411- 1097

Double Action Hand Crimping Tools 525690 and 525691

Rev D

2

of 7

Tyco Electronics Corporation

PLASTI--GRIP Terminal

PIDG Terminals

PIDG Butt Splice

Color Stripe on

Heavy Duty

Color Stripe on

Radiation Resistant

3 Equally Spaced

Color Stripes on

Insulation Restricting

Color Stripe on

Radiation Resistant

Product Color Code

PLASTI--GRIP

Butt Splice

Figure 2

Color of Insulation

Each tool handle is color coded to correspond to the

color code of the product (refer to Figure 2). Each tool

produces a dot code on the crimp to correspond to

the given wire size range (refer to Figure 1).

3. CRIMPING PROCEDURE

1. Strip the wire to the dimension given in Figure 3,

being careful to avoid nicking or damaging the

conductors.

DO NOT use wire with nicked or missing

conductors.

Strip Length

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

proper position according to Section 4.

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

is held firmly in place. DO NOT deform the wire

barrel.

6. Insert a properly stripped wire into the wire

barrel as shown in Figure 4 (for terminals) or

Figure 5, Detail A (for splices).

DO NOT allow the wire insulation to enter the

wire barrel.

7. Close the tool handles until the ratchet releases.

“B” Equals Wire Barrel

“C” Equals Insulation Barrel

Wire Barrel

Against Locator

End of Wire Conductor

Against Locator or,

If Present, Wire Stop

Crimping a Terminal

“C”

“B”

PIDG Terminal

“C”

“B”

“C”

“B”

“C” “B”

PIDG Insulation

Restricting Terminal

Figure 4

PIDG FASTON Terminal

PLASTI--GRIP Terminal

Wire Stop

NOTE

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NOTE

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