59755-1 [TE]

Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools.;


型号：	59755-1
厂家：	TE CONNECTIVITY
描述：	Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools.
文件：	总11页 (文件大小：1401K)
中文：	中文翻译
下载：	下载PDF数据表文档文件

Instruction Sheet

“T”-HEAD* Crimping Tools

59170, 59250, 59275, 59300,

69692-1 and 69693-1

408-1610

27 APR 11 Rev M

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.

• PIDG insulation restricting terminals with

TEFLONt coating, used on stranded copper wire

sizes 26 through 14.

Insulation Adjustment

Locking Screw

• 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.

Insulation Adjustment

Indicator

• PLASTI-GRIP Butt Splices on solid or stranded

copper wire sizes 26 through 22.

• Spare Wire Caps on solid or stranded copper wire

sizes 22 through 14.

Locator

Dimensions on this sheet are in millimeters [with

NOTE

inch equivalent dimensions in brackets]. Figures

and illustrations are for identification only and are

not drawn to scale.

Quick Take-Up

Trigger

Reasons for reissue of this sheet are provided in

Section 9, REVISION SUMMARY.

Color Code

Information

2. DESCRIPTION

The handles of the crimping tools are color-coded to

match the color coding of the product to be applied.

Yellow 

Handle

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.

CERTI-CRIMP* Hand Crimping Tool Ratchet Control

Figure 1

The crimping dies bottom before the ratchet

releases. This is a design feature that ensures

CAUTION

1. INTRODUCTION

maximum electrical and tensile performance of the

crimp. Do NOT re-adjust the ratchet.

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:

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.

• 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.

*Trademark



This controlled document is subject to change.

For latest revision and Regional Customer Service,

visit our website at www.te.com

1 of 11

PRODUCT INFORMATION 1-800-522-6752

LOC B

TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners.

408-1610

Figure 2 (Cont’d)

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Rev M

408-1610

Figure 2 (End)

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 product and tool combination

was used.

Crimp the color coded terminals and splices in the

matching color coded portion of the tool. Refer to

Section 3.

NOTE

3. Place terminal in crimping dies so that terminal

tongue slides under locator. See Figure 3.

Dot code will disappear after heat sealing

environment sealed splices.

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,

NOTE

apply and maintain pressure against end of splice

4. WIRE STRIPPING AND CRIMPING PROCEDURES

until Step 5 is completed. See Figure 4.

Refer to Section 5 for insulation crimp adjustment.

NOTE

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.

Do not re-terminate the splices or terminals.

CAUTION

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.

4.1. PIDG and PLASTI-GRIP Terminals and Splices

Do not allow wire insulation to enter wire barrel.

NOTE

1. Strip wire to dimensions listed in Figure 2.

Do not use wires with nicked or missing conductor

strands

NOTE

7. Hold wire in position and complete crimp by

closing handles until the ratchet releases.

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.

8. Refer to Section 6 and Figure 6 or Figure 7 for

terminal or splice "Crimp Inspection" procedure.

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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.

NOTE

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 3

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

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

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.

Figure 4

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Rev M

408-1610

Figure 6

2. Place terminal or splice in tool dies.

5. INSULATION CRIMP ADJUSTMENT

5.1. PIDG Terminals and Splices

3. Insert UNSTRIPPED wire into ONLY the

insulation barrel (see Figure 3 or Figure 4) of

terminal or splice.

PIDG terminals and splices feature a wire

"insulation grip".

NOTE

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.

Each tool has four insulation crimp positions. See

Figure 1.

5. If wire pulls out, set insulation adjustment

indicator to next tighter position - Position 3.

1. Loosen insulation adjustment locking screw (see

top of tool) and turn indicator to Position 4.

5 of 11

Rev M

408-1610

Figure 7

6. Perform a crimp and repeat adjustment as

necessary until desired insulation grip is obtained.

Do not use a tighter setting than required.

2. Set insulation adjustment indicator in Position 3

for wire having a medium insulation diameter.

3. Set insulation adjustment indicator in Position 2

for wire having a small insulation diameter.

7. Tighten insulation adjustment locking screw (see

top of tool).

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.

5.2. PLASTI-GRIP Terminals and Splices

PLASTI-GRIP terminals and splices feature a wire

"insulation support" only.

NOTE

6. CRIMP INSPECTION

Inspect crimped terminals, splices and spare wire

caps by checking the features described in Figure 6 or

Figure 7.

1. Set insulation adjustment indicator in Position 4

for wire having a large insulation diameter.

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Rev M

408-1610

Use only the crimped items that meet the conditions

shown in the ACCEPT column.

Flattened

Broken Corner

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.

Pitted

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.

NOTE

Chipped

Edge

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, and handling of the tool.

2. The type and size of the products crimped.

3. The degree of operator skill.

Figure 8

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.

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 13.

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

7.1. Cleaning

The tool should be immersed (handles partially

closed) in degreasing compound to remove

accumulated dirt, grease, and foreign matter.

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.

Make certain the degreasing compound does not

attack paint or plastic materials.

NOTE

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.

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.

The following plug gaging information for insulation

crimping chambers is provided for customers

NOTE

specifically requiring this information. If plug gaging

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).

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.

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Rev M

408-1610

Refer to the table in Figure 11 for alternate hard

gage dimensions for tools 69692-1 and 69693-1.

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.

NOTE

4. Try to insert the NO-GO element. The NO-GO

element may enter partially, but must not pass

completely through the crimping area.

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

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 12, Detail B.

To gage the crimping area(s), refer to Figure 12 and

proceed as follows:

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 12, Detail B.

1. Clean oil or dirt from the crimping chamber and

plug gage.

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,

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

REPLACEMENT AND REPAIR.

Figure 9

8 of 11

Rev M

408-1610

4. Measure the compressed solder slug for the wire-

barrel crimping chamber and check for compliance

to dimensions in Figure 9.

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.

5. Measure the compressed area for the insulation-

crimping chamber and check for compliance to the

GO dimensions in Figure 10.

6. Set the insulation adjustment to the number 4

position and insert the appropriate solder slug into

the insulation chamber.

To gage the crimping chamber using the solder slug,

proceed as follows:

1. Clean oil or dirt from the crimping chamber.

7. Cycle the tool.

2. Set insulation adjustment to the number 1

position.

8. Measure the compressed area (of the solder) for

the insulation-crimping chamber and check for

compliance to the NO-GO dimensions in Figure 10.

3. Insert proper solder slug into one crimp chamber

(see Figure 9 and Figure 10) and cycle tool.

9. Repeat the steps above for the second crimp

chamber.

Figure 10

9 of 11

Rev M

408-1610

Figure 11

Figure 12

1. Perform a crimp using the largest wire size for

7.5. Ratchet Control Inspection

your tool.

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:

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.

10 of 11

Rev M

408-1610

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.

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 (038-035)

TYCO ELECTRONICS CORPORATION

PO BOX 3608

HARRISBURG PA 17105-3608

9. REVISION SUMMARY

8. REPLACEMENT AND REPAIR

Since the previous release of this sheet, the new

company logo was applied.

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

TOOL NUMBERS AND REPLACEMENT PART NUMBER

591 SHORT HANDLE

59250 LONG HANDLE

59275 SHORT HANDLE

59300 LONG HANDLE

69692-1

LONG HANDLE

69693-1

LONG HANDLE

QTY PER

ASSY

ITEM

DESCRIPTION

Support, Locator

59755-1

59755-2

---

Screw

1-21002-3

Figure 13

11 of 11

Rev M

59755-1 [TE]

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