Instruction Sheet SUPER CHAMP* Hand Tool 408-8618 696126-1 22 JUN 10 Rev A 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. A wide selection of powered application equipment for extended-use, production operations is available. Front of Tool Handles Red (22-16) Stud Size Blue (16-14) Bolt Cutter Wire Cutter Gage Color Dots Yellow (12-10) Crimping Jaws Color Dot Chambers Figure 1 1. INTRODUCTION TERMINAL OR SPLICE SUPER CHAMP Hand Tool 696126-1, shown in WIRE SIZE Figure 1, is used to cut and strip wire and crimp the RANGE (AWG) ILLUSTRATION DESCRIPTION insulated terminals and splices to wires listed in (Not to Scale) Figure 2. The hand tool is also capable of cutting bolts and gaging various stud sizes. Ring Tongue Reasons for reissue of this instruction sheet are 22-16 Butt provided in Section 6, REVISION SUMMARY. Hook Tongue 2. DESCRIPTION Ring Tongue The hand tool consists of two jaws and handles. The jaws feature crimping chambers, a bolt cutter, Butt 16-14 wire cutter, stud size gage, and strip length gage. The Parallel crimping chambers are marked and color-coded to a specified wire size range. See Figure 1. Hook Tongue The stud size gage can be used to assist in selecting the correct terminal stud size. 16-10 Closed End Ring Tongue 3. OPERATION 12-10 Butt 3.1. Cutting the Wire Spade Tongue Place the wire between the cutting surfaces of the wire cutter, and close the handles. Figure 2 3.2. Stripping the Wire 3.3. Crimping 1. Using the strip length gage (on back of hand tool), determine the strip length of the wire. Refer to Figure 3, and proceed as follows: 2. Place the wire in the applicable position of the A. Terminals wire stripper, then close the handles, rotate the tool, and pull the wire from the tool. 1. Open the tool handles. ©2010 Tyco Electronics Corporation, Berwyn, PA This controlled document is subject to change. TOOLING ASSISTANCE CENTER 1-800-722-1111 1 of 2 All Rights Reserved For latest revision and Regional Customer Service, PRODUCT INFORMATION 1-800-522-6752 TE logo and Tyco Electronics are trademarks. visit our website at www.tycoelectronics.com *Trademark. Other products, logos, and company names might be trademarks of their respective owners. LOC B 408-8618 2. Center the wire barrel in the appropriate 8. Inspect the crimp according to the applicable crimping chamber. Application Specification (114-series). 3. Insert the stripped wire into the wire barrel 3.4. Cutting Bolts until it stops. 1. Open the tool handles. 4. Close the tool handles completely. 2. Thread the bolt into the appropriate-sized 5. Center the insulation barrel in the crimping opening on the side of the tool marked, "INSERT chamber. SCREW HERE". See Figure 1. 6. Close the tool handles completely. 3. Close the tool handles until the bolt is cut. 7. Inspect the crimp according to the applicable 3.5. Using the Stud Size Gage Application Specification (114-series). Lay the terminal stud hole over a stud size circle B. Splices marking on the jaw of the hand tool. The circles 1. Open the tool handles. represent the actual diameter of the stud. The correct stud size circle will be visible through the terminal 2. Center the wire barrel in the appropriate stud hole. crimping chamber. 3. Insert the stripped wire into the wire barrel 4. MAINTENANCE AND INSPECTION until it stops. It is recommended that a maintenance and inspection 4. Close the tool handles completely. program be performed periodically to ensure dependable and uniform terminations. Frequency of 5. Center the insulation barrel in the crimping inspection depends on: chamber. — type and size of the product crimped 6. Close the tool handles completely. — degree of operator skill 7. Re-position the splice so that the other wire — presence of abnormal amounts of dust and dirt barrel is centered in the crimping chamber. Then — your own established standards follows Steps 3 through 6. The hand tool is thoroughly inspected before packaging. Since there is a possibility of damage Crimping Terminals during shipment, the hand tool should be inspected immediately upon arrival at your facility. Wire Barrel 5. REPLACEMENT AND REPAIR Insulation This tool is not repairable. Order replacement tools Barrel through your representative, or call 1-800-526-5142, or send a facsimile of your purchase order to 717-986-7605, or write to: Crimping Splices CUSTOMER SERVICE (038-035) Wire Barrel Parallel TYCO ELECTRONICS CORPORATION Insulation PO BOX 3608 Insulation Barrel HARRISBURG PA 17105-3608 Barrel Insulation 6. REVISION SUMMARY Barrel Revisions to this instruction sheet include: Butt Wire Barrel • Updated instruction sheet to corporate requirements Wire Barrel • Modified Figures 1 and 2 Insulation Barrel • Modified Paragraph 3.3 Wire Barrel • Replaced Figure 6 with reference to application Closed End specification Figure 3 2 of 2 Rev A