59755-2 [TE]
Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools.;型号: | 59755-2 |
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.
i
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.
©2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company TOOLING ASSISTANCE CENTER 1-800-722-1111
All Rights Reserved
*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
i
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
i
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.
i
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.
i
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.
i
Do not use wires with nicked or missing conductor
strands
NOTE
i
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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Rev M
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
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.
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.
i
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.
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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
i
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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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
i
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
i
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).
i
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
i
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
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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.
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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
1
2
Support, Locator
59755-1
59755-2
1
2
---
---
---
---
Screw
1-21002-3
1-21002-3
Figure 13
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Rev M
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