59975-1 Datasheet 59975-1 | P4-P6

408-6758

Rev F

4 of 8

5.1. Visual Inspection

1. Verify that all retaining pins are in place and secured with retaining rings. If replacements are

necessary, refer to parts listed in Figure 6.

2. Inspect head assembly for worn, cracked, or broken areas. If damage is evident, return the tool for

evaluation and repair. See Section 6, REPLACEMENT AND REPAIR.

NOTE

Once per year, or every 7,500 cycles (whichever comes first), the hydraulic head should be returned to TE for magnetic

particle inspection. Additionally, inspect and service the head every month or 1,000 cycles.

5.2. Daily Maintenance

1. Hand tool should be immersed (handles partially closed) in a reliable commercial degreasing

compound to remove accumulated dirt, grease, and foreign matter. When degreasing compound is

not available, tool may be wiped clean with a soft, lint-free cloth. DO NOT use hard or abrasive objects

that could damage the tool.

2. Make certain that the retaining pins are in place and that they are secured with retaining rings.

CAUTION

Do not remove the retaining pins as permanent damage to the tool could result.

3. All pins, pivot points, and bearing surfaces should be protected with a THIN coat of any good SAE 20

motor oil. DO NOT oil excessively.

4. When the tool is not in use, keep handles closed to prevent objects from becoming lodged in the dies.

Store the tool in a clean, dry area.

5.3. Crimping Pressure Inspection

Check the crimping pressure to ensure that dies are fully bottomed before pressure is reduced by the

internal bypass valve.

1. Select the largest wire and terminal size that will be crimped in the tool.

2. Select dies in accordance with Section 3, DIE SELECTION.

3. Place terminal or splice in dies in accordance with the instructions in Section 4, CRIMPING

PROCEDURE.

4. Perform crimping procedure as described in Steps 3 thru 5 of Section 4, CRIMPING PROCEDURE.

DO NOT release hydraulic pressure at this time.

5. When ram is fully extended and Steps 1 thru 4 are completed, a scribe line should appear on the ram

at the base of the cylinder head. This indicates that the pressure requirement has been met.

CAUTION

If the scribe is NOT visible, the tool is not performing properly and should be repaired as described in Section 6,

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.

5.4. 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: lubricate monthly

Wipe excess oil from tool, particularly from crimping area.

CAUTION

Oil transferred from the crimping area onto certain terminations may affect the electrical characteristics of an application.

SAE is a trademark.

408-6758

Rev F

5 of 8

5.5. Hydraulic Fluid Level Inspection/Fill (Figure 4)

1. Turn the tool upside down and clamp it in a vise so the tool levers are in an upright position.

2. Release all pressure in tool in accordance with instructions in Section 4, CRIMPING PROCEDURE,

Step 6.

Figure 4

3. Turn the movable lever and allow the lever to close until it stops. DO NOT depress the plunger when

closing the lever.

NOTE

Keep lever in CLOSED position for remaining steps in this procedure.

4. Loosen the setscrew in cap of stationary (reservoir) lever (see Figure 1).

5. With a view from the lever grip end, turn the lever COUNTERCLOCKWISE and remove the entire

reservoir lever to expose the bladder.

6. Remove the magnetic filler plug.

 If the bladder is full, no further check is necessary and tool can be re-assembled.

 If fluid level is low, proceed to the next step.

7. Fill the bladder with fluid.

NOTE

Use care to prevent air bubbles from forming while pouring the fluid.

NOTE

The recommended fluid is Dexron II; a transmission fluid available in automotive parts and department stores.

8. Refill the bladder to point of overflow, and replace the filler plug.

9. Re-assemble the stationary lever and tighten the cap setscrew.

The tool is now ready for use.

Movable Lever in

Closed Position

Magnetic

Filler Plug

Pour Fluid

Here

Bladder

Tool Positioned

in Vise

Dexron is a trademark.

408-6758

Rev F

6 of 8

5.6. Gaging the Crimping Chamber

This inspection requires the use of a plug gage conforming to the dimensions in Figure 5.

NOTE

TE Connectivity does not manufacture or market these gages.

Proceed as follows:

1. Clean oil or dirt from die closure surfaces and plug gage elements.

2. Rotate knob on tool to select die closure to be inspected. (Refer to Section 3, DIE SELECTION.)

3. Actuate tool until dies are closed and an audible ‘pop’ is heard.

4. Align the GO element with the wire barrel crimping chamber. Push element straight into the crimping

chamber without using force.

The GO element must pass completely through the crimping chamber as shown in Figure 5.

DIE SIZE

GAGE ELEMENT DIMENSIONS “B” (mm [in.])

RADIUS “R”

NO-GO

2.184-2.192 [.0860-.0863]

2.537-2.540 [.0999-.1000]

3.58 [.141]

3.124-3.132 [.1230-.1233]

3.477-3.480 [.1369-.1370]

3.96 [.156]

4.039-4.046 [.1590-.1593]

4.392-4.394 [.1729-.1730]

5.56 [.219]

4.826-4.834 [.1900-.1903]

5.179-5.182 [.2039-.2040]

6.35 [.250]

Figure 5

5. Now align the NO-GO element and try to insert it straight into the same crimping chamber.

The NO-GO element may start entry, but MUST NOT PASS completely through as shown in Figure 5.

6. Repeat Steps 2 through 5 for each die size listed in the chart.

 If the crimping chamber conforms to the gage inspection, the tool is considered dimensionally

correct and should be lubricated with a THIN coat of any good SAE 20 motor oil.

 If the crimping chamber does not conform to the gage inspection, the tool MUST BE repaired

before returning it to service. See Section 6, REPLACEMENT AND REPAIR.

“B”

GO Dim

“B”

NO-GO Dim

7.92 [.312] Typ

“R”

Wire Barrel

Crimping

Chambers

25.4

[1.00]

Min. Typ

GO Element

NO-GO Element

P1-P3 P4-P6 P7-P8

59975-1

Mfr. #:

Buy 59975-1

Manufacturer:

TE Connectivity

Description:

HYDRAULIC HAND TOOL

Lifecycle:

New from this manufacturer.

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59975-1