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TE 59239-4 Instructions Manual

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 is available for extended-use production operations.
Figure 1: Heavy Head Hand Tools 59239-4, 59239-8, 59287-2, and 525692
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.
© 2023 TE Connectivity Ltd. family of companies.
All Rights Reserved.
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners.
Heavy Head Hand Tools 59239-4, 59239-8,
59287-2, and 525692
304.8 [12.00] approximate
1
76.2 [3.00] approximate
2
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.
Instruction Sheet
408-1261
28 FEB 2023 Rev L
1 of 19

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Summary of Contents for TE 59239-4

  • Page 1 1 of 19 For latest revision and Regional Customer Service, All Rights Reserved. visit our website at www.te.com. TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners.
  • Page 2 PIDG vinyl and stranded 5.84-6.35 [.230-.250] nylon splice copper 16-14 Yellow with black stripes (heavy duty) PLASTI-GRIP™ terminal Yellow with 3 yellow 59239-4 2.41-5.08 [.095-.200] stripes PIDG insulation restring Stranded 59239-8 nylon terminal copper Yellow with 3 brown 525692 3.02-5.08 [.119-200]...
  • Page 3 408-1261 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 5 Movable crimping dies (indenters) Stationary crimping dies (anvils) 6 Insulation crimping adjustment pin Locator...
  • Page 4 408-1261 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...
  • Page 5 408-1261 Crimping Make sure that the insulation color code of the product matches the color of the tool handles (see Figure 3). 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.
  • Page 6 408-1261 Crimping a terminal Figure 5: Terminal types 1 PIDG terminal 2 PIDG insulation-restricting terminal 3 PLASTI-GRIP terminal 4 Insulation barrel 5 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.
  • Page 7 408-1261 Crimping a butt splice Figure 7: Butt splice 1 Insulation barrel 2 Wire barrel 3 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.
  • Page 8 408-1261 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.
  • Page 9 408-1261 Inspecting the crimp 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) 1 Insulation barrel is in firm contact with wire insulation 2 Correct color code, dot code, and tool combination 3 Crimp is centered on wire barrel...
  • Page 10 408-1261 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...
  • Page 11 408-1261 Spare wire cap Inspect the crimp for the features shown in Figure 15. Do not use a cap that has any of the features of a poor crimp. Figure 15: Inspecting a spare wire cap Features of a good crimp Features of a poor crimp No flash or extruded insulation Correct color code, dot code, and tool combination...
  • Page 12 408-1261 Adjusting the insulation crimp The insulation crimping adjustment pin (Figure 16) has three positions: 1. Tight 2. Medium 3. Loose Figure 16: Insulation crimping adjustment pin To adjust the grip resulting from the crimp of the insulation barrel, proceed as follows. PIDG terminal and splice PIDG terminals and splices feature a wire insulation grip.

  • Page 13: Maintenance And Inspection

    408-1261 PLASTI-GRIP terminal PLASTI-GRIP terminals and splices feature a wire insulation support only. Ideally, the terminal or splice insulation should be in contact with the wire insulation. Insert the insulation crimp adjustment pin into the appropriate position (see Table 3). Table 3: Positions for the insulation crimp adjustment pins Insulation diameter of wire Pin position...

  • Page 14: Periodic Inspection

    408-1261 Periodic inspection Regular inspections should be performed by quality control personnel. A record of scheduled inspections should remain with the dies or be supplied to personnel responsible for the dies. Recommendations call for at least one inspection per month. Base your inspection frequency on the amount of use, ambient working conditions, operator training and skill, and established company standards.
  • Page 15 408-1261 Gaging the crimping chamber This inspection requires the use of plug gages conforming to the dimensions listed in Table 5. TE Connectivity does not manufacture or market these gages. For additional information regarding the use of plug gages, refer to instruction sheet 408-7424.
  • Page 16 408-1261 To gage the crimping chamber, proceed as follows: NOTE If gaging the crimping chamber is not required, inspect the die closure using an alternate procedure (section 5, Adjusting the insulation crimp, and section 6.3, Periodic inspection). 1. Remove traces of oil or dirt from the crimping chamber and plug gage. 2.
  • Page 17 408-1261 6. Gage the insulation barrel section of the crimping chamber by gently inserting the GO and NO GO elements as shown in Figure 20.  The GO element must pass through the length of the section, but will stop against the wire barrel section.

  • Page 18: Replacement And Repair

    Spring 6-306131-4 Screw 306106-2 45891-8 306106-2 Stationary die (insulation) 306107-2 45888-7 306107-2 Moving die (insulation) 21028-4 21028-5 21028-4 Parts not listed in Table 6 should be replaced by TE Connectivity to ensure quality and reliability. 18 of 19 Rev L...

  • Page 19: Revision Summary

    408-1261 Order replacement parts through your TE representative. You can also order parts by any of the following methods:  Go to TE.com and click the Shop TE link at the top of the page.  Call 800-522-6752.  Write to:...

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