Instruction Sheet Heavy Head Hand Tools 59239-4, 408-1261 59239-8, 59287-2, and 525692 27 AUG 15 Rev K 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. Handles Locator Stationary Crimping Dies (Anvils) Ratchet Head Insulation Crimping Adjustment Pin Movable Crimping Dies Tool Color Code: Yellow (Indenters) Tool Dot Code: 1 PRODUCT WIRE INSULATION TOOL INSULATION COLOR TYPE TYPE SIZE (AWG) DIAMETER CODE (mm in. ) PIDG* Vinyl and Yellow 12 - 10 Nylon Terminal and Solid or Stranded 5.84-6.35 Splice and Copper .230-.250 Yellow w/ Black stripes 16 - 14 PLASTI-GRIP* Terminal 2.41-5.08 Yellow w/ 3 Yellow Stripes 12 PIDG Insulation .095-.200 59239-4 Restring Nylon Stranded Copper 59239-8 3.02 - 5.08 Terminal 525692 Yellow w/ 3 Brown Stripes 10 .119 - .200 PIDG Radiation Natural with Yellow Stripe 12 - 10 Resistant Stranded Copper 6.60 .260 Max Natural with Yellow Stripe 16 - 14 Terminal and Splice Spare Wire Cap Yellow Stranded Copper 12 - 10 5.33 .210 Max 328309 PIDG Vinyl and Yellow 12 - 10 Nylon Terminal and Solid or Standed 6.99-7.62 59287-2 Splice and Copper .275-.300 Yellow w/ Black Stripe 16 - 14 PLASTI-GRIP Terminal Heavy Duty Figure 1 2015 TE Connectivity family of companies PRODUCT INFORMATION 1-800-522-6752 This controlled document is subject to change. 1 of 9 All Rights Reserved For latest revision and Regional Customer Service, *Trademark visit our website at www.te.com 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. ORIGINAL INSTRUCTIONS408-1261 1. INTRODUCTION The locator positions the product in the crimping chamber. The insulation crimping adjustment pin is Heavy Head Hand Tools (HHHT) 525692, 59239-4, used to regulate the height of the insulation crimp. 59239-8, and 59287-2 are designed to crimp the product listed in Figure 1 onto the wire also listed. Each tool handles are color coded (yellow) to correspond to the color code of the product. Each tool Dimensions are in metric units with U.S. customary NOTE produces a dot code (one dot) on the crimp to units in brackets . Figures and illustrations are for correspond to the given wire size range. Refer to reference only and are not drawn to scale. i Figure 2. 3. CRIMPING PROCEDURE For other tools accompanied by this instruction sheet, follow the instructions for the tool used to crimp the 3.1. Wire Preparation same wire size. Strip the wire within the dimensions given in Figure 3, Reasons for reissue of this instruction sheet are being careful to avoid nicking or damaging the wire provided in Section 7, REVISION SUMMARY. conductor(s). 2. DESCRIPTION DO NOT use wire with nicked or missing CAUTION conductor(s). Each tool consists of a head containing two stationary crimping dies (anvils) and two movable crimping dies (indenters), a locator, an insulation crimping adjustment pin, and handles with a ratchet. See 3.2. Crimping Figure 1. Make sure that the insulation color code of the product These tools are members of the CERTI-CRIMP* hand matches the color of the tool handles. Refer to crimping tool family. The ratchet on these tools Figure 1. ensures full crimping of the product. Once engaged, A. Terminals the ratchet will not release until the handles have been FULLY closed. 1. Insert the insulation crimp adjustment pin in the proper position according to Section 4. When closed, the crimping dies form a crimping chamber with two sections: an insulation barrel section 2. Open the crimping dies by closing the tool and a wire barrel section. The insulation barrel section handles until the ratchet releases, then allow the crimps the insulation barrel of the product onto the handles to open FULLY. wire insulation and, simultaneously, the wire barrel 3. Place the terminal in the crimping chamber so section crimps the wire barrel of the product onto the that the wire barrel butts against the locator. Refer wire conductor(s). to Figure 4. 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. Product Color Code PIDG Terminals PLASTI-GRIP Terminal PIDG Butt Splice Spare Wire Cap Color Stripe on Color of Color Stripe on Color Stripe on Heavy Duty and Insulation Heavy Duty Radiation Resistant Radiation Resistant Three Equally Spaced Color Stripes on Insulation Restricting Figure 2 Rev K 2 of 9