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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).
Die set numbers for
crimping head 69097
Wire
size
Stationary
Moving
AWG
die
die
8
46146
46145
6
46134
4
46135
46133
2
46136
1/0
46138
46137
—
—
2/0
—
—
3/0
—
—
4/0
* These dies can be used for STRATO-THERM™ heat resistant post-insulated terminals and splices.
© 2022 TE Connectivity Ltd. family of companies.
All Rights Reserved.
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and company names may be trademarks of their respective owners.
SOLISTRAND™ Crimping Dies
(Used in Crimping Heads 69097, 69099, and 1752868-1
Figure 1: Terminals and splices
1
Terminal
2
Butt splice
3
Parallel splices
4
Wire barrel for wire strip length (see Table 1 and Table 2)
Table 1: Crimping specifications
Die set
numbers for
crimping
Terminal
heads
69099 and
Minimum
1752868-1
69216*
8.33 [.328]
69217*
9.93 [.391]
69218*
11.13 [.438]
45433*
12.7 [.500]
45436*
45439*
19.05 [.750]
45442
45445
Table 2: Dies for 90° bend terminals
Wire
Die set numbers for
size
crimping heads
AWG
69099 and 1752868-1
4
69218-1
2
45433-1
1/0
45436-1
TOOLING ASSISTANCE CENTER 1-800-722-1111
PRODUCT INFORMATION 1-800-522-6752
Wire strip length for wire barrel
Butt splice
Maximum
Minimum
Maximum
9.12 [.359]
10.31 [.406]
11.13 [.438]
10.72 [.422]
11.91 [.469]
12.7 [.500]
11.91 [.469]
13.49 [.531]
14.27 [.562]
13.49 [.531]
15.09 [.594]
19.05 [.750]
19.84 [.781]
17.48 [.688]
18.26 [.719]
Wire strip length
for wire barrel
Minimum
Maximum
11.13 [.438]
11.91 [.469]
12.7 [.500]
13.49 [.531]
19.05 [.750]
19.84 [.781]
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.te.com.
Instruction Sheet
408-1697
)
Rev D
4 MAR 2022
Parallel splice
Minimum
Maximum
10.31 [.406]
11.13 [.438]
11.13 [.438]
11.91 [.469]
13.49 [.531]
14.27 [.562]
16.66 [.656]
17.48 [.688]
19.05 [.750]
19.84 [.781]
19.84 [.781]
20.62 [.812]
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Summary of Contents for TE Connectivity SOLISTRAND 69097
- Page 1 PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, All Rights Reserved. visit our website at www.te.com. TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and company names may be trademarks of their respective owners.
- Page 2 408-1697 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.
- Page 3 408-1697 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.
- Page 4 408-1697 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.
- Page 5 408-1697 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 5 of 11 Rev D...
- Page 6 408-1697 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.
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Page 7: Maintenance And Inspection
408-1697 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. - Page 8 408-1697 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.
- Page 9 408-1697 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) 9 of 11...
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Page 10: Replacement And Repair
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. 10 of 11 Rev D... -
Page 11: Revision Summary
408-1697 Figure 14: Die sets for crimping Figure 13: Die sets for crimping head 69097 heads 69099 and 1752868-1 Die set Stationary die Moving die Retaining ring Stationary die Moving die 46134 69216 307543-1 307544-1 46135 46133 69217 307543-2 307544-2 46136 303825 69218...