Tyco 59170 User manual

Instruction Sheet
T"-HEAD* Crimping Tools
59170, 59250, 59275, 59300, 408-1610
LOC B
1 of 10
E 2007 Tyco Electronics Corporation, Harrisburg, PA
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
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.tycoelectronics.com
18 SEP 07 Rev G
69692-1, nd 69693-1
PROPER USE GUIDELINES
CumulativeTraumaDisorderscanresultfromthe prolongeduseofmanually poweredhandtools.Hand toolsareintendedfor occasionaluseandlowvolume
applications. A wide selection of powered application equipment for extended-use, production operations is available.
Figure 1
Insulation
Adjustment
Locking Screw
Insulation
Adjustment
Indicator
Locator
Color Code
Information
Quick Take-Up
Trigger
Yellow
Handle
CERTI-CRIMP*
Hand Crimping Tool
Ratchet Control
Yellow
Red Blue hite
1. INTRODUCTION
This instruction sheet covers the use of “T”–HEAD
Crimping Tools 59170, 59250, 59275, 59300,
69692–1, and 69693–1. See Figure 1. These tools
crimp:
S PIDG* vinyl and nylon terminals and splices on
stranded copper wire sizes 26 through 14.
S STRATO–THERM* terminals on stranded
copper wire sizes 26 through 14.
S PIDG Insulation Restricting Nylon Terminals on
stranded copper wire sizes 26 through 14.
S PIDG insulation restricting terminals with
TEFLON t coating, used on stranded copper
wire sizes 26 through 14.
S PIDG Radiation Resistant Terminals and
Splices on stranded copper wire sizes 26
through 14.
S PLASTI–GRIP* Terminals on solid or stranded
copper wire sizes 22 through 14.
S PLASTI–GRIP Butt Splices on solid or
stranded copper wire sizes 26 through 22.
S Spare Wire Caps on solid or stranded copper
wire sizes 22 through 14.
Dimensions on this sheet are in millimeters [with
inch equi alent dimensions in brackets]. Figures
and illustrations are for identification only and are
not drawn to scale.
Reasons for reissue of this sheet are provided in
Section 9, REVISION SUMMARY.
2. DESCRIPTION
The handles of the crimping tools are color–coded to
match the color coding of the product to be applied.
The insulation adjustment indicator is used to control
crimp height of the insulation barrel. It can be set at
any of four positions corresponding to insulation
diameter.
Tools also feature a locator, quick take–up trigger, and
color code information.
The CERTI–CRIMP hand crimping tool ratchet control
ensures full crimping of the product. Once engaged,
the ratchet will not release until the handles have
been FULLY closed.
The crimping dies bottom before the ratchet
releases. This is a design feature that ensures
maximum electrical and tensile performance of
the crimp. Do NOT re-adjust the ratchet.
3. COLOR AND DOT CODING
Note that tool handles and terminal, splice and cap
insulation are color coded for a given wire range as
listed in Figure 2. Crimp the color coded terminal,
splice or cap in the matching color coded portion of
the tool. For example, when using Hand Tool 59275,
yellow coded PIDG terminals and splices and red
coded pre–insulated seated splices must be crimped
in that portion of tool displaying the red and yellow
coded dots and yellow handle. See Figure 1.
NOTE
i
CAUTION
!

408-1610
T"-HEAD Crimpin Tools
Rev G2 of 10 Tyco Electronics Corporation
IDG INSULATION
RESTRICTING
NYLON
TERMINALS
MS 7928/1-1
through -10
PRODUCT TOOL NO. AND
HANDLE
COLOR CODE
DOT
CODE
WIRE
RANGE
OR SIZE
WIRE INSULATION
DIAMETER
RANGE
59170
59250
RED AND BLUE
ONE DOT
26
INSULATION
COLOR CODE
YELLOW W/3
BLACK STRI ES
WIRE STRIP LENGTH
Terminals Splices
Min. Max. Min. Max.
24
0.66-1.40 [.026 - .055]
0.79-1.40 [.031 - .055] YELLOW W/3
BLUE STRI ES
6.35 [.25] 7.11 [.28] ĊĊ ĊĊ
IDG TERMINALS
MS 25036-143
through -147
(Class 1 Only)
IDG RADIATION
RESISTANT
TERMINALS
MS 7928/4-143
through -147
ONE DOT 26 - 24 ĊĊ
YELLOW
NATURAL
W/YELLOW STRI E
5.08 [.20] 5.84 [.23] ĊĊ ĊĊ
IDG VINYL &
NYLON TERM. OR
S LICE & 26-22 AWG
LASTI-GRI
BUTT S LICE
59275
YELLOW AND
WHITE
ONE DOT
TWO DOTS
26-22
24-20
ĊĊ
ĊĊ
YELLOW
WHITE
4.06 [.16] 4.83 [.19] 4.32 [.17] 5.08 [.20]
4.83 [.19] 5.59 [.22] 5.59 [.22] 6.35 [.25]
IDG VINYL AND
NYLON TERMINALS
AND S LICES
ALSO LASTI-GRI
22-16 AND 16-14
TERMINALS
59300
RED AND WHITE
59170
59250
RED AND BLUE
TWO DOTS 24 - 20 ĊĊ WHITE 4.83 [.19] 5.59 [.22] 5.59 [.22] 6.35 [.25]
ONE DOT 22 - 16 ĊĊ RED 5.08 [.20] 5.84 [.23] 6.35 [.25] 7.11 [.28]
ONE DOT 22 - 16 ĊĊ RED
TWO DOTS 16 - 14 ĊĊ BLUE 5.08 [.20] 5.84 [.23] 6.35 [.25] 7.11 [.28]
IDG RADIATION
RESISTANT
TERMINALS AND
S LICES
59275
YELLOW
AND WHITE
NATURAL
W/YELLOW STRI E
NATURAL W/WHITE STRI E
ONE DOT 26 - 24 S LICE ONLY
TWO DOTS 24 - 20 ĊĊ
ĊĊ ĊĊ 4.32 [.17] 5.08 [.20]
4.83 [.19] 5.59 [.22] 5.59 [.22] 6.35 [.25]
NATURAL
W/YELLOW STRI E
ONE DOT 26 - 24 TERMINALS ONLY
59300
RED AND WHITE
5.08 [.20] 5.84 [.23] ĊĊ ĊĊ
TWO DOTS 24 - 20 ĊĊ NATURAL W/WHITE STRI E 4.83 [.19] 5.59 [.22] 5.59 [.22] 6.35 [.25]
ONE DOT 22 - 16 ĊĊ NATURAL W/RED STRI E 5.08 [.20] 5.84 [.23] 6.35 [.25] 7.11 [.28]
NATURAL
W/YELLOW STRI E
ONE DOT 26 - 24 TERMINALS ONLY
59170
59250
RED AND BLUE
5.08 [.20] 5.84 [.23] ĊĊ ĊĊ
22 - 16 ĊĊ NATURAL W/RED STRI E
TWO DOTS 16 - 14 ĊĊ NATURAL W/BLUE STRI E 5.08 [.20] 5.84 [.23] 6.35 [.25] 7.11 [.28]
59275
YELLOW AND
WHITE ONE DOT 26
24
YELLOW W/BLACK STRI E
YELLOW W/BLUE STRI E 4.83 [.19] 5.59 [.22] ĊĊ ĊĊ
IDG INSULATION
RESTRICTING
NYLON
TERMINALS
22 0.97-2.79 [.038 - .110] RED W/GREEN STRI E
20 1.17-2.79 [.046 - .110] RED W/RED STRI E
18 1.42-2.79 [.056 - .110] RED W/WHITE STRI E
22 0.97-2.79 [.038 - .110] RED W/GREEN STRI E
20 1.17-2.79 [.046 - .110] RED W/RED STRI E
18 1.42-2.79 [.056 - .110] RED W/WHITE STRI E
16 1.60-3.30 [.063 - .130] BLUE W/BLUE STRI E
14 1.98-3.30 [.078 - .130] BLUE W/GREEN STRI E
59300
RED AND WHITE ONE DOT
6.35 [.25] 7.11 [.28] ĊĊ ĊĊ
59170
RED AND BLUE
ONE DOT
TWO DOTS
PLASTI-GRIP
Terminal Spare Wire
Cap
PIDG Type
Terminals
PIDG Butt Splice
PLASTI-GRIP
Butt Splice
Color Stripe
on Radiation
Resistant
3 Equally
Spaced Color
Stripes on
Nylon Terminals
Insulation
Restricting
(Nylon or
TEFLON)
Color
Stripe on
Radiation
Resistant
Figure 2 (cont’d)
0.66-1.40 [.026 - .055]
0.79-1.40 [.031 - .055]

408-1610
T"-HEAD Crimping Tools
3 of 10Rev G
Tyco Electronics Corporation
Figure 2 (end)
PIDG
STRATO-THERM
TERMINALS
ONE DOT 26 - 24 BLACKĊĊ 4.06 [.16] 4.83 [.19] ĊĊ ĊĊ
69692-1
BLACK AND
GREEN TWO DOTS 22 - 20 GREENĊĊ
ONE DOT 18 - 16 ORANGEĊĊ 5.08 [.20] 5.84 [.23] ĊĊ ĊĊ
69693-1
ORANGE AND
WHITE TWO DOTS 14 WHITEĊĊ
PIDG
INS LATION
RESTRICTING
TEFLON
STRATO-THERM
TERMINALS
ONE DOT 26 BLACK0.66-1.40 [.026 - .055] 4.83 [.19] 5.59 [.22] ĊĊ ĊĊ
69692-1
BLACK
AND
GREEN
24 BL E0.79-1.40 [.031 - .055]
22 GREEN0.97-2.79 [.038 - .110] 6.35 [.25] 7.11 [.28] ĊĊ ĊĊTWO DOTS 20 RED1.17-2.79 [.046 - .110]
ONE DOT
69693-1
ORANGE
AND
WHITE
18 WHITE1.42-2.79 [.056 - .110]
16 BL E1.60-3.30 [.063 - .130] 6.35 [.25] 7.11 [.28] ĊĊ ĊĊ
TWO DOTS 14 GREEN1.98-3.30 [.078 - .130]
PRODUCT TOOL NO. AND
HANDLE
COLOR CODE
DOT
CODE WIRE RANGE SEAL LINER COLOR CODE INSULATION COLOR CODE WIRE STRIP LENGTH
Min. Max.
59250
AND
59170
RED AND BL E
SPARE WIRE CAP
NO. 328307
SPARE WIRE CAP
NO. 328308
7.87 [.31] 8.64 [.34]
ONE DOT 22 - 18 ĊĊ RED
TWO DOTS 16 - 14 ĊĊ BL E
PRODUCT TOOL NO. AND
HANDLE
COLOR CODE
DOT
CODE
WIRE
RANGE
OR SIZE
WIRE INSULATION
DIAMETER
RANGE
INSULATION
COLOR CODE
WIRE STRIP LENGTH
T rminals Splic s
Min. Max. Min. Max.
Refer to tool label for color code information.
Note that Figure 2 indicate the number of dot
that appear embo ed on a crimped terminal,
plice or cap. Ob erve the dot code on fini hed
crimp to in ure that correct product and tool
combination wa u ed.
Dot code will di appear after heat ealing
environment ealed plice .
4. WIRE STRIPPING AND CRIMPING PROCEDURES
Refer to Section 5 for in ulation crimp
adju tment.
Do not re-terminate the plice or terminal .
4.1. PIDG and PLASTI-GRIP T rminals and Splic s
1. Strip wire to dimensions listed in Figure 2.
Do not u e wire with nicked or mi ing
conductor trand
2. Open crimping dies by closing handles until
ratchet releases. See Figure 1. Note, that once
ratchet is engaged, handles cannot be opened until
they are first fully closed.
Crimp the color coded terminals and splices in the
matching color coded portion of the tool. Refer to
Section 3.
3. Place terminal in crimping dies so that terminal
tongue slides under locator. See Figure 3.
4. Raise locator and place splice under locator as
shown in Figure 4. Splice window indent faces top
of tool.
To properly po ition pre-in ulated ealed plice,
apply and maintain pre ure again t end of plice
until Step 5 i completed. See Figure 4.
5. Press quick take–up trigger and close handles
until terminal or splice is held firmly in place. Do
not deform terminal or splice wire barrel.
6. Insert stripped wire into terminal until conductor
butts against locator. See Figure 3. Insert stripped
wire into splice until conductor butts against splice
wire stop. See Figure 4.
Do not allow wire in ulation to enter wire barrel.
7. Hold wire in position and complete crimp by
closing handles until the ratchet releases.
8. Refer to Section 6 and Figure 6 or 7 for terminal
or splice “Crimp Inspection” procedure.
NOTE
i
NOTE
i
NOTE
i
CAUTION
!
NOTE
i
NOTE
i
NOTE
i

408-1610
T"-HEAD Crimping Tool
Rev G4 of 10 Tyco Electronics Cor oration
Figure 3
C" B" C" B"
C" B"
PIDG and PLASTI-GRIP Terminals
PIDG
Terminal
PIDG Insulation
Restricting
PLASTI-GRIP
Terminal
B" Equals Wire Barrel
C" Equals Insulation Barrel
Terminal Barrel
Rests Against
Locator
Conductor Butts
Against Locator
Terminal Tongue
Slides Under
Locator
Figure 4
C" B"
C" B"
C" B" Window
Indent
Wire Sto
Window
Indent
Wire Sto
Window
Indent
Wire Sto
Environmental
Sealed Splice PIDG
PLASTI-GRIP
BUTT Splices
B" Equals Wire Barrel
C" Equals Insulation Barrel
First
Crimp
Second
Crimp
Window Indent
Faces To of
Tool
Conductor Butts
Against Wire Sto
Window Indent
Faces To of Tool
4.2. Spare Wire Cap
1. Strip wire to dimensions listed in Figure 2. Crimp
the color coded portion of the tool. Refer to
Section 3.
Do not use ire ith nicked or missing conductor
strands.
2. Place tool insulation adjustment indicator in
Position 4.
3. Close tool handles until crimping jaws partially
close, but leave enough space for cap to be
inserted between dies.
4. Raise locator so that end of cap rests against
the recessed surface of the locator as shown in
Figure 5.
Figure 5
Spare Wire Caps
Insulation
Adjustment
Indicator at
Position 4
Locator
Raise Locator so
that End of Ca Rests
Against Recessed
Surface of Locator
Wire
Barrel
5. Squeeze quick take–up trigger and close
handles until cap is held firmly in place. Do not
deform cap wire barrel.
6. Insert stripped wire into cap until conductor
bottoms in cap.
7. Hold wire in position and complete crimp by
closing handles until the ratchet releases. Handles
will open automatically and crimped cap may be
removed.
8. Refer to Section 6 and Figure 7 wire cap crimp
inspection procedure.
NOTE
i

408-1610
T"-HEAD Crimping Tools
5 of 10Rev G
Tyco Electronics Corporation
Figure 6
1
Insulation barrel is in firm contact with wire insulation.
2
Correct color code, dot code, and tool combination.
3
Wire size is within wire range stamped under terminal
tongue or on center of splice.
4
Crimp centered on wire barrel.
5
End of conductor is flush with, or extends beyond end
of terminal wire barrel.
6
End of conductor against wire stop of splice, or at least
flush with, or extended slightly beyond wire barrel.
7
Wire insulation does not enter wire barrel.
8
No nicked or missing conductor strands.
1
Wire insulation extruded. (Insulation crimp too tight on PIDG
terminals and splices) See Section 5.
2
Wrong dot code and color code combination. See Figure 2.
3
Wire size is not within wire range stamped on terminal
tongue or splice.
4
Crimp not centered on wire barrel. (Terminal was not butted
against locator. See Figure 3.)
5
End of conductor is not flush with or extending beyond end
of wire barrel. (Check for correct strip length.)
6
Excessive flash or extruded insulation, (wrong tool,
terminal, or splice combination, or damaged dies).
7
Wire insulation entered wire barrel.
8
Nicked or missing conductor strands.
9
Splice was reversed in dies (tool’s locator was not seated in
window indent of splice).
PIDG &
PLASTI-GRIP
Terminals
PIDG
Butt Splice
12
5
3
4
5
8
7
63
Wire
Stop
46
21
A Dot Code (1 or 2 Dots) Must
Appear on All Cri ped Ite s
12 6
8
4
5
3
353837
3
8
5
2
1
6
Wire Barrel Dies Cri ped
Splice Insulation
Accept Reject
5. INSULATION CRIMP ADJUSTMENT
5.1. PIDG Terminals an Splices
PIDG terminals and splices feature a wire
insulation grip".
Each tool has four insulation crimp positions. See
Figure 1.
1. Loosen insulation adjustment locking screw (see
top of tool) and turn indicator to Position 4.
2. Place terminal or splice in tool dies.
3. Insert UNSTRIPPED wire into ONLY the
insulation barrel (see Figure 3 or 4) of terminal or
splice.
4. Perform a crimp (Section 4). Remove crimped
terminal or splice and check insulation grip as
follows: Bend the wire back and forth once.
Terminal or splice should retain grip on wire
insulation.
NOTE
i

408-1610
T"-HEAD Crimpin Tools
Rev G6 of 10 Tyco Electro ics Corporatio
Figure 7
1
No flash or extruded insulation.
2
Correct color code, dot code, and tool combination.
Dot coding disappears on sealed splices when they
are heat sealed.
3
Correct wire size used.
4
Wire insulation does not enter wire barrel of splice.
5
End of conductor against wire stop of splice, or at least
flush with, or extended slightly beyond wire barrel.
6
End of conductor bottomed in cap.
7
Full width of crimp is over wire barrel.
1
Excessive flash or extended insulation. (Crimped in
smaller dies on wrong side of tool.) Also, check for
damaged dies.
2
Wrong dot code and color code combination. See Figure 2.
3
Incorrect wire size used.
4
Wire insulation entered wire barrel.
5
End of conductor is not flush with or extending beyond
end of wire barrel. (Check strip length.)
6
End of conductor not bottomed in cap.
7
Half of crimp off end of wire barrel (Cap was not bottomed
in recess of locator.)
8
Nicked or missing conductor strands.
PLASTI-GRIP
Butt Splice
8
No nicked or missing conductor strands.
9
Crimp centered on wire barrel.
10
Splice insulation is in contact with wire insulation.
9
Crimp not centered on wire barrel. (Tool locator not
seated in window indent.)
10
Splice insulation is not in contact with wire insulation.
1
5
2
11
3
9
485
7
21
3
4 8 6
Wire Stop
A Dot Code (1 or 2 Dots) Must
Appear o All Crimped Items
11 1
25
9
8
3
45
7
86
2
3
1
Accept Reject
Spare Wire Cap
5. If wire pulls out, set insulation adjustment
indicator to next tighter position — Position 3.
6. Perform a crimp and repeat adjustment as
necessary until desired insulation grip is obtained.
Do not use a tighter setting than required.
7. Tighten insulation adjustment locking screw (see
top of tool).
5.2. PLASTI-GRIP Terminals and Splices
PLASTI-GRIP terminals and splices feature a
wire insulation support" only.
1. Set insulation adjustment indicator in Position 4
for wire having a large insulation diameter.
2. Set insulation adjustment indicator in Position 3
for wire having a medium insulation diameter.
NOTE
i

408-1610
T"-HEAD Crimping Tools
7 of 10Rev G
Tyco Electronics Corporation
3. Set insulation adjustment indicator in Position 2
for wire having a small insulation diameter.
4. Set insulation adjustment indicator in Position 1
for wire having thin wall insulation. Terminal or
splice insulation should ideally be in contact with
wire insulation.
6. CRIMP INSPECTION
Inspect crimped terminals, splices and spare wire
caps by checking the features described in Figure 6
or 7.
Use only the crimped items that meet the conditions
shown in the ACCEPT column.
REJECT terminals, splices, and spare wire caps can
be avoided through careful use of instructions and by
performing regular tool maintenance as instructed in
this document.
L cat rs in Crimping T ls 69692-1 and
69693-1 are l cked in the d wn p siti n. Refer
t Instructi n Sheet 408-7424 f r crimp height
inspecti n f these t ls.
7. MAINTENANCE AND INSPECTION
Tyco Electronics recommends that a
maintenance/inspection program be performed
periodically to ensure dependable and uniform
terminations. Tools should be inspected at least once
a month. Frequency of inspection may be adjusted to
suit your requirements through experience.
Frequency of inspection is dependent upon:
1. The care, amount of use, and handling of the
tool.
2. The type and size of the products crimped.
3. The degree of operator skill.
4. The presence of abnormal amounts of dust and
dirt.
5. Your own established standards.
All tools are inspected before packaging. Since there
is a possibility of tool damage in shipment, new tools
should be inspected in accordance with Section 7
when received in your plant. Due to the precision
design,
it is important that no parts of these tools be
interchanged except those replacement parts listed in
Figure 12.
7.1. Cl aning
The tool should be immersed (handles partially
closed) in degreasing compound to remove
accumulated dirt, grease, and foreign matter.
Make certain the degreasing c mp und d es n t
attack paint r plastic materials.
Remove remaining degreasing compound with a lint
free cloth. When degreasing compounds are not
available, tool may be wiped clean with a lint free
cloth. Relubricate tool, as instructed in Paragraph 7.3
before placing it back in service.
7.2. Visual Insp ction
1. Visually inspect the tool for missing parts, then
operate the tool and note the return action of the
spring–loaded handles. If parts are missing or
defective, refer to Figure 12 for customer
replaceable parts.
2. Visually inspect the die closure surfaces for
flattened, broken, pitted, or chipped conditions.
Although dies may gage within permissible limits,
worn or damaged die closure surfaces are
objectionable and can affect the quality of the
crimp. Examples of possible damaged die closure
surfaces are shown in Figure 8.
Figure 8
Flattened
Chipped
Edge
Broken Corner
Pitted
7.3. Lubrication
Lubricate all pins, pivot points, and bearing surfaces
with SAE 20 motor oil as follows:
Tools used in daily production—Lubricate daily
Tools used daily (occasional)—Lubricate weekly
Tools 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.
NOTE
i
NOTE
i

408-1610
T"-HEAD Crimping Tools
Rev G8 of 10 Tyco Electronics Corporation
7.4. Gaging the Crimping Cham er
Each tool is inspected for proper die closures before
packaging. An inspection should be performed
periodically to check the tool die closures for
excessive wear.
The following plug gaging information for
insulation crimping chambers is provided for
customers specifically re uiring this information.
If plug gaging is not re uired, inspect the die
closures using an alternate procedure, i.e.,
performing the Insulation Crimp Adjustment"
(see Section 5) and Visual Inspection" (see
Paragraph 7.2).
This inspection requires the use of plug gages
conforming to the dimensions listed in Figures 9 and
10. Tyco Electronics does not manufacture or market
these gages.
To gage the crimping area(s), refer to Figure 11 and
proceed as follows:
1. Clean oil or dirt from the crimping chamber and
plug gage.
2. Close handles of tool until wire barrel dies are
bottomed. Do not apply additional pressure to tool
handles.
3. With wire barrel dies bottomed, inspect the wire
barrel crimping chamber using the proper plug
gage. Lift the spring–loaded locator up and hold
gage in straight alignment with the crimping
chamber. Carefully try to insert, without forcing, the
GO element. See Figure 11, Detail A. The GO
element must pass completely through the
crimping area.
4. Try to insert the NO–GO element. The NO–GO
element may enter partially, but must not pass
completely through the crimping area.
5. Set insulation adjustment indicator in Position 1.
Measure both insulation crimping chambers with
the proper GO plug gages in the same manner as
Steps 2 and 3. See Figure 11, Detail B.
6. Set insulation adjustment indicator in Position 4.
Measure both insulation crimping chambers with
the proper NO–GO plug gages in the same
manner as Steps 2 and 4. See Figure 11, Detail B.
If the crimping areas conform to the gage inspection,
the tool is considered dimensionally correct. If the
crimping areas do not conform to the inspection, the
tool must be repaired. Refer to Section 8,
REPLACEMENT AND REPAIR.
7.5. Ratchet Control Inspection
Obtain a .025–mm [.001–in.] shim that is suitable for
checking the clearance between the bottoming
surfaces of the crimping dies. To inspect the
CERTI–CRIMP hand crimping tool ratchet control:
1. Perform a crimp using the largest wire size for
your tool.
2. While holding the wire in place, squeeze the tool
handles together until the ratchet releases. Hold
the tool in this position, maintaining just enough
pressure to keep the dies closed.
3. Check the clearance between the bottoming
surfaces of the crimping dies. If the clearance is
.025 [.001] or less, the ratchet is satisfactory. If
clearance exceeds .025 [.001], the ratchet is out of
adjustment, and must be repaired. Refer to Section
8, REPLACEMENT AND REPAIR. If the tool
conforms to these inspection procedures, lubricate
it with a THIN coat of any good SAE 20 motor oil
and return it to service.
8. REPLACEMENT AND REPAIR
Replacement parts are listed in Figure 12. Parts other
than those listed in Figure 12 should be replaced by
Tyco Electronics to ensure quality and reliability of the
tool. Order replacement parts through your Tyco
Electronics 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 (38–35)
TYCO ELECTRONICS CORPORATION
P.O. BOX 3608
HARRISBURG, PA 17105–3608
For tool repair service, please contact a Tyco
Electronics Representative at 1–800–526–5136.
9. REVISION SUMMARY
Since the previous release of this sheet, the following
changes were made:
S Updated document to corporate requirements
S Added NOTE to Figure 12
NOTE
i

408-1610
T"-HEAD Crimping Tools
9 of 10Rev G
Ty o Ele troni s Corporation
Suggested Plug Gage Desig - Wire Barrel Crimpi g Chamber
B" Dia.B" Dia. NO-GO Dim.GO Dim.
Die Closure
Configuration
50.8 [2.00] Min. Typ.
TOOL IRE SIZE GAGE ELEMENT DIMENSION B"
NUMBER A G GO NO-GO
59170 and 59250
22-16 2.769 - 2.776 [.1090 - .1093] 2.918 - 2.921 [.1149 - .1150]
59170 and 59250
16-14 3.023 - 3.030 [.1190 - .1193] 3.172 - 3.175 [.1249 - .1250]
59275
26-22 1.600 - 1.608 [.0630 - .0633] 1.750 - 1.753 [.0689 - .0690]
59275
24-20 2.261 - 2.268 [.0890 - .0893] 2.410 - 2.413 [.0949 - .0950]
59300
24-20 2.261 - 2.268 [.0890 - .0893] 2.410 - 2.413 [.0949 - .0950]
59300
22-16 2.769 - 2.776 [.1090 - .1093] 2.918 - 2.921 [.1149 - .1150]
Use solder slug a d crimp height comparator. (Refere ce 408-7424)
TOOL
NUMBER IRE SIZE A G SOLDER SLUG CRIMP HEIGHT SOLDER SLUG DIAMETER REFERENCE
69692-1 26-24 2.34 + 0.05 [.092 + .002] 1/8 Diameter
22-20 2.69 + 0.05 [.106 + .002] 1/8 Diameter
69693-1 18-16 3.35 + 0.05 [.132 + .002] #18 - 1/8 Dia. #16 - 3/16 Dia.
14 3.86 + 0.05 [.152 + .002] 3/16 Diameter
Figure 9
Suggested Plug Gage Desig - I sulatio Crimpi g Chamber
GO NO-GO
GO Dim. D" NO-GO Dim.
D" Die Closure
Configuration
W"
6.35 [.250] Typ.
C"
TOOL IRE SIZE GAGE ELEMENT DIMENSION D" IDTH
NUMBER A G GO NO-GO  " (Max.)
59170 and 59250
22-16 0.762 - 0.770 [.0300 - .0303] 2.791 - 2.794 [.1099 - .1100]
3 18 [ 125]
59170 and 59250
16-14 1.016 - 1.024 [.0400 - .0403] 3.045 - 3.048 [.1199 - .1200]
3
.
18 [
.
125]
59275
26-22
0 762 - 0 770 [ 0300 - 0303]
2 029 - 2 032 [ 0799 - 0800]
2 36 [ 093]
59275
24-20
0
.
762
-
0
.
770 [
.
0300
-.
0303]
2
.
029
-
2
.
032 [
.
0799
-.
0800]
2
.
36 [
.
093]
59300
24-20
0 762 - 0 770 [ 0300 - 0303]
2 791 - 2 794 [ 1099 - 1100]
3 18 [ 125]
59300
22-16
0
.
762
-
0
.
770 [
.
0300
-.
0303]
2
.
791
-
2
.
794 [
.
1099
-.
1100]
3
.
18 [
.
125]
Use solder slug a d crimp height comparator. (Refere ce 408-7424)
TOOL
IRE SIZE
DIE CLOSURE DIM'S. C"
SOLDER SLUG
IDTH
TOOL
NO.
IRE SIZE
A G Set Insulation Adj. Indicator
at No. 1 Posn (GO) Set Insulation Adj. Indicator at No. 4 Posn (NO-GO)
SOLDER SLUG
DIAMETER REFERENCE
IDTH
 " (MAX.)
69692-1
26-24 0.635 [.0250] 1.905 [.0750] 1/8 Diameter 2.36 [.093]
69692
-
1
22-20 0.889 [.0350] 2.159 [.0850] 1/8 Diameter 2.36 [.093]
69693-1
18-16 O.762 [.0300] 2.794 [.1100] #18 - 1/8 Dia. #16 - 3/16 Dia. 3.18 [.125]
69693
-
1
14 1.016 [.0400] 3.048 [.1200] 3/16 Diameter 3.18 [.125]
Figure 10

408-1610
T"-HEAD Crimping Tools
Rev G10 of 10 Tyco Electronics Corporation
Figure 11
Inspection of Wire Barrel
Crimping Dies Inspection of Insulation Crimping Dies
Detail A Detail B
Wire Barrel
Dies are
Bottomed
But Not nder
Pressure
Insulation
Adjustment
Indicator
GO gage must pass completely
through the die closure.
NO-GO gage may enter partially, but must not
pass completely through the die closure. NO-GO gage may enter partially, but must not pass completely through the die closure.
GO gage must pass completely
through the die closure.
Insulation
Adjustment
Indicator in
Position 1
Insulation
Adjustment
Indicator in
Position 4
1
2
(With Handles Closed)
Approx. Dim.
73.03 [2.875] (Short Handle)
73.03 [2.875] (Long Handle)
Approx.
203.2 [8.00] (Short Handle)
244.48 [9.625] (Long Handle)
NOTE
i
Some tools require the
removal of the locator
to gage the tool.
TOOL NUMBERS AND REPLACEMENT PART NUMBERS
ITEM DESCRIPTION 59170 SHORT HANDLE
59250 LONG HANDLE 59275 SHORT HANDLE 59300 LONG HANDLE 69692-1 LONG HANDLE 69693-1 LONG HANDLE QT PER ASS
1 Support, Locator ĊĊ ĊĊ 59755-1 59755-2 1
2 Screw ĊĊ ĊĊ 1-21002-3 1-21002-3 2
Figure 12