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LOC B
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ORIGINAL INSTRUCTIONS
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.
408-1261
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.
NOTE
Dimensions are in metric units [with U.S. customary
units in brackets]. Figures and illustrations are for
reference only and are not drawn to scale.
The locator positions the product in the crimping
chamber. The insulation crimping adjustment pin is
used to regulate the height of the insulation crimp.
Each tool handles are color coded (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 2.
i
For other tools accompanied by this instruction sheet,
follow the instructions for the tool used to crimp the
same wire size.
Reasons for reissue of this instruction sheet are
provided in Section 7, REVISION SUMMARY.
3. CRIMPING PROCEDURE
3.1. Wire Preparation
Strip the wire within the dimensions given in Figure 3,
being careful to avoid nicking or damaging the wire
conductor(s).
CAUTION
DO NOT use wire with nicked or missing
conductor(s).
!
2. DESCRIPTION
Each tool consists of a head containing two stationary
crimping dies (anvils) and two movable crimping dies
(indenters), a locator, an insulation crimping
adjustment pin, and handles with a ratchet. See
Figure 1.
These tools are members of the CERTI-CRIMP* hand
crimping tool family. The ratchet on these tools
ensures full crimping of the product. Once engaged,
the ratchet will not release until the handles have been
FULLY closed.
When closed, the crimping dies form a crimping
chamber with two sections: an insulation barrel section
and a wire barrel section. The insulation barrel section
crimps the insulation barrel of the product onto the
wire insulation and, simultaneously, the wire barrel
section crimps the wire barrel of the product onto the
wire conductor(s).
The crimping dies bottom before the ratchet releases.
This design ensures maximum electrical and tensile
performance of the crimp. DO NOT re-adjust the
ratchet.
3.2. Crimping
Make sure that the insulation color code of the product
matches the color of the tool handles. Refer to
Figure 1.
A. Terminals
1. Insert the insulation crimp adjustment pin in the
proper position according to Section 4.
2. Open the crimping dies by closing the tool
handles until the ratchet releases, then allow the
handles to open FULLY.
3. Place the terminal in the crimping chamber so
that the wire barrel butts against the locator. Refer
to Figure 4.
Product Color Code
PIDG Terminals
PLASTI-GRIP Terminal
PIDG Butt Splice
Spare Wire Cap
Color of
Insulation
Color Stripe on
Heavy Duty and
Radiation Resistant
Color Stripe on
Heavy Duty
Color Stripe on
Radiation Resistant
Three Equally Spaced
Color Stripes on
Insulation Restricting
Figure 2
Rev K
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408-1261
4. Close the tool handles until the terminal is held
firmly in place. DO NOT deform the terminal.
5. Insert a properly stripped wire into the terminal
wire barrel until the end of the wire conductor(s)
butts against the locator.
CAUTION
DO NOT allow the wire insulation to enter the
terminal wire barrel.
!
PRODUCT
PIDG Vinyl and Nylon Terminal, PLASTI-GRIP
Terminal, and PIDG Radiation Resistant
Terminal
PIDG Insulation Restricting Nylon Terminal
PIDG Vinyl and Nylon Splice and PIDG
Radiation Resistant Splice
Spare Wire Cap
Figure 3
WIRE STRIP
LENGTH
7.94-8.73
[.312-.344]
9.65-10.4
[.380-.410]
8.64-9.65
[.340-.380]
8.64-9.65
[.340-.380]
Figure 4
6. 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 terminal.
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.
B. Butt Splices
1. Open the crimping dies by closing the tool
handles until the ratchet releases, then allow the
handles to open FULLY.
2. Depress the locator. Position the splice in the
crimping chamber so that window indent of the
splice seats over the locator. See Figure 5.
3. Close the tool handles until the splice is held
firmly in place. DO NOT deform the splice.
4. Insert a properly stripped wire into the wire barrel
of the splice until the end of the wire conductor(s)
butts against the splice wire stop.
Figure 5
Rev K
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408-1261
CAUTION
!
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.
DO NOT allow wire insulation to enter the splice
wire barrel.
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:
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.
4.1. PIDG Terminal and Splice
NOTE
PIDG terminals and splices feature a wire
insulation grip.
i
1. Insert each insulation crimp adjustment pin into
Position 3. Refer to Figure 1.
CAUTION
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.
Wire Conductor(s)
Bottomed in Spare
Wire Cap
End of Spare Wire
Cap Against
Recessed Surface
of Locator
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.
Locator
Depressed
Insulation Pin in Position 3
Figure 6
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.
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