1 of 4 ? 201 5 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 tra demarks of their respective owners. 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 . instruction sheet 408 - 6803 19 may 15 rev c figure 1 1. introduction hydraulic hand tool 59973 - 1 is designed for crimping terminals and splices in wire size ranges 6 mm 2 - 100 mm 2 [8 through 4/0 awg]. read these instructions thoroughly before crimping any terminals or splices. note dimensions in this instruction sheet are in metric units [with u.s. customary units in brackets]. figures and illustrations a re for identification only and are not drawn to scale. reasons for reissue of this instruction sheet are provided in section 7, revision summary. 2. description (figure 1) the hand tool has a stationary lever and a moveable lever. these levers are compressed to pump hydraulic fluid be hind the ram, moving it forward and thereby closing the dies. after the crimping is complete, the moveable lever is turned to depress the plunger. the moving die retracts to its original position, completing the crimping cycle. note the tool may be bench mounted by sliding it into bench mount 312324 - 1 (purchased separately) and securing it tightly with the mount setscrew. the mount has four holes for securing it to a bench. see figure 1, inset. 3. die insertion and re moval 1. strip wires to dimensions specified on instruction sheet packaged with dies. 2. insert terminal or splice in stationary die according to instruction sheet packaged with dies. 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. hydraulic hand crimping tool 59973 - 1 moveable lever striker (shown in actuated position to depress plunger) yoke (opened) cap stationary (reservoir) lever setscrew plunger (pressure released) latch pin removed setscrew (hidden) bench mount 312324 - 1 mounting holes ram (advanced to show setscrew for moving die ) setscrew (holds stationary die) original instructions
408 - 6803 rev c 2 of 4 4. crimping procedure 1. strip wires to dimensions specified on instruction sheet packaged with dies. 2. insert terminal or splic e in stationary die according to instruction sheet packaged with dies. caution ensure latch pin is fully inserted before operating hand tool . 3. pump moveable lever until moving die grips terminal or splice. caution do not deform wire barrel of terminal or splice. 4. insert stripped wire into wire barrel of terminal or splice. 5. continue pumping moveable lever. a slight click may be heard, indicating the pump has shifted into the high - pressure stage. continue pumping moveable lever. when dies have bottomed, an au dible pop will be heard. this indicates that the crimp is complete. 6. retract moveable die by opening the movable handle to the full open position, turn the movable handle (to actuate striker). do not turn the movable handle while in the closed position as you will damage t he plunger (pressure release), compress han dles to depress plunger (pressure release). movable die will now retract. see figure 1. 7. remove latch pin, open yoke, and remove crimped terminal or splice. note if terminal or splice sticks in d ie after crimping, apply a rocking motion action to remove it from the die. 8. inspect crimped terminal or splice according to inspection procedure on instruction sheet packaged with the dies. 5. maintenance/inspecti on these instructions have been approved by te connectivity design, production, and quality control engineers to provide documented maintenance and inspection procedures. through test laboratories and the inspection production assembly, the procedures described herein have been established to ensure q uality and reliability of te crimping tools. each crimping tool is assembled and inspected before shipment. te recommends that the tool be inspected immediately upon its arrival at your facility, and at regularly scheduled intervals, to ensure the tool has not been damaged during handling and use. frequency of inspection depends upon the following: care, amount of use, and handling of the tool; type and size of products crimped; degree of operator skill; and environmental conditions. danger make sure hydra ulic pressure is released before following maintenance and inspection procedures, unless otherwise specified in the procedure. 5.1. cleaning it is recommended that each operator of the tool be made aware of, and responsible for, the following steps: 1. remove all foreign particles with a clean, soft brush or clean, soft lint - free cloth. do not use hard or abrasive objects that could damage the tool. make sure the proper retaining pins are in place and secured with the proper retaining rin gs. if foreign matter canno t be removed easily, or if the proper replacement parts are not available, return the tool to your supervisor. 2. make certain all pivot points and bearing surfaces are protected with a thin coat of any good sae 20 motor oil. do not oil excessively. when the tool is not in use, keep the handles closed to prevent objects from becoming lodged in the crimping chamber, and store the tool in a clean, dry area. 5.2. hydraulic fluid level inspection (figure 2) remove tool from bench mount; then proceed as follows: 1. turn tool upside down and clamp it in a vise so that tool handles are in an upright position.
408 - 6803 rev c 3 of 4 figure 2 2. release all pressur e in tool according to instructions in step 6 of section 4, crimping procedure. 3. release striker and allow moveable lever to close until it stops. note keep handle in closed position for remaining steps in this inspection. 4. loosen setscrew in cap of stationary (reservoir) lever. see figure 1. 5. with view from handle grip end, turn handle counterclockwise and remove entire reservoir lever to expose bladder. 6. remove magnetic filler plug and wipe clean. if bladder is full, no further check is necessary and tool can be re - assembled. if fluid level is low, proceed to step 7. 7. fill bladder with fluid ? . use care to prevent air bubbles from forming while pouring the fluid. 8. refill bladder to point of overflow, and replace filler plug. 9. re - assemble reservoir handle a nd tighten cap setscrew. tool is now ready for use. 5.3. periodic inspection it is recommended at least one inspection a month. the inspection frequency should be based on the amount of use, ambient working conditions, operator training and skill, and your comp any's established standards. lubrication keep all pins, pivot points, and bearing surfaces lubricated with sae 20 motor oil as follows: tool used in daily production - lubricate daily tool used daily (occasionally) - lubricate weekly tool used weekly - lu bricate 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. visual inspection 1. make certain all retaining pins are in place and secured with retaining rings. if replacements are necessary, refer to parts listed in figure 3. 2. inspect head assembly for worn, cracked, or broken areas. if damage is evident, return the tool for evaluation and repair. see section 6, replaceme nt and repair. crimping pressure inspection check the crimping pressure to ensure that dies are fully bottomed before pressure is reduced by the internal bypass valve. the inspection should be performed using each set of dies that will be used in the head. ? recommended fluid is dexron ? ii, a transmission fluid available in automoti ve parts and department stores. dexron is a trademark. moveable lever in closed position magnetic filler plug pour fluid here bladder tool positioned in vise
408 - 6803 rev c 4 of 4 1. install dies according to paragraph 3 and the instruction sheet packaged with the dies. 2. select wire and terminal or splice appropriate for the dies being used. 3. place terminal or splice in dies according to instruction sheet packaged with dies. 4. perform crimping procedure as described in steps 3 through 5 of paragraph 4. do not release hydraulic pressure at this time. 5. check the clearance between bottoming surfaces of crimping dies. if clearance is 0.0254 mm [.001 in.] or less, bottoming is satisfactory. if clearance exceeds 0.0254 mm [.001 in.], the dies are considered as not bottoming (see paragraph 6, repair). if the tool conf orms to these inspection procedures, lubricate it with a thin coat of any good sae no.20 motor oil and return it to service. 6. replacement and repa ir customer - replaceable parts are listed in figure 3. 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 to ensure quality and reliability. order replacement par ts through your te 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 servi ce, contact a te r epresentative at 1 - 800 - 526 - 5136. 7. revision summary ? updated document to corpo rate requirements ? changed text in paragraph 4.6 tool specifications replacement parts dimension weight item part no. description qty per assy a 15.4 [6.0] 5.7 kg [12.5 lb] 1 301555 spacer 1 b 571.5 [22.5] 2 301556 spring 1 c 79.25 [3.12] 3 23057 - 6 plunger, ball 1 4 302312 pin, hinge 1 5 21045 - 9 ring, retaining 2 6 306209 - 3 pin, latch 1 7 5 - 21006 - 0 setscrew, 10 - 32 x ? l 1 figure 3 c b a (fully closed) 1 4 5 2 3 6 3
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