TE 59239-4 Bedienungsanleitung

Instruction Sheet

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PRODUCT INFORMATION

1-800-522-6752

This controlled document is subject to change.

For latest revision and Regional Customer Service,

visit our website at www.te.com.

408-1261

28 FEB 2023 Rev L

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 is available for extended-use production operations.

Figure 1: Heavy Head Hand Tools 59239-4, 59239-8, 59287-2, and 525692

304.8 [12.00] approximate

76.2 [3.00] approximate

1 Introduction

Heavy Head Hand Tools (HHHT) 525692, 59239-4, 59239-8, and 59287-2 are the tool and die set shown in

Figure 1. These tools are designed to crimp the product listed in Table 1 onto the wire also listed.

For other tools accompanied by this instruction sheet, follow the instructions for the tool used to crimp the same

wire size.

NOTE

Dimensions in this instruction sheet are in millimeters with [inches in brackets]. Figures are for reference only and are not

drawn to scale.

Read these instructions thoroughly before crimping connectors.

Heavy Head Hand Tools 59239-4, 59239-8,

59287-2, and 525692

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Table 1: Crimping specifications

Tool

Product

Wire

Type

Insulation color code

Type

Size (AWG)

Insulation diameter

mm [in.]

59239-4

59239-8

525692

PIDG™vinyl and

nylon terminal

PIDG vinyl and

nylon splice

PLASTI-GRIP™terminal

Yellow

Solid or

stranded

copper

12-10

5.84-6.35 [.230-.250]

Yellow with black stripes

16-14

(heavy duty)

PIDG insulation restring

nylon terminal

Yellow with 3 yellow

stripes

Stranded

copper

2.41-5.08 [.095-.200]

Yellow with 3 brown

stripes

3.02-5.08 [.119-200]

PIDG radiation resistant

terminal and splice

Natural with yellow stripe

Stranded

copper

12-10

6.60 [.260] maximum

16-14

(heavy duty)

Spare wire cap 328309

Yellow

Stranded

copper

12-10

5.33 [.210] maximum

59287-2

PIDG vinyl and

nylon terminal

PIDG vinyl and

nylon splice

PLASTI-GRIP terminal

Yellow

Solid or

stranded

copper

12-10

6.99-7.62 [.275-.300]

Yellow with black stripe

16-14

(heavy duty)

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2 Description

Each tool consists of a head containing two stationary crimping dies (anvils), two movable crimping dies

(indenters), a locator, an insulation crimping adjustment pin, and handles with a ratchet. See Figure 2.

Figure 2: Tool components

Head

Movable crimping dies (indenters)

Stationary crimping dies (anvils)

Insulation crimping adjustment pin

Locator

Ratchet

Handle

These tools are members of the CERTI-CRIMP™hand crimping tool family. The ratchet on these tools ensures

full crimping of the product. After it is engaged, the ratchet does not release until the handles have been fully

closed.

When closed, the crimping dies form a crimping chamber with two sections: an insulation barrel section and a

wire barrel section. The insulation barrel section crimps the insulation barrel of the product onto the wire

insulation. Simultaneously, the wire barrel section crimps the wire barrel of the product onto the wire

conductors.

The crimping dies bottom before the ratchet releases. This design ensures maximum electrical and tensile

performance of the crimp. Do not re-adjust the ratchet.

The locator positions the product in the crimping chamber. The insulation crimping adjustment pin is used to

regulate the height of the insulation crimp.

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Tool handles are colored yellow to correspond to the color code of the product. Each tool produces a dot code

(one dot) on the crimp to correspond to the given wire size range. Refer to Figure 3.

Figure 3: Product color code

PIDG terminals

PLASTI-GRIP terminal

PIDG butt splice

Spare wire cap

Color stripe on heavy duty and radiation resistant

Three equally space color stripes on insulation restricting

Color stripe on heavy duty

Color stripe on radiation resistant

Color of insulation

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3 Crimping

Make sure that the insulation color code of the product matches the color of the tool handles (see Figure 3).

3.1 Stripping the wire

Strip the wire within the dimensions listed in Table 2. Do not nick or damage the wire conductors.

CAUTION

Do not use wire with nicked or missing conductors.

Figure 4: Wire strip length

Table 2: Strip length by product

Product

Strip length

PIDG vinyl and nylon terminal

PLASTI-GRIP terminal

PIDG radiation resistant terminal

7.94-8.73 [.312-.344]

PIDG insulation restricting nylon terminal

9.65-10.4 [.380-.410]

PIDG vinyl and nylon splice

PIDG radiation resistant splice

Spare wire cap

8.64-9.65 [.340-.380]

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3.2 Crimping a terminal

Figure 5: Terminal types

PIDG terminal

PIDG insulation-restricting terminal

PLASTI-GRIP terminal

Insulation barrel

Wire barrel

To crimp a terminal, complete the following steps.

1. Insert the insulation crimp adjustment pin in the proper position as described in section 4.

2. Open the crimping dies by closing the tool handles until the ratchet releases, then allow the handles to

open fully.

3. Place the terminal in the crimping chamber so that the wire barrel butts against the locator (Figure 6).

Figure 6: Positioning the terminal

Wire barrel against locator

End of wire conductors against locator

Locator

4. Close the tool handles until the terminal is held firmly in place. Do not deform the terminal.

5. Insert a properly stripped wire into the terminal wire barrel until the end of the wire conductor(s) butts

against the locator.

6. Complete the crimp by closing the tool handles until the ratchet releases.

7. Release the tool handles, allow the handles to open fully, and remove the crimped terminal.

8. Inspect the crimp as described in sections 4.1 and 4.3. Do not use terminals that fail to meet the

required conditions.

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3.3 Crimping a butt splice

Figure 7: Butt splice

Insulation barrel

Wire barrel

Window indentation

To crimp a butt splice, complete the following steps.

1. Open the crimping dies by closing the tool handles until the ratchet releases, then allow the handles to

open fully.

2. Depress the locator. Position the splice in the crimping chamber so that window indentation of the

splice rests over the locator (Figure 8).

Figure 8: Positioning the butt splice

End of wire conductors against splice wire stop

Locator depressed

Splice window indentation over locator

3. Close the tool handles until the splice is held firmly in place. Do not deform the splice.

4. Insert a properly stripped wire into the wire barrel of the splice until the end of the wire conductor butts

against the splice wire stop.

5. Complete the crimp by closing the tool handles until the ratchet releases.

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6. Release the tool handles and allow the handles to open fully.

7. Remove the crimped splice.

8. Turn the splice around, depress the locator, and position the splice in the crimping chamber so that the

window indent of the splice seats over the locator. Follow steps 3 through 6.

9. Inspect the crimp as described in section 4.2. Do not use splices that fail to meet the required

conditions.

3.4 Crimping a spare wire cap

Figure 9: Wire barrel of spare wire cap

1. Place the tool insulation adjustment pins in the position 3.

2. Close the tool handles until the crimping dies partially close, but leave enough space for the spare wire

cap to be inserted in the crimping chamber.

3. Depress the locator so that the end of the spare wire cap rests against the recessed surface of the

locator (Figure 10).

Figure 10: Positioning the spare wire cap

Wire conductors bottomed in spare wire cap

End of spare wire cap against recessed surface of locator

Locator depressed

Insulation pin in position 3

4. Close the tool handles until the spare wire cap is held firmly in place. Do not deform the spare wire

cap.

5. Insert a properly stripped wire into the spare wire cap until the wire conductor(s) bottoms.

6. Hold the wire in position, and complete the crimp by closing the tool handles until the ratchet releases.

7. Release the tool handles, allow the handles to open fully, and remove the crimped spare wire cap.

8. Inspect the crimp as described in section 4.4. Do not use caps that fail to meet the required conditions.

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4 Inspecting the crimp

4.1 PIDG or PLASTI-GRIP terminal

Inspect the crimp for the features shown in Figure 11. Do not use a terminal that has any of the features shown

in Figure 12.

Figure 11: Features of a good crimp (terminal)

Insulation barrel is in firm contact with wire insulation

Correct color code, dot code, and tool combination

Crimp is centered on wire barrel

End of conductor is flush with (or extends beyond) end of terminal wire barrel

Wire size is within range stamped under terminal tongue

Dot code (one dot) is present

Wire insulation does not enter wire barrel

No nicked or missing conductor strands

End of conductor butts against wire stop

Figure 12: Features of a poor crimp (terminal)

Nicked or missing conductor strands

Crimp not centered on wire barrel (terminal was not against locator)

End of conductor not flush with (or extending beyond) end of terminal wire barrel (check strip length)

Wire insulation is extruded (insulation crimp is too tight)

Wrong color code and dot code combination

Excess flash or extruded insulation (wrong tool or terminal, or damaged dies)

Wire range stamped here

Wire insulation enters wire barrel

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4.2 PIDG butt splice

For a PIDG butt splice, inspect the crimp for the features shown in Figure 13. Do not use a splice that has any

of the features of a poor crimp.

Figure 13: Inspecting a butt splice

Features of a good crimp

Features of a poor crimp

Crimp is centered on wire barrel

End of conductor butts against wire stop

Insulation barrel is in firm contact with wire insulation

Correct color code, dot code, and tool combination

Nicked or missing conductor strands

Excess flash or extruded insulation (wrong tool or splice, or damaged dies)

End of conductor not flush with (or extending beyond) end of terminal wire barrel (check strip length)

Wrong color code and dot code combination

Wire insulation is extruded (insulation crimp is too tight)

4.3 PIDG insulation-restricting terminal

Inspect the crimp for the features shown in Figure 14. Do not use a terminal that has any of the features of a

poor crimp.

Figure 14: Inspecting a PIDG insulation-restricting terminal

Features of a good crimp

Features of a poor crimp

Wire insulation does not enter wire barrel

No nicked or missing conductor strands

Conductor can extend slightly beyond wire barrel

Wire insulation enters wire barrel

Nicked or missing conductor strands

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