TE Connectivity TERMI-FOIL 68026 User manual

©2012 Tyco Electronics Corporation, Berwyn, PA
All Rights Reserved
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
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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
i
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
i
CAUTION
!
NOTE
i
ORIGINAL INSTRUCTIONS

408-2363
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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

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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

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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
56
7
8