Deutsch Standard Terminal Repair - Buell XB 2008 Series Service Manual

DEUTSCH STANDARD TERMINAL REPAIR

DEUTSCH STANDARD TERMINAL CRIMPS
PART NUMBER
HD-39965-A DEUTSCH TERMINAL CRIMP TOOL
Preparing Wire Leads for Crimping
1. Use a shop gauge to determine gauge of wire lead.
2. Strip lead removing 5/32 in. (4.0 mm) of insulation.
Crimping Terminal to Lead
1. See Figure A-20. Squeeze the handles of the DEUTSCH
TERMINAL CRIMP TOOL (Part No. HD-39965-A) to open
the jaws. Push the locking bar (1) up.
2. Insert (2) terminal (socket/pin) through hole of the locking
bar, so that the rounded side of the contact barrel rests in
the nest (concave split level area) with the crimp tails
facing upward. To match the wire gauge to the crimp tool
die, refer to Table A-3.
3. Release locking bar to lock terminal in die.
If the crimp tails are slightly out of vertical alignment, the crimp
tool automatically rotates the terminal so that the tails face
sm00021
1
3
1. Open jaws and raise locking bar
2. Insert terminal in locking bar
3. Release locking bar to lock terminal in die
A-14 2008 XB Service: Appendix A Connector Repair
TOOL NAME
NOTE
2
4
Figure A-20. Crimping a Deutsch Standard Terminal
straight upward. When positioned, the locking bar fits snugly
in the space between the contact band and the core crimp tails.
4. Insert stripped wire core 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 the insulation.
5. Squeeze handle of crimp tool until tightly closed. Tool
automatically opens after the terminal is crimped.
6. Raise locking bar up and remove wire lead and terminal.
Inspecting Crimps
Inspect the wire core and insulation crimps. Distortion should
be minimal.
Table A-3. Deutsch Standard Terminal Crimp: Wire Gauge
WIRE GAUGE (AWG)
20
16-18
5
4. Insert stripped lead
5. Squeeze crimper
6. Raise locking bar and remove terminal
A.6
To Die
CRIMP TOOL DIE
Front
Middle
6