TE Connectivity 825508-5 User manual

©2012 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
*Trademark
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners.
1of 2
Instruction Sheet
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.te.com LOC B
408-2746
Hand Crimping Tool 825508-5 24 JAN 12 Rev A
1. INTRODUCTION
This tool, shown in Figure 1, is used to crimp:
•PIDG* terminals and butt splices on stranded
copper wire sizes 22-10 AWG
•PLASTI-GRIP* terminals and butt splices on solid
or stranded copper wire sizes 22-10 AWG
2. CUT WIRE
Insert wire in cutter, close handles briskly.
3. GAGE WIRE
Determine wire size by inserting unstripped wire into
the smallest color-coded gage ring that will accept the
wire. See Figure 2. After stripping, use the adjacent
crimp closure to crimp terminal or splice on wire.
4. STRIP WIRE
Partially open handles and insert wire in correct notch
of wire stripping blades. End of wire must butt against
strip length locator (controls strip length). See
Figure 3. Close handles fully and rotate tool part way
around the wire. Pull wire from tool.
Be sure there are no cut or missing conductor
strands.
5. COLOR CODE
Select the correct color-coded terminal or splice for
the wire size being used:
•Red = AWG 22-16 (0.25-1.5 mm²)
•Blue = AWG 16-14 (1.5-2.5 mm²)
•Yellow = AWG 12-10 (4-6 mm²)
6. CRIMP TERMINAL OR SPLICE
(a) Insert color-coded terminal or splice in crimp
closure adjacent to the matching color-coded wire
gage ring.
(b) Position terminal or splice in crimp closure as
shown in Figure 4 or 5.
(c) Partially close handles to hold terminal or splice
firmly in die closure.
(d) Insert stripped wire into terminal until end of
conductor is at least flush with or extended slightly
beyond end of terminal wire barrel.
Insert stripped wire into splice until end of conductor
butts against splice wire stop.
Do not use wires with nicked or missing conductor
strands.
(e) Close handles fully, then open handles by
depressing release lever.
(f) To crimp other half of splice, remove it and
reposition uncrimped half in tool as shown in Figure 5.
Follow same procedure used to crimp first half of
splice. If splice cannot be turned, turn tool around.
(g) Refer to Figure 6 for terminal or splice crimp
inspection procedure.
Figure 1
Figure 2
Figure 3
Figure 4
CAUTION
!
CAUTION
!
Strip Length Locator Crimp Closures Wire
Cutter
Release Lever WireStripping
Blades Color-Coded
Wire Gage
Rings
GageWireandUseAdjacent Crimp Closure
UseCorrect
Size Notch EndofWireButtsAgainst
Strip Length Locator
PLASTI-GRIP
Terminal
EndofInsulationBarrelis
Flush with Sides of Dies
PIDG
Terminal
“B” = Wire Barrel
“C” = Insulation Barrel
“B”
“B”
“C”
“C”
ORIGINAL INSTRUCTIONS

408-2746
2of 2
Rev A
7. REVISION SUMMARY
•Removed “AMPLIVERSAL” in title
Figure 5
Figure 6
Butt Splices
“B” “B”
“C”
“C” PIDG PLASTI-GRIP
“B” = Wire Barrel
“C” = Insulation Barrel
Wire Stop Wire Stop
EndofInsulationBarrelis
Flush with Sides of Dies
End of Insulation
Barrel is Flush
with Sides of Dies