STRATO-THERM* Termnal and Splce Hand Crmpng Tools 59294 and 59461 Instructon Sheet 408-1259 17 AUG 10 PROPER USE GUIDELINES Cumulatve Trauma Dsorders can result from the prolonged use of manually powered hand tools. Hand tools are ntended for occasonal use a low volume applcatons. A wde selecton of powered applcaton equpment for extended-use, producton operatons s avalable. 1. INTRODUCTION Fgure 1 Tyco Electroncs STRATO-THERM Termnal Hand Crmpng Tools 59294 and 59461 are used to crmp hgh-temperature and heat-resstant STRATO- THERM termnals and splces onto wre szes 16 through 10 AWG. Front Sde of Tool Insulaton Crmpng Adjustment Pn CERTI-CRIMP Tool Ratchet For other tools accompaned by ths nstructon sheet, follow nstructons as that for tools used to crmp the same wre sze. Dmensons on ths nstructon sheet are n mllmeters [followed by nches n brackets]. Reasons for ressue of ths nstructon sheet are provded n Secton 7, REVISION SUMMARY. 2. DESCRIPTION Each tool features a head contanng two statonary crmpng des (anvls) and two movable crmpng des (ndenters), a locator, an nsulaton crmpng adjustment pn, and a CERTI-CRIMP tool ratchet. When closed, the crmpng des form one crmpng chamber wth two sectons: an nsulaton barrel secton and a wre barrel secton. The nsulaton barrel secton crmps the termnal or splce onto the wre nsulaton and, smultaneously, the wre barrel secton crmps the termnal or splce wre barrel onto the strpped wre. The locator postons the termnal or splce n the crmpng chamber. The nsulaton crmpng adjustment pn s used to regulate the heght of the nsulaton crmp. The CERTI-CRIMP tool ratchet assures full crmpng of the termnal. Once engaged, the ratchet wll not release untl the tool handles have been FULLY closed. See Fgure 1. CAUTION The crmpng des bottom before the ratchet releases. Ths desgn feature ensures maxmum! electrcal and tensle performance of the crmp. Do NOT re-adjust the ratchet. 3. CRIMPING PROCEDURE 1. Strp the wre usng the recommended strplength dmensons provded n Fgure 2. Splce Tool Termnal Insulaton Barrel Sze (AWG) Fgure 2 Wre Note: Wre barrel sleeve on hgh temperature termnals and splces s color coded orange. Heat resstant termnals and splces are NOT color coded Insulaton Barrel Wre Strp Length Strp-Length Dmenson 59294 16-14 5.16-5.94 [.203-.234] 59461 12-10 8.74-9.53 [.344-.375] 2010 Tyco Electroncs Corporaton, Berwyn, PA TOOLING ASSISTANCE CENTER 1-800-722-1111 All Rghts Reserved PRODUCT INFORMATION 1-800-522-6752 TE logo and Tyco Electroncs are trademarks *Trademark. Other products, logos, and company names mght be trademarks of ther respectve owners. Ths controlled document s subject to change. For latest revson and Regonal Customer Servce, vst our webste at www.tycoelectroncs.com 1 of 6 LOC B
2. To open the crmpng des, close the tool handles untl the ratchet releases. Note that the tool handles cannot be opened untl they are FULLY closed. 3. Pull the locator down and, from the FRONT sde of the tool, nsert the termnal or splce wre barrel sleeve nto the crmpng des. Make sure that the edge of the wre barrel sleeve s flush wth the edge of the de and that t rests aganst the locator. See Fgure 3. 4. Close tool handles just enough to hold the termnal or splce wthn the crmpng des. CAUTION Closng the tool handles too tghtly wll deform the termnal or splce.! 5. Insert wre conductor through the nsulaton barrel sleeve and nto the wre barrel sleeve untl t s flush wth the outer edge of the sleeve. See Fgure 3. 6. Close the tool handles FULLY to crmp the termnal or splce, then allow the handles to open FULLY. Remove the crmped termnal or splce from the crmpng des. 7. To crmp the other half of the splce, reposton the uncrmped sleeve n the crmpng des as descrbed n Step 3. Follow Steps 4 through 6 to complete the crmp. If the splce cannot be turned around to poston the uncrmped sleeve n the crmpng des, turn the tool around. 8. Inspect the crmp. Refer to Fgure 4 for a properly crmped termnal and splce. Check the nsulaton grp on the crmped termnal or splce. Refer to Secton 4, INSULATION CRIMPING ADJUSTMENT. The hashmark code on the bottom of the wre barrel sleeve created by the tool should match the hashmark code referenced wth the approprate tool. See Fgure 4. 4. INSULATION CRIMPING ADJUSTMENT The hand tool has three nsulaton crmpng adjustment postons to adjust the wre nsulaton grp: 1-Tght, 2-Medum, and 3-Loose. To obtan the desred nsulaton grp, proceed as follows: 1. Insert nsulaton crmpng adjustment pn nto Poston 3 as shown n Fgure 1. 2. Place termnal or splce n crmpng des as descrbed n Secton 3, Step 3. 3. Insert an UNSTRIPPED wre nto only the nsulaton barrel sleeve of the termnal or splce. 4. Perform a test crmp as descrbed n Secton 3, Step 6. Remove the crmped termnal or splce and check the nsulaton support. Bend the wre back and forth once. The nsulaton barrel sleeve should retan grp on the wre nsulaton. If the wre pulls out, move the nsulaton crmpng adjustment pn to the next tghter poston (Poston 2) and proceed to Step 5. If the wre does not pull out, the pn s properly adjusted and the tool s ready for crmpng. 5. Perform another test crmp as descrbed n Step 4. Adjust pn, as necessary, untl the desred nsulaton grp s obtaned. Do not use a tghter settng than s requred. Termnal Crmp Splce Crmp Edge of Flush wth Edge of Wre Flush wth Outer Edge of Edge of Flush wth Edge of Wre Flush wth Outer Edge of Restng Aganst Locator Wndow Indent n Splce Sldes Over Locator Pull Locator Down Pull Locator Down Fgure 3 2 of 6
Properly Crmped Termnals and Splces No Wre Conductor Strands Protrudng Tool 59461 -- No Hashmarks Tool 59294 -- Two Hashmarks 2 Hashmarks on Bottom of Termnal Crmp Centered On 2 Hashmarks on Bottom of Splce 5. MAINTENANCE AND INSPECTION It s recommended that a mantenance and nspecton program be performed perodcally to ensure dependable and unform termnatons. Frequency of nspecton should be adjusted to sut your requrements through experence and depends on: 1. The care, amount of use, and handlng of the hand tool. 2. The presence of abnormal amounts of dust and drt. 3. The degree of operator skll. 4. Your own establshed standards. The hand tool s nspected and calbrated before beng shpped; however, t s recommended that the tool be nspected mmedately upon arrval to ensure that the tool has not been damaged durng shpment. 5.1. Daly Mantenance 1. The hand tool should be mmersed (handles partally closed) n a relable commercal degreasng compound to remove accumulated drt, grease, and foregn matter. When degreasng compound s not avalable, tool may be wped clean wth a soft, lnt-free cloth. Do NOT use hard or abrasve objects that could damage the tool. 2. Make certan that the retanng pns are n place and that they are secured wth retanng rngs. 3. All pns, pvot ponts, and bearng surfaces should be protected wth a thn coat of any good SAE 20 motor ol. Do not ol excessvely. 4. When the tool s not n use, keep handles closed to prevent objects from becomng lodged Fgure 4 n the crmpng des. Store the tool n a clean, dry area. 5.2. Lubrcaton Lubrcate all pns, pvot ponts, and bearng surfaces wth SAE 20 motor ol as follows: Tools used n daly producton-lubrcate daly Tools used daly (occasonal)-lubrcate weekly Tools used weekly-lubrcate monthly Wpe excess ol from tool, partcularly from crmpng area. Ol transferred from the crmpng area onto certan termnatons may affect the electrcal characterstcs of an applcaton. 5.3. Vsual Inspecton 1. Close tool handles untl ratchet releases and then allow them to open freely. If they do not open quckly and fully, the sprng s defectve and must be replaced. See Secton 6, REPLACEMENT AND REPAIR. 2. Inspect head assembly for worn, cracked, or broken des. If damage s evdent, return the tool for evaluaton and repar. Refer to Secton 6, REPLACEMENT AND REPAIR. 5.4. Gagng the Crmpng Chamber Ths nspecton requres the use of plug gages conformng to the dmensons provded n Fgure 5. Tyco Electroncs does not manufacture or market these gages. To gage the crmpng chamber, proceed as follows: 1. Remove traces of ol or drt from the crmpng chamber and plug gages. 3 of 6
2. Close the tool handles untl the crmpng des have bottomed. Do NOT force des beyond ntal contact. Fgure 5 3. Pull the locator down for access to the wre barrel secton of the crmpng chamber.algn the GO element wth the wre barrel secton of the crmpng chamber. Push element straght nto the crmpng chamber wthout usng force. The GO element must pass completely through the crmpng chamber. See Fgure 6. 4. Algn the NO-GO element and try to nsert t straght nto the same secton of the crmpng chamber. The NO-GO element may start entry, but must not pass completely through the crmpng chamber. See Fgure 6. 5. Insert tool nsulaton crmpng adjustment pn nto Poston 1. 6. Wth crmpng des bottomed, check the nsulaton barrel secton of the crmpng chamber as descrbed n Steps 4 and 5. If the crmpng chamber conforms to the gage nspecton, the tool s consdered dmensonally correct, and should be lubrcated wth a THIN coat of any good SAE 20 motor ol. If not, the tool must be returned for further evaluaton and repar. Refer to Secton 6, REPLACEMENT AND REPAIR. For addtonal nformaton regardng the use of plug gages, refer to nstructon sheet 408-7424. 5.5. CERTI-CRIMP Tool Ratchet Inspecton The ratchet feature on hand tools should be checked to ensure that the ratchet does not release prematurely, allowng the des to open before they have fully bottomed. Obtan a.025 [.001] shm that s sutable for checkng the clearance between the bottomng surfaces of the crmpng des. Proceed as follows: 1. Select the maxmum sze wre for the tool and a termnal or splce. 2. Poston the termnal or splce and wre between the crmpng des as descrbed n Secton 3. 3. Hold wre n place and squeeze tool handles untl the CERTI-CRIMP ratchet releases. Hold the handles n ths poston, mantanng just enough tenson to keep the des closed. 4. Check the clearance between the bottomng surfaces of the crmpng des wth the.025 [.001] shm. If the clearance s.025 [.001] or less, the ratchet s consdered satsfactory. If the clearance exceeds.025 [.001], the ratchet s out of adjustment and must be repared. 6. REPLACEMENT AND REPAIR Replaceable parts are lsted n Fgure 7. Parts other than those lsted n Fgure 7 should be replaced to ensure qualty and relablty of the tool. Order replacement parts through your representatve, or call 1-800-526-5142, or send a facsmle of your purchase order to 1-717-986-7605, or wrte to: CUSTOMER SERVICE (038-035) TYCO ELECTRONICS CORPORATION PO BOX 3608 HARRISBURG PA 17105-3608 For tool repar servce, please contact a representattve at 1-800-526-5136. 7. REVISION SUMMARY Snce the prevous release of ths sheet, the TE logo was updated. 4 of 6
Inspecton of the Secton of the Crmpng Chamber Inspecton of the Insulaton Barrel Secton of the Crmpng Chamber Plug Gage Plug Gage Insulaton Crmpng Adjustment Pn n Poston Number 1 Insulaton Barrel GO Element Must Pass Completely Through Crmpng Chamber GO Element Must Pass Completely Through Crmpng Chamber NO-GO Element May Enter Partally, But Must NOT Pass Completely Through the Length of the Crmpng Chamber Insulaton Barrel NO-GO Element May Enter Partally, But Must NOT Pass Completely Through the Length of the Crmpng Chambe Fgure 6 5 of 6
304.8 [12.0] 304.8 [12.0] 76.2 {3.0] (Closed) Replacement Parts Item Part Number Tool 59294 Tool 59461 Descrpton Qty Per Tool 1 304114 305526 HEAD 1 2 3-21924-4 3-21924-5 SCREW 1 3 304116 39380 INSERT, Upper Insulaton 1 4 3304117 39381 INSERT, Lower Insulaton 1 5 304115 304582 ANVIL 1 6 46444 46851 INDENTER 1 7 304124 303848-2 PIN, Insulaton Crmpng Adjustment 1 8 304120 305527 LOCATOR, Stop Assembly 1 9 1-59658-8 ROD, Ratchet 1 10 49136 HANDLE, Outsde 1 11 49137 HANDLE, Insde 1 12 49958 RATCHET, Housng Assembly 1 13 38440 RIVET 2 14 300389 PIN, Retanng 1 15 21045-3 PIN, Retanng 1 16 300389 PIN, Retanng 1 17 21045-6 RING, Retanng 2 18 303104 LINK 6 19 39146 RIVET 2 20 21028-3 PIN 1 21 2-305927-7 SCREW, Specal 1 22 304122 SPRING 1 Fgure 7 6 of 6