Panduit CT-1525 Operation Manual

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Part No. CT-1525

OPERATION MANUAL

Contour Crimp

CONTROLLED CYCLE

CRIMPING TOOL

Crimps Panduit #26-#22 AWG

insulated terminals/splices, #22-#10

AWG fully insulated disconnects/

insulated parallel splices; and

specific #22-14 AWG barrel

insulated disconnects.

Provides UL Listed and CSA Certified terminations

with applicable Panduit terminals.

INSULATED TERMINAL CRIMPING
INSTRUCTIONS

1. With the handles in the open position, and the
back of the terminal tongue turned toward the
color dots, insert the terminal into the proper
crimp pocket (See Figure 1). Refer to product
packaging for selection of proper crimp pocket.

2. Close handles until the barrel is held snugly in
position — do not deform the barrel.

3. Insert the stripped wire into the terminal until
the wire stops. Refer to product packaging for
wire strip length.

4. Crimp the terminal by closing the handles until
the controlled cycle mechanism releases.
Upon release, the handles will open automati­cally and the crimped terminal can be removed.

NOTE: Visual inspection dots (formed by the

crimp dies) on the insulation sleeve verify
proper crimp cycle.

• One (1) dot for PKT A crimp pocket

• Two (2) dots for red and blue crimp
pocket

• Three (3) dots for yellow crimp pocket

Figure 4

OPERATION INSTRUCTIONS

© Panduit Corp. 2014

Page: 1 of 2

PA22241A01

Rev.: 05 11-2014

CT-1525

MADE IN GERMANY

CT - 1525

0,5-2,5

mm

2

4,0-6,0

PKT A

12-10

AWG

22-14

Figure 1

Figure 2

Figure 3

INSULATED DISCONNECT CRIMPING
INSTRUCTIONS

1. With the handles in the open position, insert
the disconnect in the proper crimp pocket (See
Figure 1), so that the barrel is flush with the
crimp die (See Figure 2). Refer to product
packaging for selection of proper crimp pocket.

2. Close the tool handles until the barrel is held
snugly in place—do not deform the barrel.

3. Insert the stripped wire into the disconnect.
Refer to product packaging for wire strip length.
Crimp the disconnect by closing the handles
until the controlled cycle mechanism releases.
Upon release, the handles will open automati­cally and the crimped disconnect can be
removed. After crimping, inspect that the crimp

is centered on the disconnect barrel in order to
achieve optimal pullout performance.

Stripped
Wire

Slot for
Wire Stop

Terminal

Crimp Die

Insulation Closure

Die Closure Alignment

(not a crimp pocket)

CRIMP POCKETS for
Pan-Term INSULATED
terminals, disconnects and
splices.

CRIMP POCKETS for
Pan-Term fully INSULATED
disconnects, insulated
splices and barrel insulated
disconnects.

Refer to product packaging
for wire range and proper
crimp pocket. Crimp pock­ets are color coded to match
color of product insulator,
and identified with
applicable wire range.

Controlled cycle mechanism
prevents tool from opening
before crimp cycle is
complete.

Manual release lever, push
forward in the event that
controlled cycle mechanism
must be released.

Cushioned Handle Grips

CAUT ION: Verify powe r is “OFF”
befo re work ing on w iring w ith
this to ol. The cush ioned gr ips
are for th e use r ’s comf ort , and
ar e no t in t e nded to insul a t e
agai nst shoc k w hile wor king on
live elect rical circu its.

www.panduit.com

IN-SERVICE TOOLS - AFTER TOOLS HAVE BEEN IN SERVICE:NEW TOOLS - BEFORE PLACING INTO SERVICE:

INSPECTION/MAINTENANCE

VISUAL INSPECTION

1. Visually inspect the tool for missing or loose

pins, then close the tool and note the return
action of the handles.

2. Inspect the crimping dies for worn, chipped or

broken edges..

3. If parts are missing, defective or damaged, con-

tact your local Panduit Sales Office for informa­tion on repair or replacement of tools.

TROUBLESHOOTING

DIE CLOSURE INSPECTION

PRELOAD FORCE INSPECTION

Die closure is measured by using GO/NO GO gage members (dimensions listed in Table 1).

1. Clean the crimping dies and gage member

surfaces.

2. Close the tool handles until the crimping dies

are bottomed and the controlled cycle
mechanism releases. Keep the handles
closed together.

3. Using the appropriate gage member, attempt

to insert the NO GO gage into the die opening.
The NO GO side may partially enter the die
closure but must NOT pass completely
through. Perform this test for all three crimp
pockets.

4. Repeat Step 3 with the appropriate GO gage

for all three crimp pockets. The GO side must
enter and pass completely through the die
closures.

5. If both gage conditions are met, the tool is

dimensionally correct. If either condition fails,
contact Panduit Tool Service, or Panduit
EMEA Service Center for technical assistance.

1. Close the handles until the controlled cycle
mechanism is engaged, but before the
mechanism releases.

2. Apply force using force gauge to the
handles 1-1/4" (32mm) from the end of the
handles, until the controlled cycle release
mechanism releases. Record the force
gauge reading.

3. The force required to release the controlled
cycle release mechanism should be a

minimum of 20 pounds-force (89 N); and a
maximum of 30 pounds-force (133.5 N). If

out of specification, contact Panduit Tool
Service, or Panduit EMEA Service Center
for technical assistance.

Table 1

Page: 2 of 2

All Panduit crimping tools are calibrated and inspected before they are
shipped from the factory. All new tools should be inspected before being
used.

New tools are shipped, factory lubricated, in protective packaging. After
inspection, simply clean any excess oil from the crimping dies and place
into service.

When the tool is not in use, keep the handles closed to prevent objects
from becoming lodged in the crimping area. Store the tool in a clean, dry
area.

It is recommended that each operator of the tool be made aware of - and
responsible for following these maintenance steps.:

In-service tools should be cleaned and inspected at least ONCE A MONTH.
To clean-wipe with a clean cloth.

In-service tools should be lubricated ONCE A WEEK, and after every
cleaning. Lubricate all pins, pivots and bearing surfaces with DOW
CORNING®Molykote BR2 Plus. Do not use oil excessively.

Be sure to clean any excess oil from the crimping dies before using.

® Molykote BR2 Plus is the Registered Trademark of DOW CORNING

DIE CLOSURE GO / NO GO GAGE MEMBERS - TOOL NO. CT-1525

CRIMP

POCKET

AWG / mm

2

ENGLISH GO / NO GO GAGE MEMBERS METRIC GO / NO GO GAGE MEMBERS

“G” Dia. (GO) “NG” Dia. (NO GO) “G” Dia. (GO) “NG” Dia. (NO GO)

Pocket “A” .065” .073” 1,65 mm 1,85 mm

22-14 / 0,5-2,5 .076” .084” 1,93 mm 2,13 mm

12-10 / 4,0-6,0 .100” .108” 2,54 mm 2,74 mm

INSULATED SPLICE CRIMPING INSTRUCTIONS

1. With the handles in the open position, insert the splice into the proper crimp pocket (See Figure 1) so that the crimp is located on the barrel of the splice
(See Figure 3). Refer to product packaging for selection of proper crimp pocket.

2. Close the handles until the barrel is held snugly in position — do not deform the barrel.

3. Insert the stripped wire into the splice until the wire stops. Refer to product packaging for wire strip length. Crimp the splice by closing the handles until the
controlled cycle mechanism releases. Upon release, the handles will open automatically and the crimped splice can be removed.

4. Remove the splice and repeat operation for crimping the other end of the splice.

©

Panduit Corp. 2014

OPERATION INSTRUCTIONS CT-1525