Instruction Sheet Hand Crimping Tool 68026 408-2363 for TERMI-FOIL* Product 27 OCT 14 Rev K 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. Crimping Dies Handles Ratchet Jaws TERMI-FOIL TERMINAL AND SPLICE TYPE PART NUMBER MATERIAL AND FINISH 329860 Nickel-Plated Copper Double-Face Terminal 330003 Tin-Plated Copper Flag Terminal 52584 Tin Plated Copper 51943 Tin-Plated Copper (Unannealed) Splice 329656 Tin-Plated Copper Figure 1 NOTE A complete list of current terminal and splice part numbers cannot be maintained on this document. For all part numbers and their description, refer to Catalog 82039 or contact PRODUCT INFORMATION at the number at the bottom of this page. 1. INTRODUCTION Hand Crimping Tool 68026 is designed to crimp the tab end of TERMI-FOIL terminals and splices (reference part numbers are listed in Figure 1) onto foil with a maximum thickness of 0.76 mm .020 in This tool is a member of the CERTI-CRIMP* hand crimping tool family. The ratchet on these tools ensures full crimping of the product. Once engaged, the ratchet will not release until the handles have been FULLY closed. NOTE Dimensions in this instruction sheet are in metric units with U.S. customary units in brackets . Figures and illustrations 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. DESCRIPTION The tool consists of two handles, a ratchet, and two jaws each with a crimping die. The crimping dies have flat faces which squeeze the lance-faced tab end of the terminal or splice into the foil. CAUTION The dies bottom before the ratchet releases. DO NOT re-adjust the ratchet. 3. CRIMPING PROCEDURE NOTE Depending on the foil and the terminal configuration, it may be necessary to crimp the wire barrel before crimping the tab end. See Figure 2 for wire-to-tooling cross-reference for crimping the wire barrel. The applicable wire size range is stamped on the product package label. For information on using the tooling, refer to the instructions packaged with the tooling. 2014 TE Connectivity family of companies TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. 1 of 5 All Rights Reserved PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, *Trademark visit our website at www.te.com. TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners. ORIGINAL INSTRUCTIONS 408-2363 3.1. Double-Face Terminal or Splice 1. Open tool handles FULLY. 2. Place the foil between faces of the tab end of terminal or splice, and squeeze the faces together manually. See Figure 3, Detail A. 3. Place the tab end and foil between the crimping dies as shown in Figure 3, Detail B. Make sure that the tab end is completely covered by the dies. DO NOT place the wire barrel between the dies. 4. Close the tool handles until the ratchet releases, then allow handles to open freely. CAUTION DO NOT CONTINUE TO SQUEEZE THE TOOL HANDLES AFTER THE RATCHET RELEASES. Damage will occur to the tool if the ratchet is forced against the stop pin. CRIMP HEAD WIRE SIZE RANGE HAND (AWG TOOL PENUMATIC TOOL 69010 PNEUMATIC TOOL 69005 22-16 69997 --- --- 16-14 49935 300583 300454 12-10 49935 300583 300454 8 69355 38394 300454 Figure 2 5. Remove the crimped terminal or splice from the tool. 6. For long-tongued terminals, several crimps will be necessary. These crimps should overlap to ensure that the entire tab end is crimped. 7. For terminals, crimp the wire barrel using the appropriate tooling (refer to Figure 2) according to the instructions packaged with the tooling. Double-Face Terminal or Splice Wire Barrel Not Detail A Detail B Between Dies Tab End Tab End Completely Foil Covered by Dies Figure 3 3.2. Flag Terminal 1. Open tool handles FULLY. 2. Place the tab end of the terminal between the crimping dies as shown in Figure 4, Detail A. Make sure that the tab end is completely covered by the dies. DO NOT place the wire barrel between the dies. 3. Place the foil between faces of the tab end of terminal. See Figure 4, Detail B. 4. Close the tool handles until the ratchet releases, then allow handles to open freely. CAUTION DO NOT CONTINUE TO SQUEEZE THE TOOL HANDLES AFTER THE RATCHET RELEASES. Damage will occur to the tool if the ratchet is forced against the stop pin. 5. Remove the crimped terminal from the tool. 2 of 5 Rev K