Tyco 59170, 59250, 59275, 59300, 69692-1 User Manual

T"-HEAD* Crimping Tools
59170, 59250, 59275, 59300,
69692-1, and 69693-1

PROPER USE GUIDELINES

CumulativeTrauma Disorderscan resultfrom theprolonged useof manually poweredhand tools.Hand toolsare intendedfor occasionaluseand lowvolume
applications. A wide selection of powered application equipment for extended-use, production operations is available.

S

PIDG insulation restricting terminals with
TEFLONt 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.

NOTE

i

Dimensions on this sheet are in millimeters [with
inch equivalent dimensions in brackets]. Figures
and illustrations are for identification only and are
not drawn to scale.

Insulation
Adjustment
Locking Screw

Insulation
Adjustment
Indicator

Locator

Yellow

Red

White

Blue

Instruction Sheet

408-1610

18 SEP 07 Rev G

Quick Take-Up
Trigger

Yellow
Handle

CERTI-CRIMP*
Hand Crimping Tool
Ratchet Control

Figure 1

Color Code
Information

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.

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.

CAUTION

!

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.

E

2007 TycoElectronicsCorporation,Harrisburg,PA
All International Rights Reserved
TE logo and Tyco Electronics aretrademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.

TOOLING ASSISTANCE CENTER 1-800-722-1111
PRODUCT INFORMATION1-800-522-6752

This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at

www.tycoelectronics.com

1

of 10

LOC B

T"-HEAD Crimping Tools

408-1610

PLASTI-GRIP

Terminal

Color
Stripe on
Radiation
Resistant

PRODUCT

PIDG INSULATION
RESTRICTING
NYLON
TERMINALS
MS 7928/1-1
through -10

PIDG TERMINALS
MS 25036-143
through -147
(Class 1 Only)

PIDG RADIATION
RESISTANT
TERMINALS
MS 7928/4-143
through -147

PIDG VINYL &
NYLON TERM. OR
SPLICE & 26-22 AWG
PLASTI-GRIP
BUTT SPLICE

PIDG VINYL AND
NYLON TERMINALS
AND SPLICES
ALSO PLASTI-GRIP
22-16 AND 16-14
TERMINALS

PIDG RADIATION
RESISTANT
TERMINALS AND
SPLICES

PIDG INSULATION
RESTRICTING
NYLON
TERMINALS

TOOL NO. AND

HANDLE

COLOR CODE

59170
59250

RED AND BLUE

59275

YELLOW AND

WHITE

59300

RED AND WHITE

59170
59250

RED AND BLUE

59275

YELLOW

AND WHITE

59300

RED AND WHITE

59170
59250

RED AND BLUE

59275

YELLOW AND

WHITE

59300

RED AND WHITE

59170

RED AND BLUE

Spare Wire

Cap

PIDG Type

Terminals

3 Equally
Spaced Color
Stripes on

PIDG Butt Splice

Color Stripe
on Radiation
Resistant

Nylon Terminals

Insulation
Restricting

ĊĊ

ĊĊ

PLASTI-GRIP
Butt Splice

INSULATION

COLOR CODE

YELLOW W/3

BLACK STRIPES

YELLOW W/3

BLUE STRIPES

YELLOW

NATURAL

W/YELLOW STRIPE

YELLOW

WHITE

NATURAL

W/YELLOW STRIPE

NATURALW/WHITE STRIPE

NATURAL

W/YELLOW STRIPE

NATURAL

W/YELLOW STRIPE

YELLOW W/BLACK STRIPE

YELLOW W/BLUE STRIPE

WIRE STRIP LENGTH

Terminals Splices

Min. Max. Min. Max.

6.35 [.25] 7.11[.28] ĊĊ ĊĊ

5.08 [.20] 5.84 [.23] ĊĊ ĊĊ

4.06 [.16] 4.83 [.19] 4.32 [.17] 5.08 [.20]

4.83 [.19] 5.59 [.22] 5.59 [.22] 6.35[.25]

5.08 [.20] 5.84 [.23] 6.35 [.25] 7.11[.28]

ĊĊ ĊĊ 4.32 [.17] 5.08 [.20]

4.83 [.19] 5.59 [.22] 5.59 [.22] 6.35[.25]

5.08 [.20] 5.84 [.23] ĊĊ ĊĊ

5.08 [.20] 5.84 [.23] ĊĊ ĊĊ

5.08 [.20] 5.84 [.23] 6.35 [.25] 7.11[.28]

4.83 [.19] 5.59 [.22] ĊĊ ĊĊ

6.35 [.25] 7.11[.28] ĊĊ ĊĊ

(Nylon or
TEFLON)

DOT

CODE

ONE DOT

ONE DOT 26 - 24 ĊĊ

ONE DOT

TWO DOTS

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

ONE DOT 26 - 24 SPLICE ONLY

TWO DOTS 24 - 20 ĊĊ

ONE DOT 26 - 24 TERMINALS ONLY

TWO DOTS 24 - 20 ĊĊ NATURALW/WHITE STRIPE 4.83 [.19] 5.59 [.22] 5.59 [.22] 6.35[.25]

ONE DOT 22 - 16 ĊĊ NATURAL W/RED STRIPE 5.08 [.20] 5.84 [.23] 6.35 [.25] 7.11 [.28]

ONE DOT

TWO DOTS 16 - 14 ĊĊ NATURALW/BLUE STRIPE

ONE DOT

ONE DOT

ONE DOT

TWO DOTS

WIRE

RANGE

OR SIZE

26

24

26-22

24-20

26 - 24 TERMINALS ONLY
22 - 16 ĊĊ NATURALW/RED STRIPE

26
24

22 0.97-2.79 [.038 - .110] RED W/GREEN STRIPE
20 1.17-2.79 [.046 - .110] REDW/RED STRIPE
18 1.42-2.79 [.056 - .110] RED W/WHITE STRIPE
22 0.97-2.79 [.038 - .110] RED W/GREEN STRIPE
20 1.17-2.79 [.046 - .110] REDW/RED STRIPE
18 1.42-2.79 [.056 - .110] RED W/WHITE STRIPE
16 1.60-3.30 [.063 - .130] BLUE W/BLUESTRIPE
14 1.98-3.30 [.078 - .130] BLUE W/GREEN STRIPE

WIRE INSULATION

DIAMETER

RANGE

0.66-1.40 [.026 - .055]

0.79-1.40 [.031 - .055]

0.66-1.40 [.026 - .055]

0.79-1.40 [.031 - .055]

Figure 2 (cont’d)

of 10

Tyco Electronics Corporation

Rev

G2

T"-HEAD Crimping Tools

408-1610

PRODUCT

PIDG
STRATO-THERM
TERMINALS

PIDG
INSULATION
RESTRICTING
TEFLON
STRATO-THERM
TERMINALS

PRODUCT

SPAREWIRE CAP
NO. 328307

SPAREWIRE CAP
NO. 328308

NOTE

i

TOOL NO. AND

HANDLE

COLOR CODE

69692-1

BLACK AND

GREEN

69693-1

ORANGE AND

WHITE

69692-1

BLACK

AND

GREEN

69693-1

ORANGE

AND

WHITE

TOOL NO. AND

HANDLE

COLOR CODE

59250

AND

59170

RED AND BLUE

DOT

CODE

ONE DOT 26 - 24 BLACKĊĊ

TWO DOTS 22 - 20 GREENĊĊ

ONE DOT 18 - 16 ORANGEĊĊ

TWO DOTS 14 WHITEĊĊ

ONE DOT

ONE DOT

TWO DOTS 14 GREEN1.98-3.30 [.078 - .130]

WIRE

RANGE

OR SIZE

26 BLACK0.66-1.40 [.026 - .055]
24 BLUE0.79-1.40 [.031 - .055]
22 GREEN0.97-2.79[.038 - .110]
20 RED1.17-2.79 [.046 - .110]
18 WHITE1.42-2.79 [.056- .110]
16 BLUE1.60-3.30 [.063 - .130]

DOT

CODE

ONE DOT 22 - 18 ĊĊ RED

TWO DOTS 16 - 14 ĊĊ BLUE

WIRE INSULATION

DIAMETER

RANGE

WIRE

RANGE

Figure 2 (end)

Refer to tool label for color code information.
Note that Figure 2 indicates the number of dots
that appear embossed on acrimped terminal,
splice or cap. Observe the dot codeon finished
crimp to insure that correct product andtool
combination was used.

SEAL LINER

COLOR CODE

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.

INSULATION

COLOR CODE

INSULATION

COLOR CODE

WIRE STRIP LENGTH

Terminals Splices

Min. Max. Min. Max.

4.06 [.16] 4.83 [.19] ĊĊ ĊĊ

5.08 [.20] 5.84 [.23] ĊĊ ĊĊ

4.83 [.19] 5.59 [.22] ĊĊ ĊĊ

6.35 [.25] 7.11[.28] ĊĊ ĊĊTWO DOTS

6.35 [.25] 7.11[.28] ĊĊ ĊĊ

WIRE STRIP LENGTH

Min. Max.

7.87 [.31] 8.64 [.34]

NOTE

Dot code will disappear after heat sealing
environment sealed splices.

i

4. WIRE STRIPPING AND CRIMPING PROCEDURES

NOTE

Refer to Section 5 for insulation crimp
adjustment.

i

CAUTION

!

4.1. PIDG and PLASTI-GRIP Terminals and Splices

1. Strip wire to dimensions listed in Figure 2.

NOTE

Do not re-terminate the splices or terminals.

Do not use wires with nicked or missing
conductor strands

i

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.

4. Raise locator and place splice under locator as
shown in Figure 4. Splice window indent faces top
of tool.

NOTE

To properly position pre-insulated sealed splice,
apply and maintain pressure against end of splice

i

until Step 5 is 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.

NOTE

Do not allow wire insulation to enterwire barrel.

i

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.

G

Tyco Electronics Corporation

3

of 10Rev

T"-HEAD Crimping Tools

408-1610

PIDG and PLASTI-GRIP Terminals

C" B" C" B"

C" B"

Terminal Barrel
Rests Against
Locator

Conductor Butts
Against Locator

Terminal Tongue
Slides Under
Locator

Environmental
Sealed Splice

C" B"

B" Equals Wire Barrel
C" Equals Insulation Barrel

First
Crimp

Window Indent
Faces Top of
Tool

Window
Indent

Wire Stop

PIDG

Terminal

PLASTI-GRIP

Terminal

B" Equals Wire Barrel
C" Equals Insulation Barrel

Figure 3

BUTT Splices

PIDG

PLASTI-GRIP

C" B"

PIDG Insulation

C" B"

Restricting

Window
Indent

Wire Stop

Window
Indent

Wire Stop

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.

NOTE

Do not use wire with nicked ormissing conductor
strands.

i

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.

Spare Wire Caps

Insulation
Adjustment
Indicator at
Position 4

Wire
Barrel

Locator

Raise Locator so
that End of Cap Rests
Against Recessed
Surface of Locator

Figure 5

Conductor Butts
Against Wire Stop

Second
Crimp

Window Indent
Faces Top of Tool

Figure 4

of 10

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.

Tyco Electronics Corporation

Rev

G4

T"-HEAD Crimping Tools

408-1610

Accept Reject

A Dot Code (1 or 2 Dots) Must

1

2 6

Appear on All Crimped Items

1

5

2

5

PIDG &

3

8

4

5

PLASTI-GRIP

8

7

4

Terminals

353837

3

PIDG

Butt Splice

Wire
Stop

6

3

4

6

2

1

Wire Barrel Dies Crimped
Splice Insulation

3

8

5

2

1

1

Insulation barrel is in firm contact with wire insulation.

2

Correct color code, dot code, and tool combination.
Wire size is within wire range stamped under terminal

3

tongue or on center of splice.

4

Crimp centered on wire barrel.
End of conductor is flush with, or extends beyond end

5

of terminal wire barrel.
End of conductor against wire stop of splice, or at least

6

flush with, or extended slightly beyond wire barrel.

7

Wire insulation does not enter wire barrel.

8

No nicked or missing conductor strands.

5. INSULATION CRIMP ADJUSTMENT

5.1. PIDG Terminals and Splices

NOTE

PIDG terminals and splices feature a wire
insulation grip".

i

Each tool has four insulation crimp positions. See
Figure 1.

1

2
3

4

5

6

7
8
9

Figure 6

6

Wire insulation extruded. (Insulation crimp too tight on PIDG
terminals and splices) See Section 5.

Wrong dot code and color code combination. See Figure 2.
Wire size is not within wire range stamped on terminal

tongue or splice.
Crimp not centered on wire barrel. (Terminal was not butted
against locator. See Figure 3.)
End of conductor is not flush with or extending beyond end
of wire barrel. (Check for correct strip length.)
Excessive flash or extruded insulation, (wrong tool,
terminal, or splice combination, or damaged dies).

Wire insulation entered wire barrel.
Nicked or missing conductor strands.

Splice was reversed in dies (tool’s locator was not seated in
window indent of splice).

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.

G

Tyco Electronics Corporation

5

of 10Rev

T"-HEAD Crimping Tools

408-1610

Accept Reject

A Dot Code (1 or 2 Dots) Must
Appear on All Crimped Items

1

5

2

11

9

4

7

2

1

No flash or extruded insulation.
Correct color code, dot code, and tool combination.

2

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.
End of conductor against wire stop of splice, or at least

5

flush with, or extended slightly beyond wire barrel.

6

End of conductor bottomed in cap.

7

Full width of crimp is over wire barrel.

8

No nicked or missing conductor strands.

9

Crimp centered on wire barrel.

10

Splice insulation is in contact with wire insulation.

8

1

4 8 6

5

3

Wire Stop

3

PLASTI-GRIP

Butt Splice

Spare Wire Cap

1

2

3

4

5

6
7

8

9

10

11

7

Excessive flash or extended insulation. (Crimped in
smaller dies on wrong side of tool.) Also, check for
damaged dies.

Wrong dot code and color code combination. See Figure 2.
Incorrect wire size used.

Wire insulation entered wire barrel.
End of conductor is not flush with or extending beyond

end of wire barrel. (Check strip length.)
End of conductor not bottomed in cap.

Half of crimp off end of wire barrel (Cap was not bottomed
in recess of locator.)

Nicked or missing conductor strands.
Crimp not centered on wire barrel. (Tool locator not

seated in window indent.)
Splice insulation is not in contact with wire insulation.

1

2

5

9

8

4

5

1

6

8

2

3

3

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).

of 10

Figure 7

5.2. PLASTI-GRIP Terminals and Splices

NOTE

i

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.

Tyco Electronics Corporation

PLASTI-GRIP terminals and splices feature a
wire insulation support" only.

Rev

G6

T"-HEAD Crimping Tools

408-1610

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.

NOTE

i

Locators in Crimping Tools69692-1 and
69693-1 are locked in the down position. Refer
to Instruction Sheet 408-7424 forcrimp height
inspection of these tools.

7. MAINTENANCE AND INSPECTION

NOTE

Make certain the degreasing compounddoes not
attack paint or plastic materials.

i

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 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 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.

Flattened

Broken Corner

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. Cleaning

The tool should be immersed (handles partially
closed) in degreasing compound to remove
accumulated dirt, grease, and foreign matter.

Chipped
Edge

Figure 8

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.

G

Tyco Electronics Corporation

7

of 10Rev

T"-HEAD Crimping Tools

408-1610

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.

NOTE

i

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.

The following plug gaging informationfor
insulation crimping chambers is provided for
customers specifically requiringthis information.
If plug gaging is not required, inspectthe die
closures using an alternate procedure,i.e.,
performing the Insulation Crimp Adjustment"
(see Section 5) and VisualInspection" (see
Paragraph 7.2).

crimping areas do not conform to the inspection, the
tool must be repaired. Refer to Section 8,
REPLACEMENT AND REP AIR.

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 REP AIR. 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 CORPORA TION
P.O. BOX 3608
HARRISBURG, P A 17105–3608

For tool repair service, please contact a Tyco
Electronics Representative at 1–800–526–5136.

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

of 10

9. REVISION SUMMAR Y

Since the previous release of this sheet, the following
changes were made:

S

Updated document to corporate requirements

S

Added NOTE to Figure 12

Tyco Electronics Corporation

Rev

G8

T"-HEAD Crimping Tools

59170 and 59250

59275

59300

59170 and 59250

3.18 [.125]

59275

0.762-0.770 [.0300-.0303]

2.029-2.032 [.0799-.0800]

2.36 [.093]

59300

0.762-0.770 [.0300-.0303]

2.791-2.794 [.1099-.1100]

3.18 [.125]

TOOL

WIRE SIZE

SOLDER SLUG

WIDTH

69692-1

69693-1

408-1610

Suggested Plug Gage Design - Wire Barrel Crimping Chamber

Die Closure

Configuration

TOOL WIRE SIZE

NUMBER AWG

22-16 2.769 - 2.776 [.1090 - .1093] 2.918 - 2.921 [.1149 - .1150]
16-14 3.023 - 3.030 [.1190 - .1193] 3.172 - 3.175 [.1249 - .1250]
26-22 1.600 - 1.608 [.0630 - .0633] 1.750 - 1.753 [.0689 - .0690]
24-20 2.261 - 2.268 [.0890 - .0893] 2.410 - 2.413 [.0949 - .0950]
24-20 2.261 - 2.268 [.0890 - .0893] 2.410 - 2.413 [.0949 - .0950]
22-16 2.769 - 2.776 [.1090 - .1093] 2.918 - 2.921 [.1149 - .1150]

Use solder slug and crimp height comparator. (Reference 408-7424)

TOOL

NUMBER

69692-1

69693-1

WIRE SIZE

AWG

26-24 2.34 + 0.05 [.092 + .002] 1/8 Diameter
22-20 2.69 + 0.05 [.106 + .002] 1/8 Diameter
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

50.8 [2.00] Min. Typ.

GO NO-GO

SOLDER SLUG
CRIMP HEIGHT

Figure 9

NO-GO Dim.GO Dim.

B" Dia.B" Dia.

GAGE ELEMENT DIMENSION B"

SOLDER SLUG

DIAMETER REFERENCE

Die Closure

Configuration

TOOL WIRE SIZE

NUMBER AWG

NO.

AWG

26-24 0.635 [.0250] 1.905 [.0750] 1/8 Diameter 2.36 [.093]
22-20 0.889 [.0350] 2.159 [.0850] 1/8 Diameter 2.36 [.093]
18-16 O.762 [.0300] 2.794 [.1100] #18 - 1/8 Dia. #16 - 3/16 Dia. 3.18 [.125]

14 1.016 [.0400] 3.048 [.1200] 3/16 Diameter 3.18 [.125]

Set Insulation Adj. Indicator

Suggested Plug Gage Design - Insulation Crimping Chamber

GO Dim.

D"

D"

GO NO-GO

C"

GAGE ELEMENT DIMENSION D"

GO NO-GO

22-16 0.762 - 0.770 [.0300 - .0303] 2.791 - 2.794 [.1099 - .1100]
16-14 1.016 - 1.024 [.0400 - .0403] 3.045 - 3.048 [.1199 - .1200]
26-22
24-20
24-20
22-16

Use solder slug and crimp height comparator. (Reference 408-7424)

DIE CLOSURE DIM'S. C"

Set Insulation Adj. Indicator

at No. 1 Posn (GO)

at No. 4 Posn (NO-GO)

6.35 [.250] Typ.

DIAMETER REFERENCE

Figure 10

NO-GO Dim.

W"

WIDTH

W" (Max.)

W" (MAX.)

G

Tyco Electronics Corporation

9

of 10Rev

T"-HEAD Crimping Tools

408-1610

Inspection of Wire Barrel

Crimping Dies

Detail A Detail B

Wire Barrel
Dies are
Bottomed
But Not Under
Pressure

GO gage must pass completely
through the die closure.

Inspection of Insulation

Crimping Dies

Insulation
Adjustment
Indicator

Insulation
Adjustment
Indicator in
Position 1

GO gage must pass completely
through the die closure.

Insulation
Adjustment
Indicator in
Position 4

NO-GO gage may enter partially, but must not
pass completely through the dieclosure.

(With Handles Closed)
Approx. Dim.

73.03 [2.875] (Short Handle)

73.03 [2.875] (Long Handle)

Figure 11

Approx.

203.2 [8.00] (Short Handle)

244.48 [9.625] (Long Handle)

NO-GO gage may enter partially, but must not
pass completely through the dieclosure.

NOTE

Some tools require the
removal of the locator

i

to gage the tool.

1

2

ITEM DESCRIPTION 59170SHORT HANDLE

59250 LONG HANDLE

1 Support, Locator ĊĊ ĊĊ 59755-1 59755-2 1
2 Screw ĊĊ ĊĊ 1-21002-3 1-21002-3 2

of 10

TOOL NUMBERS AND REPLACEMENT PART NUMBERS

59275 SHORT HANDLE

59300 LONG HANDLE

69692-1

LONG HANDLE

Figure 12

Tyco Electronics Corporation

69693-1

LONG HANDLE

QTY PER

ASSY

Rev

G10