insulation crimp adjustment
pins are in the same position.
•Position 3 for wire having a large insulation
diameter.
•Position 2 for wire having a medium insulation
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
dependable and uniform terminations. Though
recommendations call for at least one inspection a
month, frequency of inspection depends on:
1. The care, amount of use, and handling of the tool.
2. The presence of abnormal amounts of dust and
dirt.
3. The degree of operator skill.
4. Your own established standards.
The tool is inspected before beingshipped; however, it
is recommended that the tool be inspected
immediately upon arrival to ensure that the tool has
not been damaged during shipment.
CAUTION
!

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5.1. Daily Maintenance
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.
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 the handles
closed to prevent objects from becoming lodged in
the crimping dies. Store the tool in a clean, dry area.
5.2. Periodic Inspection
A. Lubrication
Lubricate all pins, pivot points, and bearing surfaces
with any good SAE† 20 motor oil as follows:
•Tool used in daily production - daily
•Tool used daily (occasional) - weekly
•Tool used weekly - monthly
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
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.
Sometools do not havehandle return springs. This
inspection does not apply to those tools.
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.
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:
†SAE is a trademark.
If gaging the crimping chamber is not required,
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. 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.
3. Close the tool handles until the crimping dies
bottom, and hold in this position. DO NOT force
beyond initial contact.
4. Press and hold the locator down.
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.
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.
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.
5.3. Ratchet Inspection
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.
2. Obtain a 0.025 mm [.001 in.] shim that is suitable
for checking the clearance between the bottoming
surfaces of the dies.
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.
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.
NOTE
i
NOTE
i

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Figure 9
Figure 10
“W” = 6.35 +/-0.13 [.250 +/-.005]
GAGE ELEMENT DIAMETER GAGE ELEMENT DIAMETER
GO NO-GO GO NO-GO
4.293-4.300 [.1690-.1693] 4.442-4.445 [.1749-.1750] 1.626-1.633 [.0640-.0643] 2.131-2.134 [.0839-.0840]
Detail A
Inspection of Wire Barrel
Section of Crimping Chamber
Detail B
Inspection of Insulation Barrel
Section of Crimping Chamber
Crimping Dies
BottomedBut Not
Under Pressure Plug Gage
GO Element Must Pass Completely
Through Crimping Chamber GO Element Must Pass Completely Through Length of Insulation
Barrel Crimping Chamber But Stop on Wire Barrel Section
Plug Gage
Insulation Crimp
Adjustment Pin
In Position 1
NO-GO Element May Start Entry, But Must Not Pass Completely Through Crimping Chamber
CrimpingDiesBottomed
But Not Under Pressure

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6. REPLACEMENT AND REPAIR
Customer-replaceable parts are listed in
Figure 11.
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:
CUSTOMER SERVICE (038-035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
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
Figure 11
REPLACEMENT PARTS
ITEM PART NUMBER FOR TOOL 306110-9 DESCRIPTION QTYPER
TOOL
59239-4, 59239-8 59287-2 525692
1 300388 300388 300388 PIN, Retaining 2
2 21045-3 21045-3 525108 RING, Retaining 4
3 300389 300389 300389 PIN, Retaining 1
4 21045-6 21045-6 21045-6 RING, Retaining 2
5 303848-2 303848-2 303848-2 PIN ASSEMBLY, Adjustment 1
6 306110-9 306110-4 306110-9 LOCATOR, Stop 1
7 5-21028-7 5-21028-7 5-21028-7 PIN 1
8 7-59683-6 7-59683-6 7-59683-6 SPRING 1
9 6-306131-4 6-306131-4 6-306131-4 SCREW 2
10 306106-2 45891-8 306106-2 STATIONARY DIE, Insulation 1
11 306107-2 45888-7 306107-2 MOVING DIE, Insulation 1
12 21028-4 21028-5 21028-4 PIN 1

Mouser Electronics
Authorized Distributor
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525692