Tyco Electronics 59282 User manual

Instruction Sheet
408-1537
LOC B
1 of 4
E 2009 Tyco Electronics Corporation, Harrisburg, PA
All International ights eserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
TOOLING ASSISTANCE CENTE 1-800-722-1111
P ODUCT INFO MATION 1-800-522-6752 This controlled document is subject to change. For latest revision and egional Customer Service,
visit our website at www.tycoelectronics.com
13 MA 09 ev B
Hand Tool Assembly 59282
PROPER USE GUIDELINES
CumulativeTraumaDisorderscanresult fromtheprolongeduseofmanuallypoweredhand tools.Handtoolsareintendedforoccasional useandlowvolume
applications. A wide selection of powered application equipment for extended-use, production operations is available.
Figure 1
CE TI-C IMP*
Hand Tool
atchet Control
Front of Tool
(Wire Side)
Anvils (Movable Die) Crimpers (Fixed Die)
Locator
Bottoming Surface
of Dies
Handles
1. INTRODUCTION
Hand Tool Assembly 59282, shown in Figure 1, is
designed to crimp CERTI–SEAL* butt strap splice
assemblies listed in Figure 2 onto solid or stranded
wire sizes 16 through 14 AWG with an insulation
diameter range of 1.78 through 3.81 mm
[.070 through .150 in.].
Read these instructions carefully and completely
before using the tool.
Dimensions in this instruction sheet are in
millimeters [with inches in brackets]. Figures and
illustrations are for reference only and are not
drawn to scale.
Reasons for reissue are provided in Section 6,
REVISION SUMMARY.
2. DESCRIPTION
The front of the tool, into which the wire is inserted, is
marked with the wire size range and tool part number.
The tool consists of a head and handle. The head
features two movable dies (wire anvil and insulation
anvil) and two fixed dies (wire crimper and insulation
crimper). When closed, the dies form a crimping
chamber. The locator is used to properly position the
splice in the crimping chamber.
The CERTI–CRIMP hand tool ratchet control ensures
full crimping of the splice. Once engaged, the ratchet
will not release until the handles have been FULLY
closed.
The dies bottom before the ratchet releases. This
ensures ma imum electrical and tensile
performance of the crimp. DO NOT re-adjust the
ratchet.
3. CRIMPING PROCEDURE
1. Refer to Figure 2, and choose the proper wire
size and insulation diameter for the splice. Strip the
wires to the dimension listed. DO NOT cut or nick
the wire conductor.
2. Close the tool handles until the ratchet releases.
Window
Indent
Wire Strip Length
(See Table)
Note: Not to Scale
Wire Stop
Insulation Barrel Wire Barrels
ing ing
Conductor
CERTI-SEAL Butt Strap Splice Assembly
Insulation Barrel
IRE
SIZE RANGE
(A G)
INSULATION
DIAMETER
RANGE
STRIP
LENGTH SPLICE
16 14
1.78-2.92
[.070-.115] 7.87-8.38 [.310-.330] 324989
16
-
14
1.91-3.81
[.075-.150] 7.24-7.75 [.285-.305] 324549
Figure 2
NOTE
i
CAUTION
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408-1537
Han Tool Assembly 59282
Rev B2 of 4 Tyco Electronics Cor oration
3. Insert the splice into the crimping chamber until
it butts against the locator with one end resting on
the anvils as shown in Figure 3.
4. Close the tool handles just until the splice is held
in place. DO NOT deform the splice.
5. Insert one of the stripped wires into the end of
the splice protruding from the front of the tool until
it bottoms against the wire stop.
6. Hold the wire in place, and close the tool
handles until ratchet releases.
7. Rotate the splice, and position it so that the
uncrimped end rests on the anvils. Repeat Steps 4
through 6.
Figure 3
S lice Against
Locator
Anvils
End of Wire
Against S lice
Wire Sto
Back of
Tool
8. Visually inspect the crimped splice according to
Figure 4.
A split ring indicates that the wrong wire size was
used or that a die is damaged.
The splices are not repairable. Discard and
replace any defective or damaged splice. DO
NOT re-use a terminated splice by removing the
wire.
4. MAINTENANCE AND INSPECTION
4.1. Daily Maintenance
1. Clean foreign particles from tool using a soft,
clean, lint–free cloth or brush.
2. Make sure all pins and retaining rings are
secured in their proper places. Lubricate all pins,
pivot points, and bearing surfaces with a thin coat
of any good SAE 20 motor oil. DO NOT oil
excessively.
3. Store tool in a clean, dry area with handles
closed.
Figure 4
Seam of Rings Extrude
Slightly But Are Not S lit
Each Wire End (Viewed Through Window Indent)
Against Wire Sto or Flush With, or Extends
Slightly Beyond, Each S lice Wire Barrel
4.2. Perio ic Inspection
Regularly scheduled inspections should be conducted
and recorded by quality control personnel. It is
recommended that the inspection procedures be
performed once a month; more often if your work
environment, company standards, or amount of tool
use indicates the need.
A. Visual Inspection
Remove all lubrication and accumulated film by
immersing the tool in a commercial degreaser that will
not damage paint or plastic. Then:
1. Check for missing or defective pins or retaining
rings. Replace parts as necessary.
2. Close handles until ratchet releases. With
handles fully open, carefully inspect the ratchet
assembly, tool head, and die surfaces.
Worn, cracked, pitted, or chipped die surfaces, or
other obvious wear or damage to the ratchet or tool
head requires removal of the tool from service. Refer
to Section 5, REPLACEMENT AND REPAIR.
B. Gaging the Crimping Chamber
This inspection requires the use of plug gages
conforming to the dimensions provided in Figure 5.
Gage each crimping chamber section separately as
follows:
1. Remove traces of oil or dirt from the crimping
chamber and plug gage.
2. If gaging the insulation barrel section of the
crimping chamber, insert a 0.13 mm [.005 in.] shim
between the bottoming surfaces of the dies.
3. Close the tool handles until the dies are
bottomed and hold them in this position. Do not
force the dies beyond initial contact.
4. Align the plug gage GO element with the
crimping chamber section. Push the element
NOTE
i
CAUTION
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408-1537
Hand Tool Assembly 59282
3 of 4Rev B
Tyco Electronics Corporation
straight into the chamber, but do not force it. The
GO element must pass completely through the
chamber.
5. Align the NO–GO element and try to insert it
straight into the same crimping chamber section.
The NO–GO element may begin entry as shown in
Figure 4, but must not pass through the chamber.
If the crimping chamber conforms to the gage
inspection, the tool may be considered dimensionally
correct and should be lubricated with a THIN coat of
any good SAE 20 motor oil. If the crimping chamber
does NOT conform to the gage inspection, the tool
must be returned for further evaluation and repair.
See Section 5, REPLACEMENT AND REPAIR.
For additional information regarding the use of a plug
gage, refer to Instruction Sheet 408–7424.
NO-GO DiameterGO Diameter
Suggested Plug Gage Design
50.8 [2.0] Min Typ
Die Closure Configuration
Insulation Barrel Crimp Wire Barrel Crimp
GAGE ELEMENT DIAMETER
Insulation Barrel Section of
Crimping Chamber ire Barrel Section of Crimping Chamber
GO NO-GO GO NO-GO
4.064-4.072
[.1600-.1603] 4.265-4.267 [.1679-.1680] 3.353-3.360 [.1320-.1323] 3.503-3.505 [.1379-.1380]
Figure 5
ÉÉ
ÉÉ
ÉÉ
ÉÉ
ÉÉ
ÉÉ
É
É
É
É
É
É
GO Element NO-GO Element
GO element must pass
completely t roug t e
crimping c amber.
NO-GO element may enter
partially, but must not pass
completely t roug t e
crimping c amber.
Crimping
C amber
Inspection of Crimping Chamber
4.3. CERTI-CRIMP Hand Tool Ratchet Control
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 splice and
maximum size wire for the
splice.
4. Position the 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 5, REPLACEMENT AND REPAIR.
5. REPLACEMENT AND REPAIR
Customer–replaceable parts are listed in Figure 6.
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 Tyco Electronics to ensure
quality and reliability. Order replacement parts
through your Tyco Electronics 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, contact a Tyco
Electronics Representative at 1–800–526–5136.
6. REVISION SUMMARY
S Updated document to corporate requirements
S Changed dimensions in table in Figure 5

408-1537
Han Tool Assembly 59282
Rev B4 of 4 Tyco Electronics Corporation
311.15 [12.25]
2
345
6
7
8
9
9
1
51315
5
4
1
5
1
88.9 [3.5]
Handles Closed
REPLACEMENT PARTS
ITEM PART NUMBER DESCRIPTION QTY PER TOOL
1 21045-3 Retainin Rin 10
2 300388-0 Retainin Pin 2
3 303863-0 Retainin Pin 2
4 303861-0 Retainin Pin 2
5 21045-6 Retainin Rin 6
6 306100-0 Key Insert Assembly 1
7 1-304197-4 Retainin Pin 2
8 303864-0 Retainin Pin 1
9 302722-0 Washer 2
Figure 6

Mouser Electronics
Authorized Distributor
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59282