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CT-1525
OPERATION INSTRUCTIONS
PA22241A01 Rev.: 03 5-2010
CONTOUR CRIMP CONTROLLED CYCLE CRIMPING TOOL
Crimps Panduit #26-#22 AWG insulated terminals/splices, #22-#10 AWG fully insulated disconnects/ insulated parallel splices; and specific #22-14 AWG barrel insulated disconnects.
Provides UL Listed and CSA Certified terminations with applicable Panduit terminals.
(c) Panduit Corp. 2010
Die Closure Alignment (not a crimp pocket)
Figure 1
Figure 2
PKT A 4,0-6,0 mm2 0,5-2,5 12-10 AWG 22-14
CRIMP POCKETS for Pan-Term INSULATED terminals, disconnects and splices. CRIMP POCKETS for Pan-Term fully INSULATED disconnects, insulated splices and barrel insulated disconnects. Refer to product packaging for wire range and proper crimp pocket. Crimp pockets are color coded to match color of product insulator, and identified with applicable wire range. Controlled cycle mechanism prevents tool from opening before crimp cycle is complete.
Figure 3
CT - 1525
Part No. CT-1525 OPERATION MANUAL
MADE IN GERMANY
INSULATED TERMINAL CRIMPING INSTRUCTIONS
1. With the handles in the open position, and the back of the terminal tongue turned toward the color dots, insert the terminal into the proper crimp pocket (See Figure 1). Refer to product packaging for selection of proper crimp pocket. 2. Close handles until the barrel is held snugly in position -- do not deform the barrel. 3. Insert the stripped wire into the terminal until the wire stops. Refer to product packaging for wire strip length. 4. Crimp the terminal by closing the handles until the controlled cycle mechanism releases. Upon release, the handles will open automatically and the crimped terminal can be removed. NOTE: Visual inspection dots (formed by the crimp dies) on the insulation sleeve verify proper crimp cycle. * One (1) dot for PKT A crimp pocket * Two (2) dots for red and blue crimp pocket * Three (3) dots for yellow crimp pocket
Manual release lever, push forward in the event that controlled cycle mechanism must be released.
Cushioned Handle Grips
INSULATED DISCONNECT CRIMPING INSTRUCTIONS
1. With the handles in the open position, insert the disconnect in the proper crimp pocket (See Figure 1), so that the barrel is flush with the crimp die (See Figure 2). Refer to product packaging for selection of proper crimp pocket. 2. Close the tool handles until the barrel is held snugly in place--do not deform the barrel. 3. Insert the stripped wire into the disconnect. Refer to product packaging for wire strip length. Crimp the disconnect by closing the handles until the controlled cycle mechanism releases. Upon release, the handles will open automatically and the crimped disconnect can be removed. After crimping, inspect that the crimp is centered on the disconnect barrel in order to achieve optimal pullout performance.
Website: www.panduit.com Email: cs@panduit.com EU Website: www.panduit.com/emea EU Email: emeatoolservicecenter@panduit.com
Figure 4
Stripped Wire
Slot for Wire Stop
CAUTION: Verify power is "OFF" before working on wiring with this tool. The cushioned grips are for the user's comfort, and are not intended to insulate against shock while working on live electrical circuits.
Terminal Crimp Die Insulation Closure
Panduit Corp. * USA Technical Support Tel: 888-506-5400, ext. 3255 * Fax: 630-759-7532 Panduit Europe * EMEA Service Center Tel: 31 (0) 546 580 452 * Fax: 31 (0) 546 580 441
CT-1525: PA22241A01_03
Page: 1 of 2
5-2010
CT-1525 OPERATION INSTRUCTIONS INSULATED SPLICE CRIMPING INSTRUCTIONS
1. With the handles in the open position, insert the splice into the proper crimp pocket (See Figure 1) so that the crimp is located on the barrel of the splice (See Figure 3). Refer to product packaging for selection of proper crimp pocket. 2. Close the handles until the barrel is held snugly in position -- do not deform the barrel. 3. Insert the stripped wire into the splice until the wire stops. Refer to product packaging for wire strip length. Crimp the splice by closing the handles until the controlled cycle mechanism releases. Upon release, the handles will open automatically and the crimped splice can be removed. 4. Remove the splice and repeat operation for crimping the other end of the splice.
INSPECTION / MAINTENANCE
NEW TOOLS - BEFORE PLACING INTO SERVICE: All Panduit crimping tools are calibrated and inspected before they are shipped from the factory. All new tools should be inspected before being used. New tools are shipped, factory lubricated, in protective packaging. After inspection, simply clean any excess oil from the crimping dies and place into service. When the tool is not in use, keep the handles closed to prevent objects from becoming lodged in the crimping area. Store the tool in a clean, dry area. IN-SERVICE TOOLS - AFTER TOOLS HAVE BEEN IN SERVICE: It is recommended that each operator of the tool be made aware of - and responsible for following these maintenance steps.: In-service tools should be cleaned and inspected at least ONCE A MONTH. To clean-wipe with a clean cloth. In-service tools should be lubricated ONCE A WEEK, and after every cleaning. Lubricate all pins, pivots and bearing surfaces with DOW CORNING(R) Molykote BR2 Plus. Do not use oil excessively. Be sure to clean any excess oil from the crimping dies before using.
(R) Molykote BR2 Plus is the Registered Trademark of DOW CORNING
TROUBLESHOOTING
DIE CLOSURE INSPECTION Die closure is measured by using GO/NO GO gage members (dimensions listed in Table 1). Table 1
DIE CLOSURE GO / NO GO GAGE MEMBERS - TOOL NO. CT-1525
VISUAL INSPECTION 1. Visually inspect the tool for missing or loose pins, then close the tool and note the return action of the handles. 2. Inspect the crimping dies for worn, chipped or broken edges.. 3. If parts are missing, defective or damaged, contact your local Panduit Sales Office for information on repair or replacement of tools.
CRIMP POCKET AWG / mm2 Pocket "A" 22-14 / 0,5-2,5 12-10 / 4,0-6,0
ENGLISH GO / NO GO GAGE MEMBERS METRIC GO / NO GO GAGE MEMBERS "G" Dia. (GO) .065" .076" .100" "NG" Dia. (NO GO) .073" .084" .108" "G" Dia. (GO) 1,65 mm 1,93 mm 2,54 mm "NG" Dia. (NO GO) 1,85 mm 2,13 mm 2,74 mm PRELOAD FORCE INSPECTION 1. Close the handles until the controlled cycle mechanism is engaged, but before the mechanism releases. 2. Apply force to the handles 1-1/4" (32mm) from the end of the handles, until the controlled cycle release mechanism releases. Record the reading using a force gauge. 3. The force required to release the controlled cycle release mechanism should be a minimum of 15 pounds-force (67 N). If the force required is less than 15 pounds-force (67 N), contact Panduit Tool Division Tool Service Department or Panduit EMEA Service Center for technical assistance.
1. Clean the crimping dies and gage member surfaces. 2. Close the tool handles until the crimping dies are bottomed and the controlled cycle mechanism releases. Keep the handles closed together. 3. Using the appropriate gage member, attempt to insert the NO GO gage into the die opening. The NO GO side may partially enter the die closure but must NOT pass completely through. Perform this test for all three crimp pockets. 4. Repeat Step 3 with the appropriate GO gage for all three crimp pockets. The GO side must enter and pass completely through the die closures. 5. If both gage conditions are met, the tool is dimensionally correct. If either condition fails, contact PAnduit Tool Division Tool Service.
CT-1525: PA22241A01_03
Page: 2 of 2
5-2010

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