T-HEAD* Crimping Tools Instruction Sheet

59170, 59250, 59275, 59300, 408-1610

69692-1 and 69693-1 16 JUL 19 Rev N

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

INTRODUCTION
This instruction sheet covers the use of T-HEAD Crimping Tools 59170, 59250, 59275, 59300, 69692-1, and

 PIDG* vinyl and nylon terminals and splices on stranded copper wire sizes 26 through 14.
69693-1 (see Figure 1). These tools crimp:

 STRATO-THERM* terminals on stranded copper wire sizes 26 through 14.

 PIDG Insulation Restricting Nylon Terminals on stranded copper wire sizes 26 through 14.
 PIDG insulation restricting terminals with TEFLON coating, used on stranded copper wire sizes 26

 PIDG Radiation Resistant Terminals and Splices on stranded copper wire sizes 26 through 14.
through 14.

 PLASTI-GRIP* Terminals on solid or stranded copper wire sizes 22 through 14.

 PLASTI-GRIP Butt Splices on solid or stranded copper wire sizes 26 through 22.
 Spare Wire Caps on solid or stranded copper wire sizes 22 through 14.

Read these instructions thoroughly before using the tool(s).

Reasons for reissue of this instruction sheet are provided in Section 9, REVISION SUMMARY.
NOTE
All dimensions on this instruction sheet are in millimeters [with inches in brackets]. Figures are not drawn to scale.

TEFLON is a trademark.

© 2019 TE Connectivity Ltd. family of companies. PRODUCT INFORMATION 1-800-522-6752 This controlled document is subject to change.
All Rights Reserved. For latest revision and Regional Customer Service,
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*Trademark 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.
 408-1610

DESCRIPTION
The handles of the crimping tools are color-coded to match the color-coding of the product to be applied. The
insulation adjustment indicator is used to control crimp height of the insulation barrel. It can be set at any of four
positions corresponding to insulation diameter. Tools also feature a locator, quick take-up trigger, and color-
code information.

The CERTI-CRIMP hand crimping tool ratchet control ensures complete and consistent crimping of the product.
Once engaged, the ratchet will not release until the tool has fully cycled.
CAUTION
The crimping dies bottom before the ratchet releases. This is a design feature that ensures maximum electrical and tensile
performance of the crimp. DO NOT re-adjust the ratchet.

COLOR AND DOT-CODING

Note that tool handles and terminal, splice and cap insulation are color-coded for a given wire range as listed in
Figure 2. Crimp the color-coded terminal, splice or cap in the matching color-coded portion of the tool. For
example, when using Hand Tool 59275, yellow-coded PIDG terminals and splices and red-coded pre-insulated
seated splices must be crimped in that portion of tool displaying the red and yellow coded dots and yellow
handle (see Figure 1).
NOTE
Refer to tool label for color-code information. Note that Figure 2 indicates the number of dots that appear embossed on a crimped terminal,
splice or cap. Observe the dot code on finished crimp to insure the correct product and tool combination was used.
NOTE
Dot code will disappear after heat sealing environment sealed splices.

Figure 2 (Continued)

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Figure 2 (End)

WIRE STRIPPING AND CRIMPING PROCEDURES

NOTE
Refer to Section 5 for insulation crimp adjustment.

CAUTION
NEVER re-terminate terminals or splices.

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4.1. PIDG and PLASTI-GRIP Terminals and Splices

1. Strip wire to dimensions listed in Figure 2.
NOTE
DO NOT use wires with nicked or missing conductor strands.
2. Open crimping dies by closing handles until ratchet releases (see Figure 1). Note: once ratchet is
engaged, handles cannot be opened until the tool has fully cycled.
Crimp the color-coded terminals and splices in the matching color-coded portion of the tool (refer to
Section 3).
3. Place terminal in crimping dies so that terminal tongue slides under locator (see Figure 3).

Figure 3
4. Raise locator and place splice under locator as shown in Figure 4 (splice window indent faces top of
tool).
NOTE
To properly position pre-insulated sealed splice, apply and maintain pressure against end of splice until Step 5 is completed. See Figure 4.
5. Press quick take-up trigger and close handles until terminal or splice is held firmly in place. Do not
deform terminal or splice wire barrel.
6. Insert stripped wire into terminal until conductor butts against locator (see Figure 3). Insert stripped
wire into splice until conductor butts against splice wire stop (see Figure 4).
NOTE
Do not allow wire insulation to enter wire barrel.

Figure 4

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7. Hold wire in position and complete crimp by closing handles until the ratchet releases.
8. Refer to Section 6 and Figure 6 or Figure 7 for terminal or splice "Crimp Inspection" procedure.

4.2. Spare Wire Caps

1. Strip wire to dimensions listed in Figure 2. Crimp the color-coded portion of the tool. Refer to Section
3.
NOTE
Do not use wire with nicked or missing conductor strands.
2. Place tool insulation adjustment indicator in Position 4.
3. Close tool handles until crimping jaws partially close but leave enough space for cap to be inserted
between dies.
4. Raise locator so that end of cap rests against the recessed surface of the locator as shown in
Figure 5.

Figure 5
5. Squeeze quick take-up trigger and close handles until cap is held firmly in place. Do not deform cap
wire barrel.
6. Insert stripped wire into cap until conductor bottoms in cap.
7. Hold wire in position and complete crimp by closing handles until the ratchet releases. Handles will
open automatically allowing crimped cap to be removed.
8. Refer to Section 6 and Figure 7 wire cap crimp inspection procedure.

INSULATION CRIMP ADJUSTMENT

5.1. PIDG Terminals and Splices

NOTE
PIDG terminals and splices feature a wire "insulation grip".
Each tool has four insulation crimp positions. See Figure 1.
1. Loosen insulation adjustment locking screw (see top of tool) and turn indicator to Position 4.
2. Place terminal or splice in tool dies.
3. Insert UNSTRIPPED wire into ONLY the insulation barrel (see Figure 3 or Figure 4) of terminal or
splice.

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4. Perform a crimp (Section 4). Remove crimped terminal or splice and check insulation grip as follows:
Bend the wire back and forth once. Terminal or splice should retain grip on wire insulation.
5. If wire pulls out, set insulation adjustment indicator to next tighter position – Position 3.
6. Perform a crimp and repeat adjustment as necessary until desired insulation grip is obtained. Do not
use a tighter setting than required.
7. Tighten insulation adjustment locking screw (see top of tool).

5.2. PLASTI-GRIP Terminals and Splices

NOTE
PLASTI-GRIP terminals and splices feature a wire "insulation support" only.
1. Set insulation adjustment indicator in Position 4 for wire having a large insulation diameter.
2. Set insulation adjustment indicator in Position 3 for wire having a medium insulation diameter.
3. Set insulation adjustment indicator in Position 2 for wire having a small insulation diameter.
4. Set insulation adjustment indicator in Position 1 for wire having thin wall insulation. Terminal or splice
insulation should ideally be in contact with wire insulation.

CRIMP INSPECTION
Inspect crimped terminals, splices and spare wire caps by checking the features described in Figure 6 or
Figure 7, as applicable.

Use ONLY the crimped items that meet the conditions shown in the ACCEPT column.

REJECT terminals, splices, and spare wire caps can be avoided through careful use of instructions and by
performing regular tool maintenance as instructed in this document.
NOTE
Locators in Crimping Tools 69692-1 and 69693-1 are locked in the down position. Refer to Instruction Sheet 408-7424 for crimp height
inspection of these tools.

MAINTENANCE AND INSPECTION

TE recommends that a maintenance/inspection program be performed periodically to ensure dependable and
uniform terminations. Tools should be inspected at least once a month. Frequency of inspection may be
adjusted to suit your requirements through experience. Frequency of inspection is dependent upon:


The care, amount of use, and handling of the tool.


The type and size of the products crimped.


The degree of operator skill.


The presence of abnormal amounts of dust and


dirt.
Your own established standards.
All tools are inspected before packaging. Since there is a possibility of tool damage in shipment, new tools
should be inspected in accordance with Section 7 when received in your plant. Due to the precision design, it is
important that no parts of these tools be interchanged except those replacement parts listed in Figure 13.

7.1. Cleaning
The tool should be immersed (handles partially closed) in degreasing compound to remove accumulated dirt,
grease, and foreign matter.
NOTE
Make certain the degreasing compound does not attack paint or plastic materials.
Remove remaining degreasing compound with a lint free cloth. When degreasing compounds are not available,
tool may be wiped clean with a lint free cloth. Re-lubricate tool, as instructed in Paragraph 7.3 before placing it
back in service.

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Figure 6

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Figure 7

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7.2. Visual Inspection

1. Visually inspect the tool for missing parts, then operate the tool and note the return action of the
spring-loaded handles. If parts are missing or defective, refer to Figure 13 for customer replaceable
parts.
2. Visually inspect the die closure surfaces for flattened, broken, pitted, or chipped conditions. Although
dies may gage within permissible limits, worn or damaged die closure surfaces are objectionable and
can affect the quality of the crimp.
Examples of possible damaged die closure surfaces are shown in Figure 8.

Figure 8

7.3. Lubrication
Lubricate all pins, pivot points, and bearing surfaces with SAE 20 motor oil as follows:


Tools used in daily production: Lubricate daily


Tools used daily (occasional): Lubricate weekly
Tools used weekly: Lubricate monthly
Wipe excess oil from tool, particularly from crimping area. Oil transferred from the crimping area onto certain
terminations may affect the electrical characteristics of an application.

7.4. Gaging the Crimping Chamber

Each tool is inspected for proper die closures before packaging. An inspection should be performed periodically
to check the tool die closures for excessive wear.
NOTE
The following plug gaging information for insulation crimping chambers is provided for customers specifically requiring this information. If
plug gaging is not required, inspect the die closures using an alternate procedure, i.e., performing the "Insulation Crimp Adjustment" (see
Section 5) and "Visual Inspection" (see Paragraph 7.2).
NOTE
Refer to the table in Figure 11 for alternate hard gage dimensions for tools 69692-1 and 69693-1.

Gaging the Crimping Chamber Using A Plug Gage

This inspection requires the use of plug gages conforming to the dimensions listed in Figures 9 and Figure 10.
TE Connectivity does not manufacture or market these gages. Refer to Instruction Sheet 408-7424 for
information concerning plug gages.

SAE is a trademark.

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Figure 9

Figure 10

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Figure 11
To gage the crimping area(s), refer to Figure 12 and proceed as follows:
1. Clean oil or dirt from the crimping chamber and plug gage.
2. Close handles of tool until wire barrel dies are bottomed. Do not apply additional pressure to tool
handles.
3. With wire barrel dies bottomed, inspect the wire barrel crimping chamber using the proper plug gage.
Lift the spring-loaded locator up and hold gage in straight alignment with the crimping chamber.
Carefully try to insert, without forcing, the GO element. See Figure 12, Detail A. The GO element must
pass completely through the crimping area.

Figure 12
4. Try to insert the NO-GO element. The NO-GO element may enter partially but must not pass
completely through the crimping area.

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5. Set insulation adjustment indicator in Position 1. Measure both insulation crimping chambers with the
proper GO plug gages in the same manner as Steps 2 and 3. See Figure 12, Detail B.
6. Set insulation adjustment indicator in Position 4. Measure both insulation crimping chambers with the
proper NO-GO plug gages in the same manner as Steps 2 and 4. See Figure 12, Detail B.
If the crimping areas conform to the gage inspection, the tool is considered dimensionally correct. If the
crimping areas do not conform to the inspection, the tool must be repaired. Refer to Section 8,
REPLACEMENT AND REPAIR.

Gaging the Crimping Chamber Using A Solder Slug and Crimp Height Comparator
This inspection requires the use of crimp height comparators, solder slugs, and the dimensions listed in Figure
10. TE Connectivity does not manufacture or market crimp-height comparators. Refer to Instruction Sheet 408-
7424 for information concerning comparators.
To gage the crimping chamber using the solder slug, proceed as follows:
1. Clean oil or dirt from the crimping chamber.
2. Set insulation adjustment to Position 1.
3. Insert proper solder slug into one crimp chamber (see Figure 9 and Figure 10) and cycle tool.
4. Measure the compressed solder slug for the wire- barrel crimping chamber and check for compliance
to dimensions in Figure 9.
5. Measure the compressed area for the insulation- crimping chamber and check for compliance to the
GO dimensions in Figure 10.
6. Set the insulation adjustment to Position 4 and insert the appropriate solder slug into the insulation
chamber.
7. Cycle the tool.
8. Measure the compressed area (of the solder) for the insulation-crimping chamber and check for
compliance to the NO-GO dimensions in Figure 10.
9. Repeat the steps above for the second crimp chamber.

7.5. Ratchet Control Inspection

Obtain a .025-mm [.001-in.] shim that is suitable for checking the clearance between the bottoming surfaces of
the crimping dies. To inspect the CERTI- CRIMP hand crimping tool ratchet control:
1. Perform a crimp using the largest wire size for your tool.
2. While holding the wire in place, squeeze the tool handles together until the ratchet releases. Hold the
tool in this position, maintaining just enough pressure to keep the dies closed.
3. Check the clearance between the bottoming surfaces of the crimping dies. If the clearance is .025 mm
[.001 in.] or less, the ratchet is satisfactory. If clearance exceeds .025 mm [.001 in.], the ratchet is out
of adjustment, and must be repaired. Refer to Section 8, REPLACEMENT AND REPAIR.
If the tool conforms to these inspection procedures, lubricate it with a THIN coat of any good SAE 20 motor oil
and return it to service.

REPLACEMENT AND REPAIR

Replacement parts are listed in Figure 13. Parts other than those listed in Figure 13 should be replaced by TE
Connectivity to ensure quality and reliability of the tool. Order replacement parts through your TE
Representative, or call 1-800-526-5142, or send a facsimile of your purchase order to 1-717-986-7605, or write
to:

CUSTOMER SERVICE (038-035)

TE CONNECTIVITY CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608

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Tool Numbers and Replacement Part Number

591 Short Handle 59275 Short Handle 69692-1 69693-1

Item Description Qty Per Assy
59250 Long Handle 59300 Long Handle Long Handle Long Handle
1 Support, Locator --- --- 59755-1 59755-2 1
2 Screw --- --- 1-21002-3 1-21002-3 2

Figure 13

REVISION SUMMARY

 Revised with most up-to-date corporate logo, entity designation and outline structure.
Revisions to this instruction sheet include:

 Revised Section 2 and paragraph 4.1.2.

 The locations of Figures 3 thru 13 were relocated throughout the document to better align with the

 Added TEFLON and SAE trademark notations at first appearance.

relevant text.

 Corrected NOTE icon in Figure 13

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