TE Connectivity TERMI-FOIL 68026 Bedienungsanleitung

TE logo and Tyco Electronics are trademarks.

*Trademark. Other products, logos, and company names might betrademarks of their respective owners.

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.tycoelectronics.com

1of 4

LOC B

TERMI-FOIL* Hand Crimping

Tool 68026 408-2363

12 MAR 12 Rev J

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

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 INFO at the

number at the bottom of this page.

1. INTRODUCTION

TERMI-FOIL 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.

Dimensions in this instruction sheet are in metric

units [with U.S. customary units in brackets].

Figures are not drawn to scale.

NOTE

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.

The dies bottom before the ratchet releases. DO

NOT re-adjust the ratchet.

3. CRIMPING PROCEDURE

Depending on the foil and the terminal

configuration,itmaybenecessarytocrimp thewire

barrelbeforecrimping thetab end.See Figure2 for

wire-to-toolingcross-referenceforcrimpingthewire

barrel. The applicable wire size range is stamped

on the product package label. For information on

usingthe tooling,refer to theinstructions packaged

with the tooling.

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.

TERMI-FOIL TERMINAL AND SPLICE

TYPE PART

NUMBER MATERIAL AND FINISH

Double-Face

Terminal 329860 Nickel-Plated Copper

330003 Tin-Plated Copper

Flag Terminal 52584 Tin-Plated Copper

Splice 51943 Tin-Plated Copper

(Unannealed)

329656 Tin-Plated Copper

Jaws

Ratchet

Handles

Crimping

Dies

NOTE

CAUTION

NOTE

ORIGINAL INSTRUCTIONS

408-2363

2of 4

Rev J

DO NOT CONTINUE TO SQUEEZE THE TOOL

HANDLES AFTER THE RATCHET RELEASES.

Damagewill occur tothe tool if theratchet is forced

against the stop pin.

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.

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.

DO NOT CONTINUE TO SQUEEZE THE TOOL

HANDLES AFTER THE RATCHET RELEASES.

Damagewill occur to thetool if theratchet is forced

against the stop pin.

5. Remove the crimped terminal 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. Crimp the wire barrel using the appropriate

tooling (refer to Figure 2) according to the

instructions packaged with the tooling.

Figure 4

4. INSPECTION AND MAINTENANCE

4.1. Daily Maintenance

It is recommended that each operator of the tool be

made aware of-and responsible for-the following steps

of daily maintenance:

1. Remove dust, moisture, and other contaminants

with a clean brush or a soft, lint-free cloth. DO NOT

use objects that could damage the tool.

2. Make sure the proper retaining pins are in place

and secured with the proper retaining rings.

WIRE

SIZE

RANGE

(AWG)

HAND

TOOL

CRIMP HEAD

PNEUMATIC

TOOL 69010 PNEUMATIC

TOOL 69005

22-16 69997 N A N A

16-14 49935 300583 300454

12-10 49935 300583 300454

8 69355 38394 300454

CAUTION

Double-Face Terminal or Splice

Detail A

Detail B

Tab End

Foil

Wire Barrel Not

Between Dies

Tab End Completely

Covered by Dies

CAUTION

Detail A

Detail B

Wire Barrel Not

Between Dies

Tab End Completely

Covered by Dies

Foil Between

Faces of Tab End

13.84 [.545] Max.

Tab End Length

408-2363

3of 4

Rev J

3. Make certain all pins, pivot points, and bearing

surfaces are protected with a THIN coat of any good

SAE 20 motor oil. DO NOT oil excessively.

4. When the tool is not in use, keep the handles

closed to prevent objects from becoming lodged in

the crimping dies. Store the tool in a clean, dry area.

4.2. Periodic Inspection

Regular inspections should be performed by quality

control personnel. A record of scheduled inspections

should remain with the tool and be supplied to

personnel responsible for the tool. Though

recommendations call for at least one inspection a

month, the inspection frequency should be based on

the amount of use, ambient working conditions,

operator training and skill, and established company

standards. These inspections should be performed in

the following sequence:

A. A.Visual Inspection

1. Remove all lubrication and accumulated film by

immersing the tool (handles partially closed) in a

suitable commercial degreaser that will not affect

paint or plastic material.

2. Make certain all retaining pins are in place and

secured with retaining rings. If replacements are

necessary, refer to Section 5, REPLACEMENT

AND REPAIR.

3. Close the tool handles until the ratchet releases,

then allow handles to open freely. If they do not

open quickly and fully, the spring is defective and

must be replaced. See Section 5, REPLACEMENT

AND REPAIR.

DO NOT CONTINUE TO SQUEEZE THE TOOL

HANDLES AFTER THE RATCHET RELEASES.

Damagewill occur tothe tool if theratchet is forced

against the stop pin.

4. Inspect the head assembly, with special

emphasis on checking for worn, cracked, or broken

jaws. If damage to any part of the head assembly is

evident, the tool must be evaluated and repaired.

See Section 5, REPLACEMENT AND REPAIR.

B. Jaw Closure Inspection

This inspection requires the use of a plug gage

conforming to the dimensions in Figure 5. Proceed as

follows:

1. Knock out the roll pins securing dies to jaws, then

remove dies.

2. Close the tool handles to the last notch on the

ratchet (the handles will automatically open if they

are closed beyond this point).

3. Align the GO element with the tool jaws. Push the

GO element straight into the jaw closure without

using force. The GO element must pass completely

through the jaw closure as shown in Figure 5.

4. Align the NO-GO element with the jaw closure

and try to insert it into the jaw closure. The NO-GO

element may start entry but must not pass

completely through the jaw closure as shown in

Figure 5.

5. Re-install the dies and secure them with the roll

pins.

If the jaw closure conforms to the gage inspection, the

tool is considered dimensionally correct and should be

lubricated with a THIN coat of any good SAE 20 motor

oil. If not, the tool must be repaired before returning it

to service (see Section 5, REPLACEMENT AND

REPAIR).

C. Ratchet Inspection

This inspection requires the use of a plug gage

conforming to the dimensions in Figure 5. Proceed as

follows:

1. Knock out the roll pins securing dies to jaws,

remove dies, then insert the NO-GO element

between tool jaws.

Figure 5

CAUTION

PLUG GAGE DIMENSION

GO ELEMENT NO-GO ELEMENT

6.680-6.688 [.2630-.2633] 7.059-7.061 [.2779-.2780]

Suggested Plug Gage Design

76.2 [3.00]

4.8 x 4.8 [.19 x .19]

(45° Ref)

4.8 [.19]

NO-GO

Dim. GO

Dim.

Gaging the Jaw Closure

Jaw

Closure

Jaw

Closure

GO Element NO-GO Element

GO element must pass

completely through jaw

closure.

NO-GO element may enter

partially, but must not pass

completely through jaw closure.

Radius

NO-GO GO

408-2363

4of 4

Rev J

2. Close the tool handles until the ratchet releases

then allow handles to open freely, and observe the

following:

a. Handles open before the ratchet hits the

dowel pin.

b. Jaws grasp the NO-GO element.

If above conditions are met, the ratchet is

performing satisfactorily. If not, see Section 5,

REPLACEMENT AND REPAIR.

3. Re-install the dies, and secure them with the roll

pins.

5. REPLACEMENT AND REPAIR

Customer-replaceable parts are listed in Figure 6. 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 Connectivity to ensure quality and

reliability. Order replacement parts through your

representative, or call 1-800-526-5142, or send a

facsimile of your purchase order to 717-986-7605, or

write to:

CUSTOMER SERVICE (038-035)

TYCO ELECTRONICS CORPORATION

PO BOX 3608

HARRISBURG PA 17105-3608

For customer repair service, contact a representative

at 1-800-526-5136.

6. REVISION SUMMARY

Since the previous revision of this document, the

following changes were made:

•Updated dimension in table in Figure 5

Figure 6

REPLACEMENT PARTS

ITEM PART NUMBER DESCRIPTION QTY PER TOOL

1 21045-3 RING, Retaining 4

2 1-23619-6 PIN, Retaining 2

3 2-23620-9 PIN, Retaining 1

4 21045-6 RING, Retaining 2

5 39364 SPRING 1

6 1-21919-1 PIN, Dowel 1

7 6-21028-8 PIN, Roll 2

8 305956-8 ANVIL, Die 2

63.5 [2.50]

12.7 [.50] 279 [11]

Weight 404 g [13 oz]

1234

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