411- 1097

Double Action Hand Crimping Tools 525690 and 525691

Rev D

6

of 7

Tyco Electronics Corporation

Figure 8

Jaws Bottomed But

Not Under Pressure

Inspection of

Wire Barrel Section

of Crimping Chamber

Inspection of

Insulation Barrel Section

of Crimping Chamber

GO Element Must Pass

Completely Through

Crimping Chamber

Insulation Crimp Adjustment Pins in Position 1

NO--GO Element May Start Entry, But Must Not

Pass Completely Through Crimping Chamber

GO Element Must Pass

Completely Through Length of

Insulation Barrel Section But

Stop on Wire Barrel Section

4. Carefully insert the GO element into the

crimping chamber as shown in Figure 8; DO NOT

force it. For the wire barrel section of the crimping

chamber, the GO element must pass completely

through the crimping chamber. For the insulation

barrel section, the GO element must pass through

the length of the section but will stop against the

wire barrel section.

5. In the same manner, try to insert the NO--GO

element into the crimping chamber as shown in

Figure 8. The NO--GO element may begin entry,

but may not pass through the crimping chamber.

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 not, return the tool for

evaluation and repair. See Section 6,

REPLACEMENT AND REPAIR.

5.3. Ratchet Inspection

Check the ratchet to ensure that the ratchet does not

release prematurely, allowing the jaws to open before

they have fully bottomed. Proceed as follows:

1. Remove traces of oil or dirt from the bottoming

surfaces of the jaws.

2. Obtain a 0.025 mm [.001 in.] shim that is

suitable for checking the clearance between the

bottoming surfaces of the jaws.

3. Select a terminal or splice and maximum size

wire for the terminal or splice.

4. Position the terminal or splice in the crimping

chamber according to Section 3, CRIMPING

PROCEDURE. Holding the wire in place, squeeze

the tool handles together until the ratchet releases.

Hold the tool handles in this position, maintaining

just enough pressure to keep the jaws closed.

5. Check the clearance between the bottoming

surfaces of the jaws. If the clearance is 0.025 mm

[.001 in.] or less, the ratchet is satisfactory. If

clearance exceeds 0.025 mm [.001 in.], the ratchet

is out of adjustment and must be repaired. See

Section 6, REPLACEMENT AND REPAIR.

6. REPLACEMENT AND REPAIR

Customer--replaceable parts are listed in Figure 9.

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 Tyco Electronics to ensure

quality and reliability. Order replacement parts

through your 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 service, call 1--800--526--5136.

7. REVISION SUMMARY

Revisions to this instruction sheet include:

S

Updated document to corporate requirements

S

Added new data to tables in Figure 7