TE Connectivity SOLISTRAND 69097 User manual

Instruction Sheet
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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
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
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
8
46146
46145
69216*
8.33 [.328]
9.12 [.359]
10.31 [.406]
11.13 [.438]
10.31 [.406]
11.13 [.438]
6
46134
46133
69217*
9.93 [.391]
10.72 [.422]
11.91 [.469]
12.7 [.500]
11.13 [.438]
11.91 [.469]
4
46135
69218*
11.13 [.438]
11.91 [.469]
13.49 [.531]
14.27 [.562]
13.49 [.531]
14.27 [.562]
2
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
4
69218-1
11.13 [.438]
11.91 [.469]
2
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)

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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
1
Lock screw
2
Retaining ring
3
Shank
4
Stationary die
5
Moving die
6
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.

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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)
1
Lock screw
2
Stationary die
3
Moving die
4
Flat on shank faces lock screw
5
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.

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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
1
End of conductor is flush with (or extends slightly
beyond) end of wire barrel
2
Barrel is centered in die
3
Brazed seam faces moving die
1
Half of splice is centered in die
2
End of conductor butts against splice wire stop
3
Brazed seam faces moving die

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Figure 6: Parallel splice
1
Barrel is centered in die
2
End of conductor is flush with (or extends slightly beyond)end of wire barrel
3
Brazed seam faces moving die

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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)
1
Wire insulation does not enter wire barrel.
2
Crimp is centered. Crimp can be off center, but not off the end of the wire barrel.
3
Wire is visible through inspection hole of butt splice. Wire is flush with (or extends slightly
beyond) end of terminal wire barrel.
4
AWG wire size matches wire size stamped on terminal or splice and crimping dies.
5
On parallel splice, bare wire ends are flush with (or extend slightly beyond) end of barrel.
Figure 8: Features of a poor crimp (REJECT)
1
Crimp is off end of wire barrel.
2
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.
3
AWG wire size does not match wire size stamped on terminal or splice crimping dies.
4
Wire insulation enters barrel. Check for incorrect strip length.
5
Nicked or missing conductor strands.
6
Excessive flash on terminal or splice indicates wrong combination of wire, terminal,
splice, or tooling.

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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
1
Chipped
2
Flattened
3
Pitted

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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
1
Radius
5
NO GO dimension
2
GO dimension
6
Die closure configuration
3
Feature
7
Die closure dimension
4
Length
Table 3: GO / NO GO dimensions
Crimping
head
Die set
Die closure
dimension*
Gage member†dimension
GO
NO GO
GO
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

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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
1
Dies for the 69097 tool (bottomed, but not under pressure)
2
Dies for the 69099 and 1752868-1 tools (positioned at gage dimension)

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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
1
GO gage must pass completely through the die closure.
2
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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Figure 13: Die sets for crimping head 69097
Figure 14: Die sets for crimping
heads 69099 and 1752868-1
1
2
3
Stationary die
Moving die
Retaining ring
46134
46133
303825
46135
46136
46138
46137
46146
46145
Die set
1
2
Stationary die
Moving die
69216
307543-1
307544-1
69217
307543-2
307544-2
69218
307543-3
307544-3
45433
307543-4
307544-4
45436
307543-5
307544-5
45439
307543-6
307544-6
45442
307543-7
307544-7
45445
307543-8
307544-8
69218-1
307543-9
307544-9
45433-1
1-307543-5
307544-4
45436-1
1-307543-0
1-307544-0
9. REVISION SUMMARY
Revisions to this instruction sheet include:
Added crimping head 1752868-1.
Added 90° bend terminals for crimping heads 69099 and 1752868-1.
Reformatted to conform to current standard for instruction sheets.