Insulation Adjustment
Locking Screw
Insulation Adjustment
Indicator
Locator
Quick Take-Up
Trigger
CERTI-CRIMP* Hand Crimping Tool Ratchet Control
Yellow
Handle
Color Code
Information
“T”-HEAD* Crimping Tools
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.
NOTE
i
CAUTION
!
59170, 59250, 59275, 59300,
69692-1 and 69693-1
•PIDG insulation restricting terminals with
TEFLONt coating, used on stranded copper wire
sizes 26 through 14.
•PIDG Radiation Resistant Terminals and Splices
on stranded copper wire sizes 26 through 14.
•PLASTI-GRIP* Terminals on solid or stranded
copper wire sizes 22 through 14.
•PLASTI-GRIP Butt Splices on solid or stranded
copper wire sizes 26 through 22.
•Spar e Wire Cap s on solid or stran ded copper wire
sizes 22 through 14.
Reasons for reissue of this sheet are provided in
Section 9, REV
Instruction Sheet
408-1610
27 APR 11 Rev M
Dimensions on this sheet are in millimeters [with
inch equivalent dimensions in brackets]. Figures
and illustra
not drawn to scale.
tions are for identification only and are
ISION SUMMARY.
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:
Figure 1
•PIDG* vinyl and nylon terminals and splices on
stranded copper wire sizes 26 through 14.
•STRATO-THERM* terminals on stranded copper
wire sizes 26 through 14.
•PIDG Insulation Restricting Nylon Terminals on
stranded copper wire sizes 26 through 14.
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
cr
imp 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
colo
r code information.
The CERTI-CRIMP hand crimping tool ratchet control
en
sures 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 ten
crimp. Do NOT re-adjust the ratchet.
sile performance of the
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.
© 2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
*Trademark
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners.
TOOLING ASSISTANCE CENTER
PRODUCT INFORMATION
1-800-522-6752
1-800-722-1111
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.te.com
1 of 11
LOC B
408-1610
Rev M
Figure 2 (Cont’d)
2 of 11
408-1610
NOTE
i
NOTE
i
NOTE
i
CAUTION
!
NOTE
i
NOTE
i
NOTE
i
Refer to tool label for color code information. Note
that Figure 2 indicates the number of dots that
appear embossed on a crimped terminal, splice or
cap. Observe the dot code on finished crimp to
insure that correct pro
was used.
Dot code will disappear after heat sealing
environment sealed splices.
duct and tool combination
4. WIRE STRIPPING AND CRIMPING PROCEDURES
Refer to Section 5 for insulation crimp adjustment.
Do not re-terminate the splices or terminals.
4.1. PIDG and PLASTI-GRIP Terminals and Splices
1. Strip wire to dimensions listed in Figure 2.
Do not use wires with nicked or missing conductor
strands
Figure 2 (End)
Crimp the color coded terminals and splices in the
ma
Section 3.
3. Place terminal in crimping dies so that terminal
tong
4. Raise locator and place splice under locator as
sh
of tool.
5. Press quick take-up trigger and close handles
un
deform terminal or splice wire barrel.
6. Insert stripped wire into terminal until conductor
bu
wire into splice until conduct
wire stop. See Figure 4.
tching color coded portion of the tool. Refer to
ue slides under locator. See Figure 3.
own in Figure 4. Splice window indent faces top
To properly position pre-insulated sealed splice,
apply and maintain pressure against end of splice
until Step 5
til terminal or splice is held firmly in place. Do not
tts against locator. See Figure 3. Insert stripped
Do not allow wire insulation to enter wire barrel.
is completed. See Figure 4.
or butts against splice
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.
Rev M
7. Hold wire in position an
closing handles until the ratchet releases.
8. Refer to Section 6 and Figure 6 or Figure 7 for
terminal or splice "Crimp Inspection" procedure.
d complete crimp by
3 of 11
Figure 3
NOTE
i
Spare Wire Caps
Insulation
Adjustment
Indicator at
Position 4
Wire
Barrel
Locator
Raise Locator So the End
of the Cap Rests Against
the Recessed Surface of
the Locator
408-1610
4.2. .Spare Wire Caps
1. Strip wire to dimensions listed in Figure 2. Crimp
the color coded portion of the tool. Refer to
Section 3.
Do not use wire with nicked or missing conductor
strands.
2. Place tool insulation adjustment indicator in
Position 4
3. Close tool handles until crimping
close, but leave enough space for cap to be
inserted between dies.
4. Raise locator so that end of cap rests against the
re
cessed surface of the locator as shown in
Figure 5.
.
jaws partially
Figure 4
Rev M
Figure 5
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
b
ottoms in cap.
7. Hold wire in position an
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.
d complete crimp by
4 of 11
408-1610
NOTE
i
5. INSULATION CRIMP ADJUSTMENT
5.1. PIDG Terminals and Splices
PIDG terminals and splices feature a wire
"insulation grip".
Each tool has four insulation crimp positions. See
Fig
ure 1.
1. Loosen insulation adjustment loc
top of tool) and turn indicator to Position 4.
Rev M
Figure 6
king screw (see
2. Place terminal or splice in tool dies.
3. Insert UNSTRIPPED wire into ONLY the
insu
lation barrel (see Figure 3 or Figure 4) of
terminal or splice.
4. Perform a crimp (Section 4). Remove crimped
ter
minal or splice and check insulation grip as
follows: Bend the wire back and forth once. Terminal
or splice should retain grip on wire insulation.
5. If wire pulls out, set insulation adjustment
indicator
to next tighter position - Position 3.
5 of 11
408-1610
NOTE
i
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
to
p of tool).
5.2. PLASTI-GRIP Terminals and Splices
PLASTI-GRIP terminals and splices feature a wire
"insulation support" only.
1. Set insulation adjustment indicato
for wire having a large insulation diameter.
Rev M
r in Position 4
Figure 7
2. Set insulation adjustment
for wire having a medium insulation diameter.
3. Set insulation adjustment
for wire having a small insulation diameter.
4. Set insulation adjustment
for wire having thin wall insulation. Terminal or
splice insulation should ideally be in contact with
wire insulation.
indicator in Position 3
indicator in Position 2
indicator in Position 1
6. CRIMP INSPECTION
Inspect crimped terminals, splices and spare wire
caps by checking the features described in Figure 6 or
Figure 7.
6 of 11
NOTE
i
NOTE
i
Flattened
Broken Corner
Chipped
Edge
Pitted
NOTE
i
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.
Locators in Crimping Tools 69692-1 and 69693-1
are locked in the down position. Refer to Instruction
Sheet 408-7424 for crimp height inspection of
these tools.
7. MAINTENANCE AND INSPECTION
TE 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, an
2. The type and size of the products crimped.
3. The degree of operator sk
4. The presence of abnormal amounts of dust and
t.
dir
5. Your own established standards.
All tools are inspected before packaging. Since there
is a possibility
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 13.
of tool damage in shipment, new tools
d handling of the tool.
ill.
7.1. Cleaning
The tool should be immersed (handles partially
closed) in degreasing compound to remove
accumulated dirt, grease, and foreign matter.
Make certain the degreasing compound does not
attack paint or plastic materials.
Remove remaining degreasing compound with a lint
fre
e 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 Inspection
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 13 for customer
replaceable parts.
408-1610
Figure 8
2. Visually inspect the die closure surfaces for
flattened, broken, pitted, or chipped cond itio ns.
Although dies may gage within permissible limits,
worn or damaged die closure surfaces are
objectionable and can affect th e quality of the crimp.
Examples of possible damaged die closure surfaces
are shown in Figure 8.
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
ar
ea. Oil transferred from the crimping area onto
certain terminations may affect the electrical
characteristics of an application.
7.4. Gaging the Crimping Chamber
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 requiring th
is not required, 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).
is information. If plug gaging
Rev M
7 of 11
NOTE
i
408-1610
Refer to the table in Figure 11 for alternate hard
gage dimensions for tools 69692-1 and 69693-1.
A. Gaging the Crimping Chamber Using A Plug Gage
This inspection requires the use of plug gages
conforming to the dimensions listed in Figure 9 and
Figure 10. Tyco Electronics does not manufacture or
market these gages. Refer to 408-7424 for information
concerning plug gages
To gage the crimping area(s), refer to Figure 12 and
p
roceed as follows:
1. Clean oil or dirt from the crimping chamber and
p
lug gage.
2. Close handles of tool until wire barrel dies are
b
ottomed. Do not apply additional pressure to tool
handles.
3. With wire barrel dies bottomed, inspect the wire
b
arrel 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 12, Detail A. The GO
element must pass completely through the crimping
area.
4. Try to insert the NO-GO element. The NO-GO
e
lement may enter partially, but must not pass
completely through the crimping area.
5. Set insulation adjustment
Measure both insulation crimping chambers with the
proper GO plug gages in the same manner as S teps
2 and 3. See Figure 12, Detail B.
6. Set insulation adjustment
Measure both insulation crimping chambers with the
proper NO-GO plug gages in the same manner as
Steps 2 and 4. See Figure 12, Detail B.
If the crimping areas conform to the gage inspection,
the too
crimping areas do not conform to the inspection, the
tool must be repaired. Refer to Section 8,
REPLACEMENT AND REPAIR.
l is considered dimensionally correct. If the
indicator in Position 1.
indicator in Position 4.
Rev M
Figure 9
8 of 11
408-1610
B. Gaging the Crimping Chamber Using A Solder Slug
and Crimp Height Comparator
This inspection requires the use of crimp height
comparators, solder slugs, and the dimensions listed
in Figure 10. Tyco Electronics does not manufacture
or market crimp-height comparators. Refer to
408-7424 for information concerning comparators.
To gage the crimping chamber using the solder slug,
p
roceed as follows:
1. Clean oil or dirt from the crimping chamber.
2. Set insulation adjustment to the number 1
po
sition.
3. Insert proper solder slug into one crimp chamber
(
see Figure 9 and Figure 10) and cycle tool.
4. Measure the compressed solder slug for the wirerrel crimping chamber and check for compliance
ba
to dimensions in Figure 9.
5. Measure the compressed area for the insulation-
crim
ping chamber and check for compliance to the
GO dimensions in Figure 10.
6. Set the insulation adjust
position and insert the appropriate solder slug into
the insulation chamber.
7. Cycle the tool.
8. Measure the compressed area (of the solder) for
the in
sulation-crimping chamber and check for
compliance to the NO-GO dimensions in Figure 10.
9. Repeat the steps above for the second crimp
cha
mber.
ment to the number 4
Rev M
Figure 10
9 of 11
Figure 11
408-1610
7.5. Ratchet Control Inspection
Obtain a .025-mm [.001-in.] shim that is suitable for
checking the clearance between the bo tto m ing
surfaces of the crimping dies. To inspect the CERTICRIMP hand crimping tool ratchet control:
Rev M
Figure 12
1. Perform a crimp using the largest wire size for
your t
ool.
2. While holding the wire in place, squeeze the tool
ha
ndles together until the ratchet releases. Hold the
tool in this position, maintaining just enough
pressure to keep the dies closed.
10 of 11
408-1610
CUSTOMER SERVICE (038-035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
3. Check the clearance between the bottoming
surfaces of the crimping dies. If the clearance is
.025 mm [.001 in.] or less, the ratchet is satisfactory.
If clearance exceeds .025 mm [.001 in.], 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 13. Parts other
than those listed in Figure 13 should be replaced by
Tyco Electronics to ensure quality and reliability of the
tool. Order replacement parts through your TE
Representative, or call 1-800-526-5142, or send a
facsimile of your purchase order to 1-717-986-7605, or
write to:
9. REVISION SUMMARY
Since the previous release of this sheet, the new
company logo was applied.
ITEM DESCRIPTION
1 Support, Locator
2 Screw
591 SHORT HANDLE
5
9250 LONG HANDLE
--- ---
--- ---
Rev M
TOOL NUMBERS AND REPLACEMENT PART NUMBER
59275 SHORT HANDLE
59300 LONG HANDLE
69692-1
LONG HANDLE
59755-1 59755-2 1
1-21002-3 1-21002-3 2
Figure 13
69693-1
LONG HANDLE
QTY PER
ASSY
11 of 11
Loading...