Buell S1 Lightning Workshop Manual page 322

CRIMPING INSTRUCTIONS
1. See Figure 7-49. Squeeze the handles to cycle the
DEUTSCH TERMINAL CRIMP TOOL (Part No. HD-
39965) to the fully open position.
2. Raise locking bar by pushing up on bottom flange. With
the crimp tails facing upward and the rounded side of the
contact barrel resting on the concave split level area of
the crimp tool, insert contact (socket/pin) through middle
hole of locking bar.
3. Release locking bar to lock position of contact. If the
crimp tails are slightly out of vertical alignment, the crimp
tool automatically rotates the contact so that the tails
face straight upward. When correctly positioned, the lock-
ing bar fits snugly in the space between the contact band
and the core crimp tails.
4. Strip lead removing 5/32 in. (4.0 mm) of insulation. Insert
wires between crimp tails until ends make contact with
locking bar. Verify that wire is positioned so that short
pair of crimp tails squeeze bare wire strands, while long
pair folds over insulation material.
5. Squeeze handle of crimp tool until tightly closed. Tool
automatically opens when the crimping sequence is
complete. Raise up locking bar and remove contact.
NOTE
Inspect the quality of the core and insulation crimps. Distor-
tion should be minimal.
1. Insert contact through middle
hole of locking bar.
Locking bar
x0007b7x
2. Insert stripped lead until it
contacts locking bar.
4. Raise locking bar and
remove contact.
Figure 7-49. Deutsch Crimping Procedure
x0014x7x
Pin
housing
Socket
housing
Figure 7-48. 3-pin Locking Wedge Orientation
3. Close and squeeze crimp tool.
5. Inspect quality of core and
insulation crimps.
Core crimp
Insulation crimp
Arrow points to
external latch
7-47