Buell 2008 XB SERIES, Electrical Diagnostics Manual, Page: 213 / 288

A.4 DEUTSCH STANDARD TERMINALS
DEUTSCH STANDARD TERMINAL CRIMPS
TOOL NAME PART NUMBER
DEUTSCH TERMINAL CRIMP TOOL HD-39965-A
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-16 . 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.
NOTE
If the crimp tails are slightly out of vertical alignment, the crimp
tool automatically rotates the terminal so that the tails face
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
To Die
CRIMP TOOL DIE WIRE GAUGE (AWG)
Front 20
Middle 16-18
2
5
4
6
1
3
sm00021
4. 1. Insert stripped lead Open jaws and raise locking bar
2. 5. Insert terminal in locking bar Squeeze crimper
6. 3. Raise locking bar and remove terminal Release locking bar to lock terminal in die
Figure A-16. Crimping a Deutsch Standard Terminal
2008 Buell XB Diagnostics: Appendix A Connector Repair A-11