ROTO-CRIMP* Instruction Sheet Hand Crimp Hand Tools 600850 and 608850-1 408-1927 08 SEP 10 Rev D 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. 1. INTRODUCTION ROTACRIMP Hand Crimping Tools 600850 and 6008501 (shown in Figure 1) are used to apply SOLISTRAND* terminals and splices, Tubular terminals and splices, and CABLE MAKER* battery terminals onto stranded copper wire. Product CMA (circular mil area), applicable wire sizes, and wire strip engths are provided in Figure 2 and Figure 3. Dimensions in this instruction sheet are in metric NOTE units with U.S. customary units in brackets . Figures are not drawn to scale. i Do NOT use these tools on aircraft applications or DANGER on aluminum wire terminations. STOP Tool must be stored with the dies in the EA (1/0) DANGER position to eliminate tension on the handles. STOP Reasons for reissue of this instruction sheet are provided in Section 8, REVISION SUMMARY. 2. DESCRIPTION Refer to Figure 1. The hand crimping tools feature two rotating crimping dies that are held in place by springloaded indexing pins. Each die is positioned using a springloaded die locator pin. Wire size designations are embossed on the crimping dies to ensure proper setting of the crimping area, and a die order chart is included on the tool for reference. The dies are positioned according to the die order chart as shown in Figure 1. 3. CRIMPING PROCEDURE For Tubular and SOLISTRAND Terminals and Splices 3.1. Die Setting 1. Open the tool handles. 2. Check the die order chart on the tool and select the left (L) and right (R) die letters for the wire size being used. Refer to Figure 1. 3. Depress the springloaded indexing pins and rotate the desired size dies into crimping Figure 1 position. The embossed die letters must match as shown in Figure 1. 2010 Tyco Electronics Corporation, Berwyn, PA This controlled document is subject to change. TOOLING ASSISTANCE CENTER 1-800-722-1111 1 of 13 All Rights Reserved For latest revision and Regional Customer Service, PRODUCT INFORMATION 1-800-522-6752 TE logo and Tyco Electronics are trademarks. visit our website at www.tycoelectronics.com *Trademark. Other products, logos, and company names might be trademarks of their respective owners. LOC B408-1927 SOLISTRAND Terminals and Splices WIRE STRIP LENGTH (mm in. ) TERMINAL OR SPLICE APPROX WIRE 2) SIZE TERMINAL BUTT SPLICE PARALLEL SPLICE WIRE SIZE RANGE (mm (AWG) CMA ) MIN MAX MIN MAX MIN MAX 6.610.5 8.33 9.12 10.32 11.11 10.32 11.11 8 13,10020,800 .328 .359 .406 .438 .406 .438 10.516.7 9.92 10.71 11.90 12.70 11.11 11.90 6 .391 .422 .469 .50 .438 .469 20,80033,100 16.726.6 11.50 12.30 13.49 14.28 13.49 14.28 4 33,10052,600 .453 .484 .531 .562 .531 .562 26.642.4 13.09 13.89 15.08 15.87 15.08 15.87 2 52,60083,700 .515 .547 .594 .625 .594 .625 42.460.5 18.65 20.24 15.87 17.46 17.46 19.05 1/0 83,700119,500 .734 .797 .625 .688 .688 .75 60.576.2 18.65 20.24 15.87 17.46 17.46 19.05 2/0 119,500150,500 .734 .797 .625 .688 .688 .75 76.2-96.2 19.05 20.63 17.46 19.05 17.46 19.05 3/0 150,5000-190,000 .75 .812 .688 .75 .688 .75 96.2-117.0 19.44 20.63 17.46 19.05 19.05 20.63 4/0 190,000-231000 .765 .812 .688 .75 .75 .812 Figure 2 4. When the correct size dies are in position, 3.3. Performing Single Crimp on Terminals and Splices release the indexing pins. Make sure that the die With Wire Sizes 8 through 4 AWG locator pins return fully to their seated position See Figure 4. and are visible at the points indicated in Figure 1. Make sure that the wire size stamped on the NOTE terminal or splice corresponds with the wire size 3.2. Wire Preparation and Loading code embossed on the tool dies. i 1. Strip the wire(s) to the dimensions indicated in either Figure 2 or Figure 3. Do NOT use wires 1. Center the wire barrel of the terminal or splice with nicked or missing strands. in the dies. For best results, position the brazed 2. Select the proper size terminal or splice for seam of SOLISTRAND terminals against one of the wire size being used. the flats of the dies, as shown in Figure 4. 3. Determine the correct terminal or splice wire 2. Close the tool handles until the terminal or loading by referring to the terminal or splice wire splice is held firmly in place. Do not deform the size range listed in Figure 2 or Figure 3. The wire barrel. total area of the wires being used must be within 3. Insert the stripped wire into the terminal or the terminal or splice specified range. splice until the wire conductor is at least flush with, or is extending beyond, the end of the wire barrel, as shown in Figure 4. Rev D 2 of 13