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©2015 TE Connectivity family of companies All Rights Reserved *Trademark TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners. 1 of 9 Instruction Sheet 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 LOC B 408-1261Heavy Head Hand Tools 59239-4, 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. Figure 1 Handles Locator Stationary Crimping Dies (Anvils) Movable Crimping Dies (Indenters)Tool Color Code: Yellow Tool Dot Code: 1 Insulation Crimping Adjustment Pin Ratchet Head TOOL PRODUCT WIRE TYPE INSULATION COLOR CODE TYPE SIZE (AWG) INSULATION DIAMETER (mm [in.]) 59239-4 59239-8 525692 PIDG* Vinyl and Nylon Terminal and Splice and PLASTI-GRIP* Terminal Yellow Solid or Stranded Copper 12 - 10 5.84-6.35 [.230-.250]Yellow w/ Black stripes 16 - 14 ‡ PIDG Insulation Restring Nylon Terminal Yellow w/ 3 Yellow Stripes Stranded Copper 12 2.41-5.08 [.095-.200] Yellow w/ 3 Brown Stripes 10 3.02 - 5.08 [.119 - .200] PIDG Radiation Resistant Terminal and Splice Natural with Yellow Stripe Stranded Copper 12 - 10 6.60 [.260] Max Natural with Yellow Stripe 16 - 14 ‡ Spare Wire Cap 328309 Yellow Stranded Copper 12 - 10 5.33 [.210] Max 59287-2 PIDG Vinyl and Nylon Terminal and Splice and PLASTI-GRIP Terminal Yellow Solid or Standed Copper 12 - 10 6.99-7.62 [.275-.300]Yellow w/ Black Stripe 16 - 14 ‡ ‡ Heavy Duty ORIGINAL INSTRUCTIONS

DO NOT allow wire insulation to enter the splice wire barrel. 5. Complete the crimp by closing the tool handles until the ratchet releases. 6. Release the tool handles, allow the handles to open FULLY , and remove the crimped splice. 7. 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. 8. Inspect the crimp to make sure that it conforms to Figures 7 and 8. Splices not meeting the described conditions should NOT be used. C. 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. See Figure 6. 4. Close the tool handles until the spare wire cap is held firmly in place. Do NOT deform the spare wire cap. Figure 6 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 to make sure that it conforms to Figures 7 and 8. Spare wire caps not meeting the described conditions should NOT be used. 4. INSULATION CRIMP ADJUSTMENT The insulation crimping section of the hand tool has three positions: 1 (tight), 2 (medium), and 3 (loose). To adjust the grip resulting from the crimp of the insulation barrel, proceed as follows: 4.1. PIDG Terminal and Splice PIDG terminals and splices feature a wire insulation grip. 1. Insert each insulation crimp adjustment pin into Position 3. Refer to Figure 1. Make sure that both insulation crimp adjustment pins are in the same position. 2. Place the terminal or splice into the crimping chamber as described in Section 3. 3. Insert an UNSTRIPPED wire into ONLY the insulation barrel of the terminal or splice. 4. Close the tool handles until the ratchet releases. 5. Release the tool handles, and allow the handles to open FULLY. Remove the crimped terminal or splice. 6. Check the insulation barrel crimp by bending the wire back and forth once. The terminal or splice should retain its grip on the wire insulation. If it does not, insert each insulation crimp adjustment pin into the next position (Position 2). 7. Repeat Steps 2 through 6 until the correct insulation barrel grip is attained. DO NOT use a tighter position than is necessary. 4.2. 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. CAUTION Wire Conductor(s) Bottomed in Spare Wire Cap End of Spare Wire Cap Against Recessed Surface of Locator Locator Depressed Insulation Pin in Position 3 NOTE i CAUTION

Insert each insulation crimp adjustment pin into position according to the following: Make sure that both insulation crimp adjustment pins are in the same position.

  • Position 3 for wire having a large insulation diameter.
  • Position 2 for wire having a medium insulation diameter.
  • Position 1 for wire having a small insulation diameter. 5. MAINTENANCE AND INSPECTION It is recommended that a maintenance and inspection program be performed periodically to ensure dependable and uniform terminations. Though recommendations call for at least one inspection a month, frequency of inspection depends on: 1. The care, amount of use, and handling of the tool. 2. The presence of abnormal amounts of dust and dirt. 3. The degree of operator skill. 4. Your own established standards. The tool is inspected before being shipped; however, it is recommended that the tool be inspected immediately upon arrival to ensure that the tool has not been damaged during shipment. CAUTION
  1. Immerse the tool (handles partially closed) in a
  2. Make certain that the retaining pins are in place

and that they are secured with retaining rings.

  1. All pins, pivot points, and bearing surfaces should

motor oil. DO NOT oil excessively.

  1. When the tool is not in use, keep the handles

the crimping dies. Store the tool in a clean, dry area.

  • Tool used in daily production - daily
  • Tool used daily (occasional) - weekly
  • Tool used weekly - monthly Wipe excess oil from the tool, particularly from the crimping area. Oil transferred from the crimping area onto certain terminations may affect the electrical characteristics of an application. B. Visual Inspection 1. Close the tool handles until the ratchet releases and then allow them to open freely. If they do not open quickly and fully, the spring is defective and must be replaced. See Section 6, REPLACEMENT AND REPAIR. Some tools do not have handle return springs. This inspection does not apply to those tools. 2. Inspect the head for worn, cracked, or broken crimping dies. If damage is evident, return the tool for evaluation and repair. See Section 6, REPLACEMENT AND REPAIR. C. Gaging the Crimping Chamber This inspection requires the use of plug gages conforming to the dimensions provided in Figure 9. To gage the crimping chamber, proceed as follows: †SAE is a trademark. If gaging the crimping chamber is not required, inspect the die closure using an alternate procedure, i.e., the "Insulation Crimp Adjustment" (see Section 4) and "Visual Inspection" (see Paragraph 5.2.B). 1. Remove traces of oil or dirt from the crimping chamber and plug gage. 2. Insert each insulation crimp adjustment pin into Position 1. See Figure 10. 3. Close the tool handles until the crimping dies bottom, and hold in this position. DO NOT force beyond initial contact. 4. Press and hold the locator down. 5. Carefully insert the GO element into the crimping chamber as shown in Figure 10; DO NOT force it. For the wire barrel section of the crimping chamber, the GO element must pass completely through the crimping chamber. For the insulation barrel section, the GO element must pass through the length of the section but will stop against the wire barrel section. 6. In the same manner, try to insert the NO-GO element into the crimping chamber as shown in

Figure 10. The NO-GO element may begin entry, but may not pass through the crimping chamber.

  1. Remove traces of oil or dirt from the bottoming
  2. Obtain a 0.025 mm [.001 in.] shim that is suitable
  3. Select a terminal or splice and maximum size

wire for the terminal or splice.

  1. Position the terminal or splice in the crimping

the tool handles together until the ratchet releases. just enough pressure to keep the dies closed.

  1. Check the clearance between the bottoming

Section 6, REPLACEMENT AND REPAIR.