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Tyco Electronics 59239-4 Instruction Sheet

Heavy head hand tools
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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.
Stationary Crimping
Dies (Anvils)
Head
Tool Color Code: Yellow
Tool Dot Code: 1
TOOL
TYPE
PIDG* Vinyl and Nylon Terminal and
y
Splice and PLASTI-GRIP* Terminal
PIDG Insulation Restricting Nylon
59239 4
59239-4
Terminal
59239-8
525692
PIDG Radiation Resistant
Terminal and Splice
Spare Wire Cap 328309
PIDG Vinyl and Nylon Terminal and
y
59287 2
59287-2
Splice and PLASTI-GRIP Terminal
G
Heavy Duty
1. INTRODUCTION
Heavy Head Hand Tools (HHHT) 525692, 59239–4,
59239–8, and 59287–2 are designed to crimp the
product listed in Figure 1 onto the wire also listed.
E
2007 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
Heavy Head Hand Tools
59239-4, 59239-8,
59287-2, and 525692
Locator
Movable Crimping
Dies (Indenters)
PRODUCT
INSULATION
COLOR CODE
Yellow
y
Yellow with Black Stripe
Yellow with 3 Yellow Stripes
g
y
Yellow with 3 Brown Stripes
Natural with Yellow Stripe
Natural with Black Stripe
Yellow
Yellow
y
Yellow with Black Stripe
Figure 1
TOOLING ASSISTANCE CENTER 1-800-722-1111
PRODUCT INFORMATION 1-800-522-6752
Handles
Insulation Crimping
Adjustment Pin
TYPE
Solid or Stranded
Copper
Stranded Copper
Stranded Copper
Stranded Copper
Stranded Copper
Stranded Copper
Solid or Stranded
Copper
NOTE
Measurements are in metric units [with U.S.
customary units in brackets]. Figures and
i
illustrations are for reference only and are not
drawn to scale.
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com
Instruction Sheet
408-1261
18 OCT 07
Rev F
Ratchet
WIRE
INSULATION
SIZE (AWG)
DIAMETER
(mm [in.])
12-10
5.84-6.35
G
[.230-.250]
16-14 HD
2.41-5.08
12
[.095-.200]
3.02-5.08
10
[.119-.200]
12-10
6.60 [.260]
[
]
G
Max
16-14 HD
12-10
5.33 [.210] Max
12-10
6.99-7.62
G
[.275-.300]
16-14 HD
1 of 9
LOC B

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Summary of Contents for Tyco Electronics 59239-4

  • Page 1 For latest revision and Regional Customer Service, All International Rights Reserved visit our website at www.tycoelectronics.com TE logo and Tyco Electronics are trademarks. LOC B *Trademark. Other products, logos, and company names used are the property of their respective owners.

  • Page 2: Crimping Procedure

    408-1261 HHHT 59239-4, 59239-8, 59287-2, and 525692 NOTE For other tools accompanied by this instruction 3. CRIMPING PROCEDURE sheet, follow the instructions for the tool used to crimp the same wire size. 3.1. Wire Preparation Strip the wire within the dimensions given in Figure 3,...
  • Page 3 408-1261 HHHT 59239-4, 59239-8, 59287-2, and 525692 8. Inspect the crimp to make sure that it conforms to Figures 7 and 8. Terminals not meeting the described conditions should NOT be used. Strip Length B. Butt Splices 1. Open the crimping dies by closing the tool...
  • Page 4 408-1261 HHHT 59239-4, 59239-8, 59287-2, and 525692 8. Inspect the crimp to make sure that it conforms To adjust the grip resulting from the crimp of the to Figures 7 and 8. Splices not meeting the insulation barrel, proceed as follows: described conditions should NOT be used.
  • Page 5 408-1261 HHHT 59239-4, 59239-8, 59287-2, and 525692 ACCEPT REJECT PIDG Terminal and PLASTI-GRIP Terminal Wire Range Stamped Here A Dot Code (1 Dot) Must Appear on All Crimped Products Wire Range Stamped Here PIDG Butt Splice Insulation barrel is in firm contact with wire insulation.

  • Page 6: Maintenance And Inspection

    408-1261 HHHT 59239-4, 59239-8, 59287-2, and 525692 ACCEPT REJECT PIDG Insulation Restricting Terminals Spare Wire Cap Correct color code, dot code, and tool combination. Wrong dot code and color code combination. Conductors may extend slightly beyond wire barrels on Excessive flash or extruded insulation (crimped in terminals.

  • Page 7: Replacement And Repair

    3. Close the tool handles until the crimping dies parts is necessary. Parts other than those listed bottom, and hold in this position. DO NOT force should be replaced by Tyco Electronics to ensure beyond initial contact. quality and reliability. Order replacement parts 4.
  • Page 8 408-1261 HHHT 59239-4, 59239-8, 59287-2, and 525692 Suggested Plug Gage Design Wire Barrel Section of Crimping Chamber Insulation Barrel Section of Crimping Chamber GO Dia NO-GO Dia GO Dia NO-GO Dia W" W" 50.8 [2.0] Min Typ 6.35 [.250] Min Typ...

  • Page 9: Revision Summary

    408-1261 HHHT 59239-4, 59239-8, 59287-2, and 525692 76.2 [3.00] Approx 304.8 [12.00] Approx REPLACEMENT PARTS PART NUMBER FOR TOOL QTY PER ITEM ITEM DESCRIPTION DESCRIPTION TOOL 59239-4, 59239-8 59287-2 525692 300388-0 300388-0 300388-0 PIN, Retaining 21045-3 21045-3 525108-0 RING, Retaining...

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59239-859287-2525692

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