Instruction Sheet ROTOCRIMP* Hand Crimping Tools 4081927 600850 and 6008501 14 AUG 03 Rev C 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 extendeduse, production operations is available. 1. INTRODUCTION Embossed Letters Must Mate as Shown ROTACRIMP Hand Crimping Tools 600850 and Die Locator Pin in Die Order Chart 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 lengths are provided in Figures 2 and 3. E A Dimensions in this instruction sheet are in metric NOTE units with U.S. customary units in brackets . Die Figures are not drawn to scale. Indexing Do NOT use these tools on aircraft applications Pin DANGER or on aluminum wire terminations. Tool must be stored with the dies in the EA (1/0) DANGER position to eliminate tension on the handles. Reasons for reissue of this instruction sheet are provided in Section 8, REVISION SUMMARY. * 2. DESCRIPTION (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 Store Tool in locator pin. Wire size designations are embossed on This Setting the crimping dies to ensure proper setting of the crimping area, and a die order chart is included on the Die Order Chart tool for reference. The dies are positioned according to the die order chart as shown in Figure 1. 3. CRIMPING PROCEDURE Wire Size 8 AWG Wire Size 6 AWG For Tubular and SOLISTRAND Terminals and Splices Wire Size 4 AWG Wire Size 2 AWG 3.1. Die Setting 1. Open the tool handles. 2. Check the die order chart on the tool and select Wire Size 1/0 AWG Wire Size 2/0 AWG 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 position. The embossed die letters must match as shown in Wire Size 3/0 AWG Wire Size 4/0 AWG Figure 1. 4. When the correct size dies are in position, release the indexing pins. Make sure that the die locator pins return fully to their seated position and Figure 1 are visible at the points indicated in Figure 1. 2003 Tyco Electronics Corporation, Harrisburg, PA This controlled document is subject to change. TOOLING ASSISTANCE CENTER 18007221111 1 of 12 For latest revision, call the FAX/PRODUCT INFO number. FAX/PRODUCT INFO 18005226752 All International Rights Reserved AMP and Tyco are trademarks. *Trademark For Regional Customer Service, visit our website at LOC B Other products, logos, and company names used are the property of their respective owners. www.tycoelectronics.comROTOCRIMP Hand Crimping Tools 600850 and 6008501 4081927 SOLISTRAND Terminals and Splices Ring Terminal Butt Splice Parallel Splice WIRE STRIP LENGTH (mm in. ) TERMINAL APPROX OR SPLICE WIRE BUTT PARALLEL TERMINAL WIRE SIZE RANGE SIZE SPLICE SPLICE 2 (mm CMA ) (AWG) 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 20,80033,100 .391 .422 .469 .50 .438 .469 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 76.296.2 19.05 20.63 17.46 19.05 17.46 19.05 3/0 150,500190,000 .75 .812 .688 .75 .688 .75 96.2117.0 19.44 20.63 17.46 19.05 19.05 20.63 4/0 190,000231,000 .765 .812 .688 .75 .75 .812 Figure 2 Tubular Terminals and Splices Ring Terminal Parallel Splice Butt Splice WIRE STRIP LENGTH (mm in. ) TERMINAL APPROX OR SPLICE WIRE INLINE BUTT PARALLEL TERMINAL WIRE SIZE RANGE SIZE SPLICE SPLICE SPLICE 2 (mm CMA ) (AWG) MIN MAX MIN MAX MIN MAX MIN MAX 6.610.5 19.05 19.84 19.84 20.63 19.05 19.84 8 13,10020,800 .75 .781 .781 .812 .75 .781 10.516.7 19.05 19.84 19.84 20.63 19.05 19.84 6 20,80033,100 .75 .781 .781 .812 .75 .781 16.726.6 19.05 19.84 19.84 20.63 19.05 19.84 4 33,10052,600 .75 .781 .781 .812 .75 .781 26.642.4 19.05 19.84 22.22 23.02 22.22 23.02 2 52,60083,700 .75 .781 .875 .906 .875 .906 42.460.5 19.05 19.84 19.05 19.84 23.81 24.60 22.22 23.02 1/0 83,700119,500 .75 .781 .75 .781 .938 .906 .875 .906 60.576.2 19.05 19.84 19.05 19.84 24.60 25.40 22.22 23.02 2/0 119,500150,500 .75 .781 .75 .781 .969 1.00 .875 .906 76.296.2 20.63 21.43 20.63 21.43 26.19 26.98 25.40 26.19 3/0 150,500190,000 .812 .844 .812 .844 1.031 1.062 1.00 1.031 96.2117.0 20.63 21.43 20.63 21.43 32.54 33.33 25.40 26.19 4/0 190,000231,000 .812 .844 .812 .844 1.281 1.312 1.00 1.031 Figure 3 2 of 12 Rev C