Instruction Sheet
SOLISTRAND* Crimping Dies
(Used in Crimping Heads
69097 and 69099)
Butt Splices
“B”
WIRE
SIZE,
AWG
25 APR 11
Parallel Splices
“B”
DIE SET NUMBERS FOR
CRIMPING HEAD 69097
“B” = Wire Barrel
DIE SET
NUMBERS
FOR
CRIMPING
HEAD
69099
MIN.
STATIONARY
DIE
MOVING
DIE
8
46146
46145
69216D
6
46134
46133
69217D
4
46135
46133
69218D
Rev C
“B”
ORIGINAL INSTRUCTIONS
Terminals
408-- 1697
WIRE STRIP LENGTH for WIRE BARREL “B”
TERMINAL
BUTT SPLICE
PARALLEL SPLICE
MAX.
MIN.
MAX.
MIN.
MAX.
8.33 [.328]
9.12 [.359]
10.31 [.406]
11.13 [.438]
10.31 [.406]
11.13 [.438]
9.93 [.391]
10.72 [.422]
11.91 [.469]
12.7 [.500]
11.13 [.438]
11.91 [.469]
11.13 [.438]
11.91 [.469]
13.49 [.531]
14.27 [.562]
13.49 [.531]
14.27 [.562]
2
46136
46133
45433D
12.7 [.500]
13.49 [.531]
15.09 [.594]
19.05 [.750]
16.66 [.656]
17.48 [.688]
1/0
46138
46137
45436D
19.05 [.750]
19.84 [.781]
17.48 [.688]
18.26 [.719]
19.05 [.750]
19.84 [.781]
2/0
------
------
19.05 [.750]
19.84 [.781]
17.48 [.688]
18.26 [.719]
19.05 [.750]
19.84 [.781]
3/0
------
------
45439D
45442
19.05 [.750]
19.84 [.781]
17.48 [.688]
18.26 [.719]
19.05 [.750]
19.84 [.781]
4/0
------
------
45445
19.05 [.750]
19.84 [.781]
17.48 [.688]
18.26 [.719]
19.84 [.781]
20.62 [.812]
DThese dies may be used for STRATO--THERM* heat resistant post--insulated terminals and splices.
Figure 1
1. INTRODUCTION
This instruction sheet provides instructions on product
application, and maintenance and inspection
procedures for SOLISTRAND Crimping Dies which
are used in Crimping Heads 69097 and 69099. See
Figure 1.
These dies are used to crimp SOLISTRAND
Terminals and Splices onto solid or stranded copper
wire in AWG sizes of 8--4/0.
Basic instructions on the use of the dies, die insertion
and removal, etc., are provided in Section 2,
INSTRUCTIONS. Section 3, CRIMP INSPECTION
features a terminal and splice crimp inspection
procedure. Section 4, MAINTENANCE AND
INSPECTION, will enable you to establish and
maintain a die certification program.
The dies are coated with a preservative to prevent
rust and corrosion. Wipe this preservative from the
dies, particularly from the crimping areas.
For further instructions relative to the hydraulic power
unit and hydraulic crimping heads, refer to the
E2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
*Trademark
instructions packaged with the tools or contact the
Tooling Assistance Center number at the bottom of
this page.
NOTE
i
Dimensions in this instruction sheet are in
millimeters [with inches in brackets]. Figures are
for reference only, and are not drawn to scale.
Reasons for reissue of this instruction sheet are
provided in Section 6, REVISION SUMMARY.
2. INSTRUCTIONS
2.1. Die Insertion
DANGER
Avoid personal injury. Disconnect power unit from
power supply when changing dies.
A. Crimping Head 69097
1. Loosen the lock screw in the top section of the
crimping head. See Figure 2.
TOOLING ASSISTANCE CENTER 1--800--722--1111
PRODUCT INFORMATION 1--800--522--6752
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.te.com
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1 of 8
LOC B
408- 1697
Crimping Head 69099
(Die Set 69218 Shown)
Crimping Head 69097
Lock Screw
Lock Screw
Retaining Ring
Shank
Stationary Die
Moving Die
Stationary Die
Flat on Shank
Faces Lock Screw
Moving Die
Ram Locking
Screw
Ram Locking
Screw
Figure 2
Figure 3
NOTE
NOTE
i
Lock screws in the top section of the crimping
head and in the ram are not used when installing
dies with retaining rings on shanks.
2. Insert the shank of the stationary die into the top
section of the crimping head. See Figure 2. The
retaining clip will hold the die in place.
3. Activate the power unit to advance the ram until
the lock screw is visible.
4. Loosen the lock screw and insert the shank of
the moving die into the ram well. See Figure 2. The
retaining ring will hold the die in place.
5. Activate the power unit to complete the cycle
and allow the ram to return to the “DOWN”
position.
B. Crimping Head 69099
1. Loosen the lock screw in the top section of the
crimping head. See Figure 3.
2. Insert the shank of the stationary die into the top
section of the crimping head and tighten the lock
screw. See Figure 3.
2 of 8
i
Ensure that the dies are inserted “fully” and that
the “flats” on the shanks are facing the lock
screws.
3. Loosen the ram lock screw and insert the shank
of the moving die into the ram well. Tighten the
lock screw. See Figure 3.
2.2. Die Removal
In crimping head 69097, insert the screwdriver blade
under the base of the stationary and moving dies.
Apply a prying action to loosen and remove the dies.
In crimping head 69099, loosen the lock screws in the
top section of the crimping head and ram and remove
the dies.
2.3. Wire Stripping and Crimping Procedures
A. Wire Stripping Procedure
Strip the wire to the dimensions shown in the table
in Figure 1.
CAUTION
Do not nick or cut the conductor strands.
!
B. Crimping Procedure
DANGER
Avoid personal injury. When operating the power
unit, exercise caution while holding terminals,
splices, or wire near the crimping area.
Rev C
408- 1697
Terminals
Butt Splices
Center Half of
Butt Splice in
Stationary Die
End of Conductor is Flush
or Extended Slightly Beyond
End of Wire Barrel
Center Terminal
Barrel in
Stationary Die
End of Conductor Butts
Against Splice Wire Stop
Brazed Seam
Faces Moving
Die
Brazed Seam Faces Moving Die
Figure 5
Figure 4
Ensure that the wire size stamped on the terminal
or splice corresponds with the wire size stamped
on the stationary die. Crimping head 69099 is
shown in Figures 3 thru 6. The crimping procedure
is identical when using crimping head 69097.
A
Parallel Splices
Center Parallel Splice
Barrel in Stationary Die
1. Place the terminal or splice in the stationary die
as shown in Figures 4, 5, or 6. For best results,
position the terminal or splice so that the brazed
seam faces the moving die.
End of Conductor is
Flush or Extended
Slightly Beyond
End of Wire Barrel
2. Activate the power unit so that the crimping die
advances and holds the terminal or splice in place.
Do not deform the terminal or splice barrel.
3. Insert the stripped wire all the way into the
terminal or splice barrel.
B
Brazed Seam Faces Moving Die
End of Conductor is Flush
or Extended Slightly Beyond
End of Wire Barrel
Center Parallel
Splice Barrel in
Stationary Die
4. Activate the power unit to complete the crimp.
5. To crimp the other half of the butt splice, remove
and reposition the uncrimped half in the stationary
die. Insert the wire and crimp the splice.
6. Refer to Section 3, CRIMP INSPECTION and
Figure 7 for crimp inspection information.
NOTE
i
Rev C
If SOLISTRAND terminals or splices stick in the
die after crimping, apply a rocking motion to
remove them from the die.
Figure 6
Brazed Seam
Faces Moving Die
3 of 8
408- 1697
3. CRIMP INSPECTION
Inspect crimped terminals and splices by checking the
features described in Figure 7. Use only the terminals
and splices that meed the conditions shown in the
“ACCEPT” column. “REJECT” terminals and splices
can be avoided through careful use of instructions in
Section 2, INSTRUCTIONS, and by performing
regular die maintenance as instructed in Section 4,
MAINTENANCE AND INSPECTION PROCEDURES.
ACCEPT
3
REJECT
1
1
4
4
2
2
3
4
1
4
1
3
5
6
3
4
1
5
3
2
3
2
4
1
Crimps centered. Crimps may be off center, BUT NOT
OFF END OF WIRE BARREL.
2
AWG wire size being used matches wire size
stamped on terminal or splice and crimping dies.
3
Wire insulation does not enter wire barrel.
4
Wire is visible through inspection hole or butt splices.
Wire is flush with or extends slightly beyond end of
terminal wire barrel.
5
On parallel splices, bare wire ends must be flush with
or extend slightly beyond end of barrel.
1
1
Crimped off end of splice or terminal wire barrel.
2
AWG wire size being used does not match wire size
stamped on terminal or splice crimping dies.
3
Wire insulation entered barrel of terminal or splice.
CHECK FOR INCORRECT STRIP LENGTH.
4
Wire not inserted far enough in terminal or splice. End
of wire must be visible through inspection hole of butt
splices, and be flush with or extend slightly beyond
end of terminal wire barrel or parallel splice.
5
Excessive “flash” on terminal or splice indicates wrong
combination of wire, terminal, splice, or tooling.
6
Nicked or missing conductor strands.
Figure 7
4 of 8
Rev C
408- 1697
4. MAINTENANCE AND INSPECTION PROCEDURES
TE Connectivity recommends that a maintenance and
inspection program be performed periodically to
ensure dependable and uniform terminations. Dies
should be inspected at least once a month.
Frequency of inspection may be adjusted to suit your
requirements through experience. Frequency of
inspection is dependent upon:
S The care, amount of use, and handling of the
dies.
S The type and size of the products crimped.
S The degree of operator skill.
S The presence of abnormal amount of dust and
dirt.
S Your own established standards.
Since there is a possibility of die damage in shipment,
new dies should be inspected in accordance with the
following instructions when received in your plant.
4.1. Cleaning
Do not allow deposits of dirt, grease, and foreign
matter to accumulate in the die closure surfaces and
on the bottoming surfaces of the dies. These deposits
may prevent the dies from bottoming fully and may
also cause excessive wear in the die closure
surfaces, thereby affecting the quality of the crimp.
The dies should be wiped clean frequently with a
clean cloth.
Dies for the 69099 Tool
1. Clean oil and dirt from the die closure surfaces
and plug gage members.
2. Assemble and adjust the dies to meet the “gage
dimension” indicated in Figure 10, Detail “A”.
3. With the crimping dies assembled as described
in steps 1 and 2, check the wire barrel crimp die
closure using the proper plug gage. Hold gage in
straight alignment with the die closure and carefully
try to inset them without forcing the GO member
as shown in Figure 10, Detail “A”. The GO member
must pass completely through the die closure as
shown in Figure 10, Detail “B”.
4. Try to insert the NO--GO member. The NO--GO
member may enter partially, but must not pass
completely through the die closure. See Figure 10,
Detail “B”.
5. If the dies meet the GO NO--GO gage
conditions, the dies may be considered
dimensionally correct. If you find that the dies no
not conform with the GO NO--GO gage conditions,
contact your local TE Field Representative.
Flattened
Area
4.2. Visual Inspection
Visually inspect the die closure surfaces for broken,
pitted, or chipped areas. Although dies may gage
within possible limits, worn or damaged die closure
surfaces are objectionable and can affect the quality
of the crimp. Examples of possible damaged die
closure surfaces are shown in Figure 8.
Chipped
Area
4.3. Die Closure Inspection
Every die set is inspected for proper die closure
before packaging. An inspection should be performed
periodically to check the die closure for excessive
wear. The die closure inspection is accomplished
using the GO NO--GO plug gage. TE neither
manufactures nor sells plug gages. A suggested plug
gage design and the GO NO--GO dimensions of the
plug gage members are listed in Figure 9. The
following procedure is recommended for inspecting
the die closure.
Pitted Area
Dies for the 69097 Tool
1. Clean oil and dirt from the die closure surfaces
and plug gage members.
2. Assemble the dies so that they are bottomed
but not under pressure. See Figure 10, Detail “A”.
Rev C
Figure 8
5 of 8
408- 1697
Suggested Plug Gage Design
Die Closure
Configuration
GO
Dimension
“B”
NO-- GO
Dimension
“B”
“C” Typ.
“R”
“R”
“L” Typ.
“A” Dim.
CRIMPING
HEAD
69097
DIE
SET
DIE CLOSURE
DIMENSIONS “A”{
GO
NO-- GO
GO
NO-- GO
46145,
46146
2.54 [.1000]
2.692 [.1060]
2.54--2.548
[.1000--.1003]
2.690--2.692
[.1059--.1060]
46133,
46134
3.937 [.1550]
4.089 [.1610]
3.937--3.945
[.1550--.1553]
46133,
46135
4.724 [.1860]
4.877 [.1920]
46133,
46136
5.436 [.2140]
46137,
46138
}
RADIUS
“R”
GAGE MEMBER
LENGTH
“L”
“C”
3.18 [.125]
25.4 [1.000]
12.7 [.500]
4.087--4.089
[.1609--.1610]
4.34 [.171]
25.4 [1.000]
11.10 [.437]
4.724--4.732
[.1860--.1863]
4.874--4.877
[.1919--.1920]
5.54 [.218]
25.4 [1.000]
11.10 [.437]
5.588 [.2200]
5.436--5.443
[.2140--.2143]
5.585--5.588
[.2199--.2200]
6.35 [.250]
25.4 [1.000]
11.10 [.437]
5.207 [.2050]
5.359 [.2110]
5.207--5.215
[.2050--.2053]
5.357--5.359
[.2109--.2110]
7.29 [.287]
31.75 [1.500]
14.27 [.562]
69216
2.54 [.1000]
2.692 [.1060]
2.54--2.548
[.1000--.1003]
2.690--2.692
[.1059--.1060]
3.18 [.125]
25.4 [1.000]
12.7 [.500]
69217
3.150 [.1240]
3.302 [.1300]
3.150--3.157
[.1240--.1243]
3.299--3.302
[.1299--.1300]
4.34 [.171]
25.4 [1.000]
8.64 [.340]
69218
3.962 [.1560]
4.115 [.1620]
3.962--3.970
[.1560--.1563]
4.112--4.115
[.1619--.1620]
5.54 [.218]
25.4 [1.000]
9.91 [.390]
45433
4.547 [.1790]
4.699 [.1850]
4.547--4.554
[.1790--.1793]
4.696--4.699
[.1849--.1850]
6.35 [.250]
31.75 [1.500]
11.51 [.453]
45436
5.207 [.2050]
5.359 [.2110]
5.207--5.215
[.2050--.2053]
5.357--5.359
[.2109--.2110]
7.52 [.296]
38.1 [1.500]
15.88 [.625]
45439
5.867 [.2310]
6.020 [.2370]
5.867--5.875
[.2310--.2313]
6.017--6.020
[.2369--.2370]
8.33 [.328]
38.1 [1.500]
15.88 [.625]
45442
6.604 [.2600]
6.756 [.2660]
6.604--6.612
[.2600--.2603]
6.754--6.756
[.2659--.2660]
9.52 [.375]
38.1 [1.500]
15.88 [.625]
45445
7.417 [.2920]
7.569 [.2980]
7.417--7.424
[.2920--.2923]
7.567--7.569
[.2979--.2980]
10.69 [.421]
38.1 [1.500]
15.88 [.625]
69099
{
GAGE MEMBER}
DIMENSIONS “B”
Die closure dimensions apply when dies are bottomed, but not under pressure, (Dies for 69097 tool).
Die closure dimensions apply when dies are positioned at “gage dimension” indicated in Figure 10, Detail “A”, (Dies for 69099 tool).
Material -- Tool Steel
Figure 9
6 of 8
Rev C
408- 1697
Inspection of Wire Barrel Crimping Dies with Plug Gage
Dies Bottomed,
but Not Under
Pressure
Detail “A”
Detail “B”
Dies for
69097 Tool
“GO” Gage Must Pass Completely
Through the Die Closure
Dies Positioned at
“Gage Dimension”
Dies for
69099 Tool
42.26 [1.664]
Gage Dimension
“NO--GO” Gage May Enter Partially,
but Must Not Pass Completely
Through the Die Closure
Figure 10
Die Sets for Crimping Head 69099
Die Sets for Crimping Head 69097
3
2
2
1
1
3
ITEM
DESCRIPTION
DIE SETS FOR CRIMPING HEAD 69099
69216
69217
69218
45433
45436
45439
45442
45445
1
DIE, Moving
307544--1
307544--2
307544--3
307544--4
307544--5
307544--6
307544--7
307544--8
2
DIE, Stationary
307543--1
307543--2
307543--3
307543--4
307543--5
307543--6
307543--7
307543--8
ITEM
DESCRIPTION
1
DIE, Moving
2
DIE, Stationary
3
RING, Retaining
DIE SETS FOR CRIMPING HEAD 69097
46133
46134
46135
46136
46137
46145
46138
46146
------
303825
Figure 11
Rev C
7 of 8
408- 1697
5. REPLACEMENT PARTS
Customer--replaceable parts are listed in Figure 11.
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 TE to ensure quality and
reliability. Order replacement parts through your TE
Representative, or call 1--800--526--5142, or send a
facsimile of your purchase order to 717--986--7605, or
write to:
8 of 8
CUSTOMER SERVICE (038--035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105--3608
For customer repair service, contact a TE
Representative at 1--800--526--5136.
6. REVISION SUMMARY
S Updated document to corporate requirements
S New logo
Rev C