696201-1

Instruction Sheet Super CHAMP* Hand Tool 696201–1 408–8619 29 JAN 02 Rev O PROPER USE GUIDELINES Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools. Hand tools are intended for occasional use and low volume applications. Stud Size Gages HERE Tool Handles STRIPPED WIRE LENGTH 22–14 12–10 12–10 22–14 TERMINAL SPLICE CLOSE 16 14 12 7 MM CUTTER WIRE 10–24 Crimping Dies 6–32 10–32 8–32 Wire Cutter 4–40 Bolt Cutters Front of Tool Bolt Cutters Figure 1 1. INTRODUCTION NOTE Super CHAMP Service Hand Tool 696201–1 is a service hand tool used to cut and strip wire, and crimp the terminals and spices shown in Figure 2. Dimensions are in metric units [with U.S. customary units in brackets] unless otherwise specified.. 2. HAND TOOL OPERATION Terminal/Splice Wire Size Stud Size 10 6 22 – 16 AWG WG –– Butt Splice 6 10 16 – 144 AWG WG 1/4 Butt Splice Parallel Splice 10 122 – 100 AWG WG Cut the wire with wire cutter portion of the service hand tool. Place wire between the cutting surfaces and close the handles. Refer to Figure 3. 2.2. Stripping the Wire Strip the wire using the stripping portion of the hand tool. See Figure 3. Use the strip length gage on the tool to determine the strip length, place the wire in the appropriate stripping position, close the handles, rotate the tool, and pull the wire from the tool. 2.3. Crimping Terminals 1. Cut and strip the wire as described in Paragraphs 2.1 and 2.2. 2. Open the handles. 3. Place the terminal/splice in the appropriate position of the crimping tool. See Figure 4. 16 – 10 AWG Closed–End Connector 22 – 16 AWG 6 4. Insert the stripped wire into the terminal barrel. 16 – 14 AWG 8 5. Close the handles and crimp the terminals/splices as shown in Figure 5. 12 – 10 AWG 10 Figure 2 E2002 Tyco Electronics Corporation, Harrisburg, PA. All International Rights Reserved. AMP and Tyco are trademarks. *Trademark Butt Splice 2.1. Cutting the Wire 6. Crimped terminals/splices should appear as shown in Figure 6. This controlled document is subject to change. For latest revision call the AMP FAX* number. TOOLING ASSISTANCE CENTER 1–800–722–1111 AMP FAX/PRODUCT INFO 1–800–522–6752 For Regional Customer Service, visit our website at www.tycoelectronics.com 1 of 2 LOC B 408–8619 Super Champ Hand Tool 696201–1 HERE 12 14 16 7 MM STRIPPED WIRE LENGTH 22–14 CLOSE CUTTER WIRE Frequency of inspection should be adjusted to suit your requirements. Frequency of inspection depends on: Wire Strippers Wire Cutter 12–10 12–10 TERMINAL 22–14 SPLICE S The type and size of the product crimped. S The degree of operator skill. S The presence of abnormal amounts of dust and dirt. S Your own established standards. Each tool is thoroughly inspected before packaging. Since there is a possibility of damage during shipment, new tooling should be inspected immediately upon arrival at your facility. Strip Length Gage 4. REVISION SUMMARY Figure 3 Per EC 0990–1496–01: Crimp Insulation Crimp Wire Crimp Insulation Terminals 10–32 10–24 8–32 6–32 4–40 S Initial release of 408–8619 Crimp Wire Crimp Insulation Parallel Splices Crimp 22 –16 (Red) or 16 – 14 (Blue) Crimp 12–10 Terminals (Yellow) Terminals Figure 4 2.4. Cutting Bolts 1. Open the tool handles. 2. Thread the bolt into the appropriate sized opening on the side of the tool marked, “INSERT SCREW HERE”. See Figure 1. NOTE Be sure to allow an extra 3.05 [.12] for the thickness of the tool. Crimp Insulation Crimp Wire Crimp Insulation Butt Splices Crimp Insulation Make One Crimp Here Closed End Splices Figure 5 2.5. Using the Stud Size Gage The stud size gage can be used to assist in selecting the correct terminal stud size. The circles on the tool handle represent the actual diameter of the stud. The correct stud size circle is completely visible through the terminal stud hole. Refer to the other side of the hand tool. 3. MAINTENANCE AND INSPECTION It is recommended that a maintenance and inspection program be performed periodically to ensure dependable and uniform terminations. 2 of 2 Figure 6 Rev O