411- 1097
Double Action Hand Crimping Tools 525690 and 525691
Rev D6 of 7 Tyco Electronics Corporation
Figure 8
Jaws Bottomed But
Not Under Pressure
pect
o
of
Wire Barrel Section
of Crimping Chamber
pect
o
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:
SUpdated document to corporate requirements
SAdded new data to tables in Figure 7
