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©2012 Tyco Electronics Corporation, a TE Connectivity Ltd. Company All Rights Reserved *Trademark TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners. 1 of 6 Instruction Sheet 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 LOC B 408-1254 Terminal and Splice Crimping Tools 69339, 69354-1, and 69355 11 JUN 12 Rev D 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. Figure 1 1. INTRODUCTION This instruction sheet provides information for product application and maintenance and inspection procedures for Terminal and Splice Crimping Tools 69339, 69354-1, and 69355. These tools are used to crimp:
- SOLISTRAND* Terminals, butt and parallel splices on solid or stranded copper wire sizes 6 and 8 AWG
- SOLISTRAND Flag Terminals on solid or stranded copper wire size 8 AWG
- STRATO-THERM* heat resistant uninsulated terminals on solid or stranded copper wire size
8 AWG
Basic instructions on the use of this tool, wire preparation, tool adjustments, etc. are provided in Section 2, INSTRUCTIONS. Section 3 features a terminal CRIMP INSPECTION procedure. Section 4 contains a MAINTENANCE and INSPECTION PROCEDURE. Tools are coated with preservative to prevent rust and corrosion. Wipe this preservative from the tool, particularly from the crimping area. Read these instructions carefully before using the tool. Reasons for reissue of this sheet are provided in Section 5, REVISION SUMMARY. 2. INSTRUCTIONS FOR WIRE STRIPPING AND CRIMPING PROCEDURES 1. Strip wires to the dimensions listed in Figure 2. 2. Open crimping dies by closing handles until CERTI-CRIMP hand crimping tool ratchet control releases. See Figure 1. Note that once the ratchet is engaged, handles cannot be opened again until they are fully closed. Determine correct terminal or splice wire loading by referring to the CMA range listed in Figure 2. Terminals 3. Center wire barrel of terminal in nest of stationary die as shown in Figure 3A. 4. Center wire barrel of flag terminal in dies being sure that “tongue” portion of wire barrel is against indenter of moving die as shown in Figure 3B. Nest Indenter Tool Wire Size Markings CERTI-CRIMP* Hand Crimping Tool Ratchet Control NOTE Dimensions are in millimeters [with inch equivalents in brackets]. Figures and illustrations are for identification only and are not drawn to scale. CAUTION Do NOT use wire with nicked or missing strands. NOTE Be sure wire size displayed on tool head and in stationary die nest matches wire size stamped on the terminal or splice. i i ORIGINAL INSTRUCTIONS
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 head of crimping tool. 3 Insulation does not enter wire barrel. 4 Wire is visible through inspection hole of 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.
6 Wire size embossed on crimped wire barrel matches wire
size stamped on terminal or splice. 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 and head of crimping tool. 3 Insulation entered barrel of terminal or splice. CHECK FOR INCORRECT STRIP LENGTH. 4 Wire not inserted far enough in terminal of 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 wire,
terminal or splice, or tooling combination was used. 6 Nicked or missing strands.
7 Wire size embossed on crimped wire barrel does not match
wire size stamped on terminal or splice. Figure 5 5. Close handles until terminal is held firmly in place. Do NOT deform terminal wire barrel. 6. Insert stripped wire into terminal until end of wire is at least flush with or extended slightly beyond end of wire barrel. See Figures 3A or 3B. 7. To complete the crimp, close the handles until the CERTI-CRIMP hand crimping tool ratchet control releases. Handles can now be opened and the crimped terminal may be removed. 8. Refer to Section 3 and Figure 5 for terminal crimp inspection procedures. Splices 9. Center one half of the butt splice in nest as shown in Figure 4A or 4B. For best results, when brazed seam on splice is visible, position the seam toward the indenter. 10. Center parallel splice in nest as shown in Figure 4C. Be sure brazed seam faces indenter. 11. Close handles until splice is held firmly in place. Do NOT deform splice wire barrel. 12. Insert stripped wire into butt splices until end of wire butts against wire stop in splice as shown in Figure 4A or 4B. Insert stripped wire into parallel ACCEPT REJECT Wire Range Stamped Here Embossed Wire Size Embossed Wire Size Embossed Wire Size Wire Range Stamped Here Sight Hole Type Standard Type Wire Range Stamped Under Tongue Embossed Wire Size Embossed Wire Size Wire Range Stamped Under Tongue Wire Range Stamped Here Embossed Wire Size Embossed Wire Size Embossed Wire Size Wire Range Stamped Here TERMINAL FLAG TERMINAL PARALLEL SPLICE BUTT SPLICE
NOTE: Approximately 307.98 mm [12.125 in.] Long, Assembled, and Handles Closed ITEM No. DESCRIPTION QTY PER TOOL HAND TOOLS 69339 69354-1 69355