Instruction Sheet DoubleActionHandCrimpingTools 411--1097 525690and525691 27 MAY 10 Rev D PROPERUSEGUIDELINES CumulativeTraumaDisorderscanresultfromtheprolongeduseofmanuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume applications.Awide selection ofpowered application equipmentforextended--use,production operationsisavailable. Insulation Crimp Adjustment Pins (ShowninPosition3) Color--Coded Handle Ratchet Fixed Jaw (Crimper) Locator/Insulation Movable Jaw Stop (Anvil) TETool WWirireeSSizizeeRRaangenge (AWG) PartNumber ColorCode DotCode 525690 Red 1 20--18 525691 Blue 2 16--14 Figure 1 These tools are members of the CERTI--CRIMP* 1. INTRODUCTION hand crimping tool family. The ratchet on these tools Double Action Hand Crimping Tools 525690 and ensures full crimping of the product. Once engaged, 525691 crimp a wide variety of PIDG* terminals and the ratchet will not release until the handles have splices and PLASTI--GRIP* terminals and splices been FULLY closed. onto stranded copper wire sizes 20 through 14 AWG. See Figure 1. Read these instructions thoroughly The jaws bottom before the ratchet releases. This before using the tools. CAUTION design ensures maximum electrical and tensile Dimensions in this instruction sheet are in NOTE performance of the crimp. DO NOT re--adjust the millimeters with inches in brackets . Figures are ratchet. not drawn to scale. i The locator/insulation stop positions the product Reasons for reissue of this instruction sheet are between the jaws and aids in locating the wire in the provided in Section 7, REVISION SUMMARY. product. When closed, the jaws form a crimping chamber with two sections: an insulation barrel section and a wire barrel section. The insulation barrel 2. DESCRIPTION section crimps the insulation barrel of the product Each tool features a fixed jaw (crimper), a movable onto the wire insulation and, simultaneously, the wire jaw (anvil), a locator/insulation stop, and a ratchet barrel section crimps the wire barrel of the product attached to a handle. onto the wire conductors. E2010 Tyco Electronics Corporation, Berwyn, PA TOOLING ASSISTANCE CENTER1--800--722--1111 This controlled document is subject to change. 1 of 7 PRODUCT INFORMATION 1--800--522--6752 Forlatest revision and Regional CustomerService, All Rights Reserved visit ourwebsite atwww.tycoelectronics.com TE logo and Tyco Electronics are trademarks. LOC B *Trademark. Otherproduct names, logos, orcompany names might be trademarks of theirrespective owners.411-1097 DoubleActionHandCrimpingTools525690and525691 ProductColorCode PIDG Terminals PLASTI--GRIP Terminal PLASTI--GRIP PIDG Butt Splice Butt Splice Color Stripe on Color Stripe on Color Stripe on Radiation Resistant Heavy Duty Radiation Resistant 3 Equally Spaced Color of Insulation Color Stripes on Insulation Restricting Figure 2 Each tool handle is color coded to correspond to the DO NOT allow the wire insulation to enter the NOTE color code of the product (refer to Figure 2). Each tool wire barrel. produces a dot code on the crimp to correspond to i the given wire size range (refer to Figure 1). 7. Close the tool handles until the ratchet releases. 3. CRIMPINGPROCEDURE 1. Strip the wire to the dimension given in Figure 3, Crimping aTerminal being careful to avoid nicking or damaging the conductors. B Equals Wire Barrel C Equals Insulation Barrel DO NOT use wire with nicked or missing NOTE PIDG Insulation conductors. PIDG Terminal Restricting Terminal i C B C B Strip Length PIDG FASTON Terminal PLASTI--GRIP Terminal C B C B Wire Stop Terminal Splice 5.08--5.84 .20--.23 6.35--7.11 .25--.28 Figure 3 2. Insert the insulation crimp adjustment pins in the Wire Barrel proper position according to Section 4. Against Locator 3. Open the tool jaws by closing the handles until the ratchet releases, then allow the handles to open FULLY. 4. Place the terminal or splice in the crimping chamber as shown in Figure 4 (for terminals) or Figure 5 (for splices). 5. Close the tool handles until the terminal or splice End of Wire Conductor is held firmly in place. DO NOT deform the wire Against Locator or, barrel. If Present, Wire Stop 6. Insert a properly stripped wire into the wire Figure 4 barrel as shown in Figure 4 (for terminals) or Figure 5, Detail A (for splices). 2 of 7 Tyco ElectronicsCorporation RevD