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408-1261

9

 of 9

Rev K

6. REPLACEMENT AND REPAIR

Customer-replaceable parts are listed in 
Figure 11.

A complete inventory should be stocked and 
controlled to prevent lost time when replacement of 
parts is necessary. Parts other than those listed should 
be replaced by TE Connectivity to ensure quality and 
reliability. Order replacement parts through your 
representative, or call 1-800-526-5142, or send a 
facsimile of your purchase order to 717-986-7605, or 
write to:

CUSTOMER SERVICE (038-035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608

For customer repair service, call 1-800-526-5136.

7. REVISION SUMMARY

Updated document to corporate requirements

Added new information to Figures 9 and 10

Figure 11

REPLACEMENT PARTS

ITEM

PART NUMBER FOR TOOL 306110-9

DESCRIPTION

QTY PER 

TOOL

59239-4, 59239-8

59287-2

525692

1

300388

300388

300388

PIN, Retaining

2

2

21045-3

21045-3

525108

RING, Retaining

4

3

300389

300389

300389

PIN, Retaining

1

4

21045-6

21045-6

21045-6

RING, Retaining

2

5

303848-2

303848-2

303848-2

PIN ASSEMBLY, Adjustment

1

6

306110-9

306110-4

306110-9

LOCATOR, Stop

1

7

5-21028-7

5-21028-7

5-21028-7

PIN

1

8

7-59683-6

7-59683-6

7-59683-6

SPRING

1

9

6-306131-4

6-306131-4

6-306131-4

SCREW

2

10

306106-2

45891-8

306106-2

STATIONARY DIE, Insulation

1

11

306107-2

45888-7

306107-2

MOVING DIE, Insulation

1

12

21028-4

21028-5

21028-4

PIN

1

Summary of Contents for 59239-4

Page 1: ...lable Figure 1 Handles Locator StationaryCrimpingDies 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 3...

Page 2: ...ductor 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 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 p...

Page 3: ... 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 wi...

Page 4: ...es 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 ...

Page 5: ...408 1261 5 of 9 Rev K Figure 7 ...

Page 6: ...N 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 T...

Page 7: ...nt 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...

Page 8: ...il B Inspection of Insulation Barrel Section of Crimping Chamber Crimping Dies Bottomed But Not Under Pressure Plug Gage GO Element Must Pass Completely Through Crimping Chamber GO Element Must Pass Completely Through Length of Insulation Barrel Crimping Chamber But Stop on Wire Barrel Section Plug Gage Insulation Crimp Adjustment Pin In Position 1 NO GO Element May Start Entry But Must Not Pass C...

Page 9: ...rvice call 1 800 526 5136 7 REVISION SUMMARY Updated document to corporate requirements Added new information to Figures 9 and 10 Figure 11 REPLACEMENT PARTS ITEM PART NUMBER FOR TOOL 306110 9 DESCRIPTION QTY PER TOOL 59239 4 59239 8 59287 2 525692 1 300388 300388 300388 PIN Retaining 2 2 21045 3 21045 3 525108 RING Retaining 4 3 300389 300389 300389 PIN Retaining 1 4 21045 6 21045 6 21045 6 RING ...

Page 10: ...Mouser Electronics Authorized Distributor Click to View Pricing Inventory Delivery Lifecycle Information TE Connectivity 525692 ...

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