ROTO-CRIMP* Hand Crmp Hand Tools Instructon Sheet 600850 and 608850-1 408-1927 08 SEP 10 PROPER USE GUIDELINES Cumulatve Trauma Dsorders can result from the prolonged use of manually powered hand tools. Hand tools are ntended for occasonal use and low volume applcatons. A wde selecton of powered applcaton equpment for extended-use, producton operatons s avalable. 1. INTRODUCTION ROTA CRIMP Hand Crmpng Tools 600850 and 600850 1 (shown n Fgure 1) are used to apply SOLISTRAND* termnals and splces, Tubular termnals and splces, and CABLE MAKER* battery termnals onto stranded copper wre. Product CMA (crcular ml area), applcable wre szes, and wre strp engths are provded n Fgure 2 and Fgure 3. Dmensons n ths nstructon sheet are n metrc unts [wth U.S. customary unts n brackets]. Fgures are not drawn to scale. DANGER STOP Do NOT use these tools on arcraft applcatons or on alumnum wre termnatons. DANGER STOP Tool must be stored wth the des n the E A (1/0) poston to elmnate tenson on the handles. Fgure 1 Reasons for ressue of ths nstructon sheet are provded n Secton 8, REVISION SUMMARY. 2. DESCRIPTION Refer to Fgure 1. The hand crmpng tools feature two rotatng crmpng des that are held n place by sprng loaded ndexng pns. Each de s postoned usng a sprng loaded de locator pn. Wre sze desgnatons are embossed on the crmpng des to ensure proper settng of the crmpng area, and a de order chart s ncluded on the tool for reference. The des are postoned accordng to the de order chart as shown n Fgure 1. 3. CRIMPING PROCEDURE For Tubular and SOLISTRAND Termnals and Splces 3.1. De Settng 1. Open the tool handles. 2. Check the de order chart on the tool and select the left (L) and rght (R) de letters for the wre sze beng used. Refer to Fgure 1. 3. Depress the sprng loaded ndexng pns and rotate the desred sze des nto crmpng poston. The embossed de letters must match as shown n Fgure 1. 2010 Tyco Electroncs Corporaton, Berwyn, PA TOOLING ASSISTANCE CENTER 1-800-722-1111 All Rghts Reserved PRODUCT INFORMATION 1-800-522-6752 TE logo and Tyco Electroncs are trademarks. *Trademark. Other products, logos, and company names mght be trademarks of ther respectve owners. Ths controlled document s subject to change. For latest revson and Regonal Customer Servce, vst our webste at www.tycoelectroncs.com 1 of 13 LOC B
SOLISTRAND Termnals and Splces TERMINAL OR SPLICE WIRE SIZE RANGE (mm 2) [CMA]) APPROX WIRE SIZE (AWG)] WIRE STRIP LENGTH (mm [n.]) TERMINAL BUTT SPLICE PARALLEL SPLICE MIN MAX MIN MAX MIN MAX 6.6 10.5 [13,100 20,800] 8 8.33 [.328] 9.12 [.359] 10.32 [.406] 11.11 [.438] 10.32 [.406] 11.11 [.438] 10.5 16.7 [20,800 33,100] 6 9.92 [.391] 10.71 [.422] 11.90 [.469] 12.70 [.50] 11.11 [.438] 11.90 [.469] 16.7 26.6 [33,100 52,600] 4 11.50 [.453] 12.30 [.484]] 13.49 [.531] 14.28 [.562] 13.49 [.531] 14.28 [.562] 26.6 42.4 [52,600 83,700] 2 13.09 [.515] 13.89 [.547] 15.08 [.594] 15.87 [.625] 15.08 [.594] 15.87 [.625] 42.4 60.5 [83,700 119,500] 1/0 18.65 [.734] 20.24 [.797] 15.87 [.625] [.688] [.688 60.5 76.2 [119,500 150,500] 2/0 18.65 [.734] 20.24 [.797] 15.87 [.625] [.688] [.688]] 76.2-96.2 [150,5000-190,000] 3/0 [.688] [.688]] ] 96.2-117.0 [190,000-231000] 4/0 19.44 [.765] [.688]] 4. When the correct sze des are n poston, release the ndexng pns. Make sure that the de locator pns return fully to ther seated poston and are vsble at the ponts ndcated n Fgure 1. 3.2. Wre Preparaton and Loadng 1. Strp the wre(s) to the dmensons ndcated n ether Fgure 2 or Fgure 3. Do NOT use wres wth ncked or mssng strands. 2. Select the proper sze termnal or splce for the wre sze beng used. 3. Determne the correct termnal or splce wre loadng by referrng to the termnal or splce wre sze range lsted n Fgure 2 or Fgure 3. The total area of the wres beng used must be wthn the termnal or splce specfed range. Fgure 2 3.3. Performng Sngle Crmp on Termnals and Splces Wth Wre Szes 8 through 4 AWG See Fgure 4. Make sure that the wre sze stamped on the termnal or splce corresponds wth the wre sze code embossed on the tool des. 1. Center the wre barrel of the termnal or splce n the des. For best results, poston the brazed seam of SOLISTRAND termnals aganst one of the flats of the des, as shown n Fgure 4. 2. Close the tool handles untl the termnal or splce s held frmly n place. Do not deform the wre barrel. 3. Insert the strpped wre nto the termnal or splce untl the wre conductor s at least flush wth, or s extendng beyond, the end of the wre barrel, as shown n Fgure 4. 2 of 13
If Tubular Termnals and Splces TERMINAL OR SPLICE SIZE WIRE RANGE (MM 2 [CMA]0 APPRX WIRE SIZE (AWG) WIRE STRIP LENGTH TERMINAL IN-LINE SPLICE BUTT SPLICE PARALLEL SPLICE MIN MAX MIN MAX MIN MAX MIN MAX 6.6-10.5 [13,000-20,000 8 -- -- [.781} 10.5-16.7 [20,800-33,100] 6 -- --- [.781} 16.7-26.6 [33,100-52,600] 4 -- -- [.781} 26.6-42.4 [52,600-83,700] 2 [.781 -- -- 22.22 [.875] 23.02 [.906] 22.22 [.875] 23.02 [.906] 42.4-60.5 [83,700-119,500] 1/0 23.81 [.938] 24.60 [.906] 22.22 [.875] 23.02 [.906] 60.5-76.2 [83,700-119,500] 2/0 24.60 [.969] 25.4 [1.00] 22.22 [.875] 23.02 [.906] 76.2-96.2 [150,500-190,000] 3/0 21.43 [.844] 21.43 [.844] 26.19 [1.031] 26.98 [1.062] 25.40 [1.00] 26.19 [1.031] 96.2-117.0 [190,000-231,000] 4. Close the tool handles untl the handles bottom. Open the handles and remove the crmped termnal or splce. 5. crmpng a butt splce, repeat the procedure for the opposte end of the splce. 6. Refer to Secton 5, CRIMP INSPECTION, to nspect the termnal or splce crmp. 3.4. Performng Dual Crmp on Termnals and Splces Wth Wre Szes 2 through 4/0 AWG (Fgure 5) A. Frst Crmp 4/0 21.43 [.844 Make sure that the wre sze beng used, the wre sze stamped on the termnal or splce, and the wre sze code embossed on the des all correspond. 1. Poston the end of the termnal or splce wre barrel n the des as shown n Fgure 5. Fgure 3 21.43 [.844] 32.54 [1.281} 33.33 [1.312] 25.40 [1.00] 26.19 [1.031] For best results, poston the brazed seam of the SOLISTRAND termnal aganst one of the flats of the des, as shown n Fgure 5. Make sure that the crmps do not overlap or go off ether end ofthe wre barrel. 2. Close the tool handles untl the termnal or splce s held n place. Do not deform the wre barrel. 3. Insert the strpped wre nto the termnal or splce wre barrel untl the end of the conductor s flush wth, or s extended slghtly beyond, the wre barrel. 4. Close the tool handles untl the handles bottom. B. Second Crmp 1. Move the termnal or splce nto poston for the second crmp, then close the tool handles to complete the crmp. Do not overlap the crmps. 3 of 13
Refer to Secton 5, CRIMP INSPECTION, to nspect the termnal or splce crmp. 3.5. Performng Dual Crmp on Butt Splces Wth Wre Szes 2 through 4/0 AWG (Fgure 5) Make sure that the wre sze beng used, the wre sze stamped on the butt splce, and the wre sze code embossed on the des all correspond. Fgure 4 6. Close the tool handles untl the handles bottom. Do not overlap the crmps. B. Thrd and Fourth Crmps 1. Poston the butt splce for the thrd crmp, as shown n Fgure 5. A. Frst and Second Crmps 1. Poston the end of the butt splce wre barrel n the des. For best results, poston the brazed seam of the SOLISTRAND butt splce aganst one of the flats of the des, as shown n Fgure 5. Make sure that the crmps do not overlap or go off ether end of the wre barrel. 2. Close the tool handles untl the butt splce s held n place. Do not deform the wre barrel. 3. Insert a properly strpped wre nto the frst end of the butt splce untl the wre bottoms aganst the splce wre stop. 2. Close the tool handles untl the butt splce s held n place. Do not deform the wre barrel. 3. Insert a properly strpped wre nto the opposte end of the butt splce untl the wre bottoms aganst the butt splce wre stop. 4. Close the tool handles untl the handles bottom. 5. Move the butt splce nto poston for the fourth crmp, as shown n Fgure 5. 6. Close the tool handles untl the handles bottom. Do not overlap the crmps. 7. Refer to Secton 5, CRIMP INSPECTION, to nspect the butt splce crmp. 4. Close the tool handles untl the handles bottom. 5. Move the butt splce nto poston for the second crmp, as shown n Fgure 5. 4 of 13
Crmpng Tubular or SOLISTRAND Butt Splces Crmpng Tubular or SOLISTRAND Parallel Splces Fgure 5 5 of 13
3.6. Performng Dual Crmp on Parallel Splces Wth Wre Szes 2 through 4/0 AWG (Fgure 5) A. Frst Crmp Make sure that the wre sze beng used, the wresze stamped on the parallel splce, and the wre sze code embossed on the des all correspond. 1. Poston the end of the parallel splce wre barrel n the des. For best results, poston the brazed seam of the SOLISTRAND parallel splce aganst one of the flats of the des, as shown n Fgure 5. Make sure that the crmps do not overlap or go off ether end of the wre barrel. 2. Close the tool handles untl the parallel splce s held n place. Do not deform the wre barrel. 3. Insert the properly strpped wre nto the wre barrel untl the ends of the conductors are flush wth, or extended slghtly beyond, the end of the wre barrel. 4. Close the tool handles untl the handles bottom. B. Second Crmp 1. Move the parallel splce nto poston for the second crmp and close the tool handles. Do not overlap the crmps. 2. Insert the properly strpped wre nto the wre barrel untl the ends of the conductors are flush wth, or extended slghtly beyond, the end of the wre barrel. 3. Refer to Secton 5, CRIMP INSPECTION, to nspect the parallel splce crmp. 4. CRIMPING PROCEDURE FOR CABLE MAKER BATTERY TERMINALS 4.1. De Settng Proper de poston s determned by the part number of the termnal beng crmped and by the number dsplayed n Area 1 of the termnal, as shown n Fgure 6. To set the de poston: 1. Open the tool handles. 2. Depress the sprng loaded ndex pns. 3. Rotate the des untl the embossed wre sze letters n each de crmp area match the code letters dsplayed n Area 1 of the termnal. 4. Release the ndexng pns, makng sure that the de locator pns return fully and are vsble at the ponts ndcated n Fgure 1. 4.2. Wre Preparaton and Loadng 1. Strp the wres to the dmensons ndcated n Fgure 6. CAUTION! Do not use wres wth ncked or mssng strands. 2. Select the proper termnal for the wre nsulaton dameter beng used. The nsulaton dameter must fall wthn the nsulaton dameter range for the termnal beng used. Refer to Fgure 6. 4.3. Crmpng Straght Termnals (Fgure 7) CAUTION Make sure that crmps do not overlap or go off the end of the wre barrel.! A. Frst Crmp 1. Poston the end of the straght termnal wre barrel n the des. 2. Close the tool handles untl the straght termnal s held n place. Do not deform the wre barrel. 3. Insert the properly strpped wre nto the straght termnal wre barrel untl the wre bottoms. 4. Close the tool handles untl the des bottom. B. Second Crmp 1. Move the straght termnal nto poston for the second crmp, then close the tool handles. 2. Refer to Secton 5, CRIMP INSPECTION, to nspect the straght termnal crmp. 4.4. Crmpng Flag Termnals (Fgure 7) CAUTION Make sure that crmps do not overlap or go off the end of the wre barrel.! A. Frst Crmp 1. Orent and poston the flag termnal n the tool des as shown n Fgure 7. 2. Close the tool handles untl the flag termnal s held n place. Do not deform the wre barrel. 3. Insert the properly strpped wre untl the end of the conductor s flush wth, or extends about 0.79 mm [.0312 n.] beyond, the end of the termnal wre barrel. 4. Close the tool handles untl the des bottom. B. Second Crmp 1. Move the flag termnal nto poston for the second crmp. Refer to Fgure 7. Close the tool handles to complete the crmp. 2. Refer to Secton 5, CRIMP INSPECTION, to nspect the flag termnal crmp. 6 of 13
Straght Termnal CABLE MAKER Battery Termnals Area 1 (Tool De Settng) 20.64-21.43 mm [.812-.844 n.] Wre Strp Length Area 2 (Tool De Settng) Flag Termnals (Standard Barrel) : Not to Scale. Area 2 (Tool De Settng) Length of Wre Barrel +0.795 mm [+.030 n.] Wre Strp Length Area 1 (Tool De Settng) Flat Termnal (Left Hand) Area 1 (Tool De Settng) Flat Termnal (Rght Hand) Flat Termnal (Long Barrel) Area 1 (Tool De Settng) 18.26- mm [.719-.750 n.] Wre Strp Length 18.26- mm [.719-.750 n.] Wre Strp Length Length of Wre Barrel +0.795 mm [+.030 n.] Wre Strp Length STRAIGHT TERMINAL STANDARD BARREL FLAG TERMINALS LONG BARREL LEFT HAND RIGHT HAND WIRE DIAMETER RANGE (mm [n.}) TOOL DIE SETTING (See Area 1 on Termnaal 29251 -- -- -- -- 29253 -- -- -- -- 29245-3 -- 29717-1 601305-1 601305-2 29245-5 -- 29717-2 601305-3 601305-4 29249 -- -- -- -- 29249-3 -- -- -- -- 29249-5 -- -- -- -- 29243 29705 29716-1 601306-1 601306-2 29711 -- 29716-2 601306-3 601306-4 29712 29706 -- -- -- 29702 -- 29718-1 -- -- 29713 -- 29718-2 -- -- 29714 -- 29709 -- 608792-4 29715 -- 29710 -- 608794-4 Fgure 6 5.562-6.908 [.219-.272] 4.749-5.537 [.187-.218] 9.779-10.972 [.385-.432] 6.934-8.763 [.273-.345] 10.998-12.115 [.433-.477] 12.141-13.614 [.478-.536] 13.639-16.383 [.537-.645] J-H K-K E-A H-H A-C A-B A-A 7 of 13
CABLE MAKER Battery Termnals 5. CRIMP INSPECTION Inspect crmped termnals and splces by checkng the features descrbed n Fgures 8 and 9. Use only termnals and splces that meet the condtons descrbed. Damaged product should not be used. 6. MAINTENANCE AND INSPECTION Hand tools are nspected before shpment. The tool receved should be nspected mmedately upon arrval to ensure that t has not been damaged durng shpment, and that t performs accordng to the crtera descrbed n ths sheet. If the tool s damaged upon arrval, retan the shppng contaner, fle a clam wth the carrer, and notfy Tyco Electroncs mmedately. 6.1. Daly Mantenance 1. Remove dust, mosture, and other contamnants from the tool wth a clean brush or a soft, lnt free cloth. Do NOT use objects that could damage the tool. 2. Make certan that all pns, pvot ponts, and bearng surfaces are protected wth a THIN coat of any good SAE 20 motor ol. Do NOT ol excessvely. Fgure 7 3. When the tool s not n use, keep the handles closed to prevent objects from becomng lodged n the crmpng areas and store the tool n a clean, dry area. 6.2. Perodc Inspecton Regular nspectons should be performed by qualty control personnel. A record of scheduled nspectons should reman wth the tool or be suppled to personnel responsble for the tool. Though recommendatons call for at least one nspecton per month, the nspecton frequency should be based on the amount of use, workng condtons, operator tranng and skll, and establshed company standards. These nspectons should be performed n the followng sequence: A. Vsual Inspecton 1. Remove all lubrcaton and accumulated flm by mmersng the tool (handles partally closed) n a sutable commercal degreaser that wll not affect pant or plastc materal. 2. Make certan that all parts are securely n place. If replacements are necessary, refer to Secton 7. 8 of 13
3. Inspect crmpng areas for chpped or cracked surfaces. Fgure 8 B. Handle Adjustment Inspecton (Fgure 10) The handle adjustment should be checked to ensure that the des are bottomng fully. The handle adjustment feature s provded to compensate for normal de wear. 9 of 13
To check the handle adjustment: 1. Open the tool handles fully. 2. Rotate the des nto adjustment poston (De Settng E A). 3. Close the tool handles untl the des are touchng, but not under pressure. 4. Measure the dstance between the tool handles, as shown n Fgure 10. The measurement must be between 34.92 and 41.27 mm [1.375 and 1.625 n.]. If the adjustment does not fall wthn ths range, the adjustment must be tghtened or loosened as necessary. To loosen the adjustment: a.turn both adjustment (ADJ) screws counterclockwse approxmately one half to three quarter turn. b.slghtly loosen both lock (LOCK) screws by turnng them counterclockwse. c.flex the tool by openng and closng the tool handles. Fgure 9 d.tghten both lock screws. e.close the tool handles untl the des are touchng, but not under pressure. Check the measurement between the tool handles. If necessary, repeat the adjustment procedure To tghten the adjustment:. a.turn both lock (LOCK) screws counterclockwse approxmately one half to three quarter turn. b.turn both adjustment (ADJ) screws clockwse approxmately one half to three quarter turn. c.flex the tool by openng and closng the tool handles. d.tghten both lock (LOCK) screws. Fgure 10 e.close the tool handles untl the des are touchng but not under pressure. Check the measurement between the tool handles and repeat the adjustment procedure f necessary f. 10 of 13
Des n Settng E - A Des Touchng But Not Under Pressure nformaton on obtanng customer repar servce. Crmp Heght Measurements (Tool Handles Properly Adjusted. See Paragraph 6.2,B.) Adjustment Screws Lock Screws Measure at Mdponts of Flats Avod Brazed Seam 34.92-41.27 mm [1.375-1.625 n.] Cross Secton of Crmped Wre Barrel Fgure 10 C. Crmp Heght Inspecton (Fgure 11) Crmp heght nspectons should be performedperodcally to determne f the tool s mantanng proper crmpng dmensons. To check the crmp heght: 1. Perform the handle adjustment nspecton as descrbed n Paragraph 6.2, B, Handle Adjustment Inspecton. Adjust the handles f necessary. 2. Crmp a properly prepared stranded wre n SOLISTRAND termnal or splce, as prevously descrbed. CAUTION Do not use wres wth mssng conductor strands.! 3. Usng a conventonal cone pont mcrometer, measure the crmp heghts at the mdponts of flats A and B, as shown n Fgure 11. The SUM of the two measurements equals the crmp heght dmenson. Do not allow the cone pont to enter the termnalbrazed seam. 4. Fgure 11 lsts the crmp heght dmenson (sum of A and B measurements) range for each wre sze. If the measured dmenson s wthn the lsted range, the de closure s consdered dmensonally correct. 5. If the measured crmp heght dmenson s not wthn the specfed range (and the tool handles are properly adjusted), refer to Secton 7 for WIRE SIZE (AWG) 8 6 4 2 1/0 2/0 3/0 4/0 Fgure 11 7. REPLACEMENT AND REPAIR CRIMP HEIGHT DIMENSION range (mm [n.]) 10.464 11.049 [.412.435] 13.004 13.589 [.512.535] 16.230 16.916 [.639.666] 19.405 20.142 [.764.793] 22.631 23.418 [.891.922 25.146 26.111 [.990 1.028] 28.854 30.022 [1.136 1.182] 32.562 33.833 [1.282 1.332] Customer replaceable parts are lsted n Fgure 12. A complete nventory should be stocked and controlled to prevent lost tme when replacement of parts s necessary. Parts other than those lsted should be replaced to ensure qualty and relablty. Order 11 of 13
replacement parts through your Tyco Electroncs Representatve, or call 1 800 526 5142, or send a facsmle of your purchase order to 717 986 7605, or wrte to: CUSTOMER SERVICE (038-035) TYCO ELECTRONICS CORPORATION PO BOX 3608 HARRISBURG PA 17105-3608 Snce the prevous release of ths nstructon sheet, the TE logo has been appled 12 of 13
ITEM PART NUMBER DESCRIPTION QTY PER TOOL 1 1-21004-2 SCREW, Shldr,.312 n. Da 2 2 604222-1 GUARD 1 3 604224-1 BUSHING 1 4 604223-1 PAWL 1 5 21021-5 NUT,.25 In. 2 6 986816-2 SPRING 1 7 604228-1 RACK 1 8 21021-1 NUT,.312 n. 1 9 604229-1 WASHER, Ant-Frcton 1 10 2-21004-1 SCREW, Shldr,.38 n. 1 11 600852 ASSEMBLY, De Indexng Pn 2 12 604274-1 GRIP, Handle 2 13 600881 DIE, Rght 1 14 600880 DIE, Left 1 15 2-21004-0 BOLT, Shldr 2 16 600862-2 BOLT, Shldr 2 17 21021-6 NUT 2 18 21021-7 NUT 2 Fgure 12 13 of 13