TE Connectivity SOLISTRAND 69097 User manual

Instruction Sheet

1 of 11

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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.

408-1697

4 MAR 2022 Rev D

1. INTRODUCTION

This instruction sheet provides procedures for product application, maintenance, and inspection of

SOLISTRAND crimping dies, which are used in crimping heads 69097, 69099, and 1752868-1. These dies are

used to crimp SOLISTRAND terminals and splices onto solid or stranded copper wire in AWG sizes of 8-4/0

(see Table 1).

Figure 1: Terminals and splices

Terminal

Butt splice

Parallel splices

Wire barrel for wire strip length (see Table 1 and Table 2)

Table 1: Crimping specifications

Wire

size

AWG

Die set numbers for

crimping head 69097

Die set

numbers for

crimping

heads

69099 and

1752868-1

Wire strip length for wire barrel

Stationary

die

Moving

die

Terminal

Butt splice

Parallel splice

Minimum

Maximum

Minimum

Maximum

Minimum

Maximum

46146

46145

69216*

8.33 [.328]

9.12 [.359]

10.31 [.406]

11.13 [.438]

10.31 [.406]

11.13 [.438]

46134

46133

69217*

9.93 [.391]

10.72 [.422]

11.91 [.469]

12.7 [.500]

11.13 [.438]

11.91 [.469]

46135

69218*

11.13 [.438]

11.91 [.469]

13.49 [.531]

14.27 [.562]

13.49 [.531]

14.27 [.562]

46136

45433*

12.7 [.500]

13.49 [.531]

15.09 [.594]

19.05 [.750]

16.66 [.656]

17.48 [.688]

1/0

46138

46137

45436*

19.05 [.750]

19.84 [.781]

17.48 [.688]

18.26 [.719]

19.05 [.750]

19.84 [.781]

2/0

—

45439*

3/0

—

45442

4/0

—

45445

19.84 [.781]

20.62 [.812]

* These dies can be used for STRATO-THERM™ heat resistant post-insulated terminals and splices.

Table 2: Dies for 90° bend terminals

Wire

size

AWG

Die set numbers for

crimping heads

69099 and 1752868-1

Wire strip length

for wire barrel

Minimum

Maximum

69218-1

11.13 [.438]

11.91 [.469]

45433-1

12.7 [.500]

13.49 [.531]

1/0

45436-1

19.05 [.750]

19.84 [.781]

SOLISTRAND™ Crimping Dies

(Used in Crimping Heads 69097, 69099, and 1752868-1)

408-1697

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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 instructions packaged with the tools or contact the Tooling Assistance Center

number at the bottom of this page.

NOTE

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 9, REVISION SUMMARY.

2. INSERTING THE DIES

CAUTION

To avoid injury, disconnect the power unit from the power supply before changing dies.

2.1. Crimping head 69097

1. Loosen the lock screw in the top section of the crimping head (Figure 2).

NOTE

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.

Figure 2: Crimping head 69097

Lock screw

Retaining ring

Shank

Stationary die

Moving die

Ram locking screw

2. Insert the shank of the stationary die into the top section of the crimping head. The retaining clip holds

the die in place.

3. Activate the power unit to advance the ram until the lock screw is visible.

408-1697

Rev D

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4. Loosen the lock screw.

5. Insert the shank of the moving die into the ram well. The retaining ring holds the die in place.

6. Activate the power unit to complete the cycle and allow the ram to return to the DOWN position.

2.2. Crimping head 69099 and 1752868-1

1. Loosen the lock screw in the top section of the crimping head (Figure 3).

Figure 3: Crimping head 69099 (die set 69218 shown)

Lock screw

Stationary die

Moving die

Flat on shank faces lock screw

Ram locking screw

2. Insert the shank of the stationary die into the top section of the crimping head.

NOTE

Ensure that the dies are inserted fully and that the flats on the shanks are facing the lock screws.

3. Tighten the lock screw.

4. Loosen the ram lock screw.

5. Insert the shank of the moving die into the ram well.

6. Tighten the lock screw.

3. REMOVING THE DIES

Crimping head 69097: Insert the screwdriver blade under the base of the stationary and moving dies. Use a

prying action to loosen and remove the dies.

Crimping heads 69099 and 1752868-1: Loosen the lock screws in the top section of the crimping head and

ram. Remove the dies.

408-1697

Rev D

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4. STRIPPING THE WIRES

Strip the wire to the dimensions listed in Table 1.

CAUTION

Do not nick or cut the conductor strands.

5. CRIMPING

DANGER

Avoid personal injury. When operating the power unit, exercise caution while holding terminals, splices, or wire near the

crimping area.

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 Figure 3 through Figure 6. The crimping procedure is identical

when using crimping head 69097.

1. Place the terminal or splice in the stationary die as shown in Figure 4 through Figure 6. For best

results, position the terminal or splice so that the brazed seam faces the moving die.

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.

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 6, INSPECTING THE CRIMP for crimp inspection information.

7. NOTE

8. If SOLISTRAND terminals or splices stick in the die after crimping, use a rocking motion to remove them.

Figure 4: Terminal

Figure 5: Butt splice

End of conductor is flush with (or extends slightly

beyond) end of wire barrel

Barrel is centered in die

Brazed seam faces moving die

Half of splice is centered in die

End of conductor butts against splice wire stop

Brazed seam faces moving die

408-1697

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Figure 6: Parallel splice

Barrel is centered in die

End of conductor is flush with (or extends slightly beyond)end of wire barrel

Brazed seam faces moving die

408-1697

Rev D

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6. INSPECTING THE CRIMP

Inspect crimped terminals and splices by checking the features described in Figure 7 and Figure 8. Use only

the terminals and splices that meet the conditions shown in Figure 7. Poor crimps (Figure 8) can be avoided

through careful use of the instructions in sections 2 through 5, and by performing regular die maintenance as

instructed in section 7, MAINTENANCE AND INSPECTION.

Figure 7: Features of a good crimp (ACCEPT)

Wire insulation does not enter wire barrel.

Crimp is centered. Crimp can be off center, but not off the end of the wire barrel.

Wire is visible through inspection hole of butt splice. Wire is flush with (or extends slightly

beyond) end of terminal wire barrel.

AWG wire size matches wire size stamped on terminal or splice and crimping dies.

On parallel splice, bare wire ends are flush with (or extend slightly beyond) end of barrel.

Figure 8: Features of a poor crimp (REJECT)

Crimp is off end of wire barrel.

Wire is not inserted far enough into terminal or splice. End of wire is not visible through

inspection hole of butt splice, or is not flush with (or slightly beyond) end of terminal wire

barrel or parallel splice.

AWG wire size does not match wire size stamped on terminal or splice crimping dies.

Wire insulation enters barrel. Check for incorrect strip length.

Nicked or missing conductor strands.

Excessive flash on terminal or splice indicates wrong combination of wire, terminal,

splice, or tooling.

408-1697

Rev D

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7. MAINTENANCE AND INSPECTION

Perform a maintenance and inspection program at least once a month to ensure dependable and uniform

terminations. Frequency of inspection can be adjusted to suit your requirements through experience.

Frequency of inspection depends upon:

The care, amount of use, and handling of the dies.

The type and size of the products crimped.

The degree of operator skill.

The presence of abnormal amounts of dust or dirt.

Your own established standards.

Dies can be damaged during shipment. When you receive new dies, inspect them in accordance with the

following instructions.

7.1. Cleaning

Do not allow deposits of dirt, grease, and foreign matter to accumulate on the die closure surfaces or the

bottoming surfaces of the dies. These deposits can prevent the dies from bottoming fully and cause excessive

wear in the die closure surfaces, affecting the quality of the crimp. Wipe the dies clean frequently with a clean

cloth.

7.2. Visual inspection

Visually inspect the die closure surfaces for broken, pitted, or chipped areas (Figure 9). Even if the dies gage

within permissible limits, worn or damaged die closure surfaces are objectionable and can affect the quality of

the crimp.

Figure 9: Damaged die closure surfaces

Chipped

Flattened

Pitted

408-1697

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7.3. Die closure inspection

Every die set is inspected for proper die closure before packaging. Inspect the dies periodically to check the die

closure for excessive wear.

Plug gage design

The die closure inspection uses a GO / NO GO plug gage. Figure 10 shows a recommended plug gage design.

The GO / NO GO dimensions of the plug gage members are listed in Table 3.

Figure 10: Recommended plug gage design

Radius

NO GO dimension

GO dimension

Die closure configuration

Feature

Die closure dimension

Length

Table 3: GO / NO GO dimensions

Crimping

head

Die set

Die closure

dimension*

Gage member†dimension

NO GO

Radius

Length

Feature

69097

46145

46146

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]

46133

46134

3.937

[.1550]

4.089

[.1610]

3.937-3.945

[.1550-.1553]

4.087-4.089

[.1609-.1610]

4.34 [.171]

25.4 [1.000]

11.10 [.437]

46133

46135

4.724

[.1860]

4.877

[.1920]

4.724-4.732

[.1860-.1863]

4.874-4.877

[.1919-.1920]

5.54 [.218]

25.4 [1.000]

11.10 [.437]

46133

46136

5.436

[.2140]

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]

46137

46138

5.207

[.2050]

5.359

[.2110]

5.207-5.215

[.2050-.2053]

5.357-5.359

[.2109-.2110]

6.35 [.250]

31.75 [1.500]

14.27 [.562]

69099

and

1752868-1

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

69218-1

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

45433-1

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

45436-1

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]

* For the 69097 tool, die closure dimensions apply when dies are bottomed, but not under pressure. For the 69099 and 1752868-1 tools,

die closure dimensions apply when dies are positioned at the gage dimension indicated in Figure 11.

†Material: Tool steel

408-1697

Rev D

9 of 11

Preparing the dies for inspection

Before inspecting the die closure, prepare the dies as follows:

1. Clean oil and dirt from the die closure surfaces and plug gage members.

2. Position the dies as shown in Figure 11.

Figure 11: Positioning the dies for gaging

Dies for the 69097 tool (bottomed, but not under pressure)

Dies for the 69099 and 1752868-1 tools (positioned at gage dimension)

408-1697

Rev D

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Gaging the dies

The following procedure is recommended for inspecting the die closure.

1. Clean oil and dirt from the die closure surfaces and plug gage members.

2. With the crimping dies assembled as described in Preparing the dies for inspection, check the

wire barrel crimp die closure using the proper plug gage. Hold the gage in straight alignment with

the die closure and carefully try to insert it without forcing the GO member as shown in Figure 11.

The GO member must pass completely through the die closure as shown in Figure 12.

3. 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 12.

If the dies meet the GO / NO GO gage conditions, the dies can be considered dimensionally

correct.

If the dies do not conform with the GO / NO GO gage conditions, contact your local TE field

representative.

Figure 12: Gaging the dies

GO gage must pass completely through the die closure.

NO-GO gage can enter partially, but must not pass completely through the die closure.

8. REPLACEMENT AND REPAIR

Customer-replaceable parts are shown in Figure 13 and Figure 14 on page 11. Stock and control a complete

inventory 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 dies through your TE representative. You

can also order parts by any of the following methods:

Go to TE.com and click the Shop TE link at the top of the page.

Call 800-522-6752.

Write to:

CUSTOMER SERVICE (038-035)

TE CONNECTIVITY CORPORATION

PO BOX 3608

HARRISBURG PA 17105-3608

For customer repair services, call 800-522-6752.

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