Tyco Electronics 525690, 525691 Instruction Sheet

Instruction Sheet

WireSizeRange

Double Action Hand Crimping Tools

PROPER USE GUIDELINES

Cumulative Trauma Disorders can resultfromthe prolonged useof manually powered hand tools. Hand tools areintended for occasional useand low volume
applications. A wide selection of powered application equipment for extended--use, production operations is available.

Insulation Crimp Adjustment Pins
(ShowninPosition3)

Ratchet

Fixed Jaw
(Crimper)

411--1097

27 MAY 10 Rev D525690 and 525691

Color--Coded
Handle

Locator/Insulation
Stop

Part Number Color Code Dot Code

525690 Red 1 20--18

525691 Blue 2 16--14

Movable Jaw
(Anvil)

TE Tool

1. INTRODUCTION

Double Action Hand Crimping Tools 525690 and
525691 crimp a wide variety of PIDG* terminals and
splices and PLASTI-- GRIP* terminals and splices
onto stranded copper wire sizes 20 through 14 AWG.
See Figure 1. Read these instructions thoroughly
before using the tools.

NOTE

Dimensions in this instruction sheet are in
millimeters [with inches in brackets]. Figures are

i

not drawn to scale.

Reasons for reissue of this instruction sheet are
provided in Section 7, REVISION SUMMARY.

2. DESCRIPTION

Each tool features a fixed jaw (crimper), a movable
jaw (anvil), a locator/insulation stop, and a ratchet
attached to a handle.

Wire Size Range

(AWG)

Figure 1

These tools are members of the CERTI--CRIMP*
hand crimping tool family. The ratchet on these tools
ensures full crimping of the product. Once engaged,
the ratchet will not release until the handles have
been FULLY closed.

CAUTION

The jaws bottom before the ratchet releases. This
design ensures maximum electrical and tensile

!

performance of the crimp. DO NOT re--adjust the
ratchet.

The locator/insulation stop positions the product
between the jaws and aids in locating the wire in the
product. When closed, the jaws form a crimping
chamber with two sections: an insulation barrel
section and a wire barrel section. The insulation barrel
section crimps the insulation barrel of the product
onto the wire insulation and, simultaneously , the wire
barrel section crimps the wire barrel of the product
onto the wire conductors.

E2010 Tyco Electronics Corporation, Berwyn, PA
All Rights Reserved
TE logo and Tyco Electronics ar e trademarks.
*Trademark. Other product names, logos, or company names might be trademarks of their respective owners.

TOOLING ASSISTANCE CENTER 1--800--722--1111
PRODUCT INFORMATION 1--800--522- -6752

This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com

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LOC B

Double Action Hand Crimping Tools 525690 and 525691

P

r

oduct ColorCode

411- 1097

PLASTI--GRIP TerminalPIDG Terminals PIDG Butt Splice

Color Stripe on
Radiation Resistant

3 Equally Spaced
Color Stripes on
Insulation Restricting

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).

Color Stripe on
Heavy Duty

3. CRIMPING PROCEDURE

1. Strip the wire to the dimension given in Figure 3,
being careful to avoid nicking or damaging the
conductors.

NOTE

DO NOT use wire with nicked or missing
conductors.

i

PLASTI--GRIP

Color of Insulation

Figure 2

NOTE

Butt Splice

DO NOT allow the wire insulation to enter the
wire barrel.

Color Stripe on
Radiation Resistant

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7. Close the tool handles until the ratchet releases.

Crimping a Terminal

“B” Equals Wire Barrel
“C” Equals Insulation Barrel

PIDG Terminal

“C” “B”

PIDG Insulation

Restricting Terminal

“C” “B”

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).

PIDG FASTON Terminal PLASTI--GRIP Terminal

“C” “B”

Wire Barrel
Against Locator

End of Wire Conductor
Against Locator or,
If Present, Wire Stop

Wire Stop

Figure 4

“C” “B”

Rev D2 of 7 Tyco Electronics Corporation

Double Action Hand Crimping Tools 525690 and 525691

411- 1097

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.

Crimping a Butt Splice

“B” Equals Wire Barrel
“C” Equals Insulation Barrel

“C” “B”

Detail A

PIDG Splice

Window
Indent

Wire Stop

Locator Seats in
Window Indent

PLASTI--GRIP Splice

“C” “B”

Window
Indent

Wire Stop

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

NOTE

PIDG terminals and splices feature a wire
“insulation grip.”

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1. Insert each insulation crimp adjustment pin into
Position 3. Refer to Figure 1.

CAUTION

!

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.

Make sure that both insulation crimp adjustment
pins are in the same position.

End of Wire Conductor
Against Splice Wire Stop

Detail B

Locator Seats in
Window Indent

End of Wire Conductor
Against Splice Wire Stop

Figure 5

Wire Barrel

Remaining
Wire Barrel

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

NOTE

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Insert each insulation crimp adjustment pin into
position according to the following:

CAUTION

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.

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.

3 of 7Rev D Tyco Electronics Corporation