411- 1097

Double Action Hand Crimping Tools 525690 and 525691

3

of 7

Rev D

Tyco Electronics Corporation

8. Release the tool handles, and allow them to

open FULLY. Remove the crimped terminal or

splice.

9. For splices, position the remaining wire barrel in

the crimping chamber as shown in Figure 5, Detail

B. Repeat Steps 5 through 8.

10. Inspect crimped terminal or splice by checking

the features described in Figure 6. Terminals and

splices not meeting the described conditions

should NOT be used.

Figure 5

Crimping a Butt Splice

“C” “B”

PIDG Splice

“B” Equals Wire Barrel

“C” Equals Insulation Barrel

“C” “B”

PLASTI--GRIP Splice

Wire Stop

Window

Indent

Locator Seats in

Window Indent

End of Wire Conductor

Against Splice Wire Stop

Wire Stop

Window

Indent

Detail A

Detail B

Locator Seats in

Window Indent

End of Wire Conductor

Against Splice Wire Stop

Wire Barrel

Remaining

Wire Barrel

4. INSULATION CRIMP ADJUSTMENT

The insulation barrel section of the crimping chamber

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 Terminals and Splices

PIDG terminals and splices feature a wire

“insulation grip.”

1. Insert each insulation crimp adjustment pin into

Position 3. Refer to Figure 1.

Make sure that both insulation crimp adjustment

pins are in the same position.

2. Position the terminal or splice in the crimping

chamber as described in Section 3.

3. Insert an UNSTRIPPED wire into ONLY the

insulation barrel of the terminal or splice.

4. Close the tool handles until the ratchet releases.

5. Release the tool handles, and allow the handles

to open FULLY. Remove the crimped terminal or

splice.

6. Check the insulation barrel crimp by bending the

wire back and forth once. The terminal or splice

should retain its grip on the wire insulation. If it

does not, insert each insulation crimp adjustment

pin into the next position (Position 2).

7. Repeat Steps 2 through 6 until the correct

insulation barrel grip is attained. DO NOT use a

tighter position than is necessary.

4.2. PLASTI- GRIP Terminals and Splices

PLASTI--GRIP terminals and splices feature a

wire “insulation support” only. Ideally, the terminal

or splice insulation should be in contact with the

wire insulation.

Insert each insulation crimp adjustment pin into

position according to the following:

Make sure that both insulation crimp adjustment

pins are in the same position.

— Position 3 for wire having a large insulation

diameter.

— Position 2 for wire having a medium insulation

diameter.

— Position 1 for wire having a small insulation

diameter.

NOTE

i

CAUTION

!

NOTE

i

CAUTION

!