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
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