Tyco Electronics 59239-4 User manual

Instruction Sheet
Heavy Head Hand Tools
59239-4, 59239-8, 408-1261
LOC B
1 of 9
E 2007 Tyco Electronics Corporation, Harrisburg, A
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
TOOLING ASSISTANCE CENTER 1-800-722-1111
RODUCT INFORMATION 1-800-522-6752 This controlled document is subject to change. For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com
18 OCT 07 Rev F
59287-2, and 525692
PROPER SE G IDELINES
CumulativeTraumaDisorderscanresultfromthe prolongeduseofmanually poweredhandtools.Hand toolsareintendedfor occasionaluseandlowvolume
applications. A wide selection of powered application equipment for extended-use, production operations is available.
Stationary Crimping
Dies (Anvils)
Locator
Ratchet
Insulation Crimping
Adjustment in
Movable Crimping
Dies (Indenters)
Handles
Head
Tool Color Code: Yellow
Tool Dot Code: 1
PROD CT WIRE
TOOL TYPE INS LATION
COLOR CODE TYPE SIZE (AWG) INS LATION
DIAMETER
(mm [in.])
IDG* Vinyl and Nylon Terminal and Yellow Solid or Stranded 12-10 5.84-6.35
yy
Splice and LASTI-GRI * Terminal Yellow with Black Stripe Copper 16-14 HD
G
[.230-.250]
59239-4 IDG Insulation Restricting Nylon Yellow with 3 Yellow Stripes
Stranded Copper
12 2.41-5.08
[.095-.200]
59239 4
59239-8
525692
gy
Terminal Yellow with 3 Brown Stripes
Stranded Copper
10 3.02-5.08
[.119-.200]
IDG Radiation Resistant Natural with Yellow Stripe
Stranded Copper
12-10 6.60 [.260]
Terminal and Splice Natural with Black Stripe
Stranded Copper
16-14 HD G
[]
Max
Spare Wire Cap 328309 Yellow Stranded Copper 12-10 5.33 [.210] Max
59287 2
IDG Vinyl and Nylon Terminal and Yellow Solid or Stranded 12-10 6.99-7.62
59287
-
2
yy
Splice and LASTI-GRI Terminal Yellow with Black Stripe Copper 16-14 HD
G
[.275-.300]
G Heavy Duty
Figure 1
1. INTROD CTION
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.
Measurements are in metric units [with U.S.
customary units in brackets]. Figures and
illustrations are for reference only and are not
drawn to scale.
NOTE
i

408-1261
HHHT 59239-4, 59239-8, 59287-2, nd 525692
Rev F2 of 9 Tyco Electronics Corporation
For other tools accompan ed by th s nstruct on
sheet, follow the nstruct ons for the tool used to
cr mp the same w re s ze.
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 cr mp ng des bottom before the ratchet
releases. Th s des gn ensures max mum
electr cal and tens le performance of the cr mp.
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 Prep r tion
Strip the wire within the dimensions given in Figure 3,
being careful to avoid nicking or damaging the wire
conductor(s).
DO NOT use w re w th ncked or m ss ng
conductor(s).
3.2. Crimping
Make sure that the nsulat on color code of the
product matches the color of the tool handles.
Refer to F gure 1.
A. Termin ls
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.
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 w re nsulat on to enter the
term nal w re barrel.
Spare W re CapPLASTI-GRIP Term nalPIDG Term nals PIDG Butt Spl ce
Color Stripe on
Heavy Duty
Color Stripe on
Heavy Duty and
Radiation Resistant
3 Equally Spaced
Color Stripes on
Insulation Restricting
Color Stripe on
Radiation Resistant Color of
Insulation
Product Color Code
Figure 2
NOTE
i
CAUTION
!
CAUTION
!
NOTE
i
CAUTION
!

408-1261
HHHT 59239-4, 59239-8, 59287-2, and 525692
3 of 9Rev F
Tyco Electronics Corporation
Strip Length
PRODUCT IRE STRIP
LENGTH
PIDG inyl 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 inyl and Nylon Splice and
PIDG Radiation Resistant Splice 8.64-9.65 [.340-.380]
Spare Wire Cap 8.64-9.65
[.340-.380]
Figure 3
Figure 4
C" B"
PIDG Terminal
C" B"
PLASTI-GRIP Terminal
C" B"
PIDG Insulation Restricting Terminal
B" Equals Wire Barrel
C" Equals Insulation Barrel
Crimping a Terminal
Locator
Wire Barrel
Against Locator
End of Wire Conductor(s)
Against Locator
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.
Figure 5
B" Equals Wire Barrel
C" Equals Insulation Barrel
Crimping a Butt Splice
C" B"
Window Indent
Locator
Depressed
End of Conductor(s)
Against Splice Wire Stop
B" C"
Splice Window
Indent Over Locator
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.
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.
CAUTION
!

408-1261
HHHT 59239-4, 59239-8, 59287-2, and 525692
Rev F4 of 9 Tyco Electronics Corporation
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.
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.
Figure 6
Crimping a Spare Wire Cap
Wire Conductor(s)
Bottomed in
Spare Wire Cap
Insulation Adjustment Pin in Position 3
Locator
Depressed
B" E uals Wire Barrel
B"
End of Spare Wire Cap
Against Recessed
Surface of Locator
4. INS LATION CRIMP ADJ STMENT
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 te minals and splices featu e a wi e
insulation g ip.
1. Insert each insulation crimp adjustment pin into
Position 3. Refer to Figure 1.
Make su e that both insulation c imp adjustment
pins a e 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 te minals and splices featu e a
wi e insulation suppo t" only. Ideally, the te minal
o splice insulation should be in contact with the
wi e insulation.
Insert each insulation crimp adjustment pin into
position according to the following:
Make su e that both insulation c imp adjustment
pins a e 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.
NOTE
i
CA TION
!
NOTE
i
CA TION
!

408-1261
HHHT 59239-4, 59239-8, 59287-2, and 525692
5 of 9Rev F
Ty o Ele troni s Corporation
Figure 7
ACCEPT REJECT
Insulation barrel is in firm onta t with wire insulation.
Corre t olor ode, dot ode, and tool ombination.
Wire size is within wire range stamped under
terminal tongue or on enter of spli e.
Crimp entered on wire barrel.
End of ondu tor is flush with, or extends beyond, end
of terminal wire barrel.
End of ondu tor against wire stop of spli e, or at least
flush with, or extended slightly beyond wire barrel.
Wire insulation does not enter wire barrel.
No ni ked or missing ondu tor strands.
Wire insulation extruded (insulation rimp too tight on
PIDG terminals and spli es).
Wrong dot ode and olor ode ombination.
Wire size is not within wire range stamped on terminal
tongue or spli e.
Crimp not entered on wire barrel (terminal was not
against lo ator).
End of ondu tor is not flush with, or extending
beyond, end of wire barrel ( he k wire strip length).
Ex essive flash or extruded insulation (wrong tool,
terminal, or spli e ombination; or dies are damaged).
Wire insulation entered wire barrel.
Ni ked or missing ondu tor strands.
PIDG Terminal and
PLASTI-GRIP Terminal
PIDG Butt Splice
A Dot Code (1 Dot) Must Appear on
All Crimped Produ ts
Wire Range
Stamped Here
Wire Range
Stamped Here
3
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
124
5
4
5
8
26
1
3
587
8
6
1
52
5
87 6
4
6
1
2

408-1261
HHHT 59239-4, 59239-8, 59287-2, an 525692
Rev F6 of 9 Tyco Electron cs Corporat on
Figure 8
Correct color code, dot code, and tool comb nat on.
Conductors may extend sl ghtly beyond w re barrels on
term nals.
No flash or extruded nsulat on.
W re nsulat on does not enter w re barrel of term nal
or cap.
End of conductor bottomed n cap.
Full w dth of cr mp s over w re barrel of cap.
No n cked or m ss ng conductor strands.
Correct w re s ze used.
Wrong dot code and color code comb nat on.
Excess ve flash or extruded nsulat on (cr mped n
wrong tool or d es are damaged).
W re nsulat on entered w re barrel of term nal or cap.
End of conductor not bottomed n cap.
Part of cr mp off end of w re barrel of cap (cap was
not bottomed n recess of locator).
N cked or m ss ng conductor strands.
Incorrect w re s zes used.
ACCEPT REJECT
PIDG Insulation Restricting Terminals
Spare Wire Cap
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
472
31
6
8
47
5
36
4
5
6
7
1
2
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 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.
5.1. Daily Maintenance
1. Immersed 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.

408-1261
HHHT 59239-4, 59239-8, 59287-2, nd 525692
7 of 9Rev F
Tyco Electronics Corporation
5.2. Periodic Inspection
A. Lubric tion
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. Visu l 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.
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. G ging the Crimping Ch mber
This inspection requires the use of plug gages
conforming to the dimensions provided in Figure 9.
To gage the crimping chamber, proceed as follows:
If gaging the crimping chamber is not re uired,
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. R tchet 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.
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 Tyco Electronics 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.
NOTE
i

408-1261
HHHT 59239-4, 59239-8, 59287-2, and 525692
Rev F8 of 9 Tyco Electronics Corporation
Wire Barrel Section of Crimping Chamber
Die Closure
Configuration
GO Dia NO-GO Dia
50.8 [2.0] Min Typ
GO NO
GO
6.35 [.250] Min Typ
Die Closure
Configuration
GO Dia NO-GO Dia
W" = 4.34 [.171] Max Width
Insulation Barrel Section of Crimping Chamber
W"
Suggested Plug Gage Design
W"
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]
Figure 9
Figure 10
Detail A
Inspection of Wire Barrel Section
of Crimping Chamber
Detail B
Inspection of Insulation Barrel Section
of Crimping Chamber
Crimping Dies
Bottomed But Not
nder Pressure
Plug Gage Plug Gage
Insulation Crimp
Adjustment Pin
in Position 1
Crimping Dies
Bottomed But Not
nder Pressure
GO Element Must Pass Completely
Through Crimping Chamber
NO-GO Element May Start Entry, But Must Not
Pass Completely Through Crimping Chamber
GO Element Must Pass Completely Through Length of
Insulation Barrel Section But Stop on Wire Barrel Section

408-1261
HHHT 59239-4, 59239-8, 59287-2, and 525692
9 of 9Rev F
Tyco Electronics Corporation
76.2 [3.00]
Approx
304.8 [12.00]
Approx
2
1
8
69
7
12
3
4
5
10
11
REPLACEMENT PARTS
ITEM
PART N MBER FOR TOOL
DESCRIPTION
QTY PER
ITEM
59239-4, 59239-8 59287-2 525692
DESCRIPTION
TOOL
1 300388-0 300388-0 300388-0 PIN, Retaining 2
2 21045-3 21045-3 525108-0 RING, Retaining 4
3 300389-0 300389-0 300389-0 PIN, Retaining 1
4 21045-6 21045-6 21045-6 RING, Retaining 2
5 303848-2 303848-2 303848-2 PIN ASSEMBL , 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 STATIONAR DIE, Insulation 1
11 306107-2 45888-7 306107-2 MOVING DIE, Insulation 1
12 21028-4 21028-5 21028-4 PIN 1
Figure 11
7. REVISION S MMARY
Revisions to this instruction sheet include:
S Updated document to corporate requirements
S Add gage information to table in Figure 9