408- 2029

7 of 10Rev D

Single Crimp

SOLISTRAND Terminals

and Splices

Dual Crimp

SOLISTRAND Terminals

and Splices

Terminal

Parallel

Splice

Butt Splice

Terminal

Crimp centered. Crimp may be off center BUT NOT

OFF END OF WIRE BARREL.

Wire size stamped on terminal or splice matches

CMA of wire being used.

Insulation does not enter wire barrel.

Wire is visible through inspection hole of butt splice.

On terminals and parallel splices, bare wire ends

must be flush with or extend slightly beyond end of wire

barrel.

Crimps evenly spaced BUT N OT OVERLAPPED OR

OFF END OF WIRE BARREL.

Wire size stamped on terminal or splice matches

CMA of wire being used.

Insulation does not enter wire barrel.

Wire is visible through inspection hole of butt splice.

On terminals and parallel splices, bare wire ends

must be flush with or extend slightly beyond end

of wire barrel.

Wire Size

Stamped Under

Tongue

Wire Size

Stamped

on Splices

Wire Size

Stamped Under

Tongue

Parallel

Splice

Butt Splice

Wire Size

Stamped

on Splice

Figure 7

Wire Size

Stamped

on Splice

408- 2029

Rev D8 of 10

CABLE MAKER Battery Terminals

Crimps evenly spaced BUT N OT OVERLAPPED OR

OFF END OF WIRE BARREL.

Diameter of stripped wire is within wire diameter

range of terminal.

No nicked or missing conductor strands.

Wire fully inserted.

Selected die numbers match the number displayed in

Area 2.

Crimps properly located. Crimps must not be off end of wire

barrel.

End of conductor is flush or extended approximately

0.79 [.031] beyond end of terminal wire barrel.

Diameter of stripped wire is within wire diameter

range of terminal.

No nicked or missing conductor strands.

Selected die numbers match the number displayed in

Area 2.

Area 2

Straight Terminal Flag Terminal

Straight T

erminal Flag Ter minal

Figure 8

Figure 9

Dies Bottomed

But Not Under

Pressure

No. 4 Dies in

Crimp Position

Adjustment

Screws

Lock

Screws

28.58 [1.125]

38.10 [1.500]

5. To loosen the adjustment:

a. --Turn both adjustment (ADJ) screws

COUNTERCLOCKWISE approximately 1/8 to

1/4 turn.

b. --Slightly loosen both lock (LOCK) screws by

turning them COUNTERCLOCKWISE.

c. --Flex the tool by opening and closing the tool

handles.

d. --Tighten both lock screws.

e. --Close the tool handles until the dies are

bottomed, but not under pressure. Check the

measurement between the tool handles and

repeat the adjustment procedure if necessary.

6. To tighten the adjustment:

a. --Turn both lock (LOCK) screws

COUNTERCLOCKWISE approximately 1/2 to

3/4 turn. --Turn both adjustment (ADJ) screws

CLOCKWISE approximately 1/8 to 1/4 turn.

b. --Flex the tool by opening and closing the tool

handles.

c. --Tighten both lock (LOCK) screws.

d. --- Close the tool handles until the dies are

bottomed but not under pressure. Check the

measurement between the tool handles and

repeat the adjustment procedure if necessary.

408- 2029

9 of 10Rev D

C. Crimp Height Inspection (Figure 10)

Crimp height inspections should be performed

periodically to determine if the tool is maintaining

proper crimping dimensions. To check the crimp

height:

1. Perform the handle adjustment inspection as

described in Paragraph B, Handle Adjustment

Inspection. Adjust the handles if necessary.

2. Crimp a properly prepared stranded wire in a

SOLISTRAND terminal or splice, as previously

described.

Do not use wires with missing conductor str ands.

3. Using a conventional cone--point micrometer ,

measure the crimp heights at the midpoints of flats

“A” and “B”, as shown in Figure 10. The SUM of

the two measurements equals the crimp height

dimension.

Do not allow the cone point to enter the terminal

brazed seam.

4. Figure 10 lists the crimp height dimension (sum

of “A” and “B” measurements) range for each wire

size. If the measured dimension is within the listed

range, the die closure is considered dimensionally

correct.

5. If the measured crimp height dimension is not

within the specified range (and the tool handles are

properly adjusted), crimping tool should be

returned to TE for reconditioning. Refer to Section

8, REPAIR/REPLACEMENT.

8. REPAIR/REPLACEMENT

Replaceable parts are listed in Figure 11. Parts other

than those listed in Figure 11 should be replaced by

TE to ensure quality and reliability of the tool. Order

replacement parts through your TE representative, or

call 1--800--526--5142, or send a facsimile of your

purchase order to 1--717--986--7605, or write to:

CUSTOMER SERVICE (38--35)

TYCO ELECTRONICS CORPORATION

P.O. BOX 3608

HARRISBURG, PA 17105--3608

For tool repair service, please contact a TE

Representative at 1--800--526--5136.

9. REVISION SUMMARY

S Updated document to corporate requirements

S New logo

Figure 10

1/0

WIRE

SIZE,

AWG

CRIMP HEIGHT

DIMENSION

RANGE

CRIMP HEIGHT

MEASUREMENTH

MEASUREMENTS

“A” + “B” =

CRIMP HEIGHT

DIMENSION

Crimp Height Measurements

(Tool Handles Properly Adjusted. See paragraph 7.2, B)

“A”

“B”

Measure at

Midpoints

of Flats

Avoid

Brazed

Seam

Cross Section

of Crimped Wir e

Barrel

“A” + “B” = Crimp

Height Dimension

“A”

H Tool handles properly adjusted.

10.46--11.05

[.412--.435]

13.00--13.59

[.512--.535]

16.23--16.92

[.639--.666]

19.41--20.14

[.764--.793]

22.63--23.42

[.891--.922]

NOTE

Part #	9245
Description	SWITCH P-P MOM NO 2POS CAP
Category	SWITCH
Availability	Out of Stock
Qty	0

9245

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