Instruction Sheet SUPERCHAMP*ServiceHandTool 408--8620 696202-1 06 JAN 10 Rev C Insulated Handles Open--Barrel Product Insulation Crimper Bolt Cutters Open--Barrel Product Wire Crimpers Closed--Barrel Product and Tab--Lok FASTON Flag Terminal Tab--Lok FASTON* Flag Insulation Crimper Terminal Wire Crimper Closed--Barrel Product Wire Crimpers Open--Barrel Product Insulation Crimpers Figure 1 Open tool handles slightly, and proceed with the 1. INTRODUCTION following. SUPER CHAMP Service Hand Tool 696202--1 crimps various open--barrel and closed--barrel A. CrimpingtheWireBarrel terminals, contacts, and splices with or without insulation support and Tab--Lok FASTON flag 1. Center the wire barrel in the appropriate wire terminals. The tool will also cut bolts of various barrel crimper. Refer to Figure 2. common U.S. thread configurations. OpenBarrel (CrimpersB, C, D) Dimensions in this instruction sheet are in NOTE Make sure that the end of the wire barrel millimeters with inches in brackets . Figures are opening faces the letter marking on the tool. not drawn to scale. i ClosedBarrel (CrimpersJ, K, L) The wire barrel insulation color must match the Reasons for reissue of this instruction sheet are crimper color code. provided in Section 4, REVISION SUMMARY. Flag Terminal (CrimperA) 2. DESCRIPTION (See Figure 1) Make sure that the terminal is angled The tool consists of two jaws and handles. approximately 45 degrees with the locking tab resting on the bottom jaw. 3. USINGTHETOOL 2. Squeeze the tool handles together just enough 3.1. CrimpingProduct to hold the wire barrel in place. Select an appropriate terminal, contact, or splice for 3. Insert the stripped wire into the wire barrel. the tool. Strip the wire to the proper length (determine 1 strip length by adding 0.79 .031 ( / ) to the length 4. Holding the wire in place, squeeze the tool 32 of the wire barrel). Refer to Figure 2. handles together to complete the crimp. E2010 Tyco Electronics Corporation, Harrisburg, PA TOOLING ASSISTANCE CENTER1--800--722--1111 This controlled document is subject to change. 1 of 3 PRODUCT INFORMATION 1--800--522--6752 Forlatest revision and Regional CustomerService, All International Rights Reserved visit ourwebsite atwww.tycoelectronics.com TE logo and Tyco Electronics are trademarks. LOC B *Trademark. Otherproducts, logos, and company names used are the property of theirrespective owners.408-8620 SUPERCHAMPServiceHandTool696202-1 CrimpingOpen-Barrel Terminals Insulation Barrel Wire Barrel Wire Strip Length Properly Crimped Open--Barrel Terminal Wire Barrel Crimp: ForReferenceOnly (Wire Size AWG) B (18) -- C (16) -- D (14) Insulation Barrel Crimp: E -- F -- G -- H Crimping Closed-Barrel Terminals Insulation Barrel Wire Barrel Properly Crimped Closed--Barrel Terminal Insulation Barrel Crimp: M Wire Barrel Crimp Color Code: J (Yellow) -- K (Red or Blue) -- L (Uninsulated) Crimping Flag Terminals Center Wire Insulation Insulation and Conductors Wire Barrel Between Insulation Barrel Barrel and Wire Barrel Locking Tab Terminal May Be Rotated Slightly Properly Crimped Flag Terminal Close Jaws Slightly Until Insulation Barrel Crimp: Wire Barrel Crimp: Locking Tab Touches M A Bottom of Wire Barrel Figure 2 2 of 3 Tyco ElectronicsCorporation RevC