Instruction Sheet ROTA-CRIMP*HandCrimpingTools 408--2029 601075and601075-1 21APR 11 RevD PROPERUSEGUIDELINES CumulativeTraumaDisorderscanresultfromtheprolongeduseofmanuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume applications.Awideselectionofpoweredapplicationequipmentforextended--use,productionoperationsisavailable. 1. INTRODUCTION 3. CRIMPINGPROCEDUREFOR SOLISTRANDTERMINALS ANDSPLICES This instruction sheet covers TE Connectivity Hand 3.1. DieSetting (Figure 1) Crimping Tools 601075 and 601075--1, which are used to apply SOLISTRAND* and CABLE MAKER* 1. Open the tool handles. terminals to stranded copper wire. Figure 2 provides 2. Check the die order chart on the tool and select a list of applicable wire sizes, terminal or splice CMA the left (L) and right (R) die numbers for the wire range, and the appropriate minimum and maximum size being used. wire strip lengths for each wire size and connector type. Embossed Numbers Must Match Do NOT use these tools on aircraft applications NOTE or on aluminum wire terminations. Locator Locator Pin Pin i Reasons for reissue are provided in Section 9, REVISION SUMMARY. Indexing Pins 2. DESCRIPTION The hand crimping tools feature two rotating crimping dies that are held in place by spring--loaded indexing pins. Each die is positioned using a spring--loaded die locator pin. Wire size designations are embossed on the crimping dies to assure proper setting of the crimping area, and a die order chart is included on the Figure 1 tool for easy reference. SOLISTRANDTERMINALSANDSPLICES Ring Type Butt Splice Parallel Splice Terminal WIRESTRIPLENGTH BUTT PARALLEL TERMINALORSPLICE APPROX TERMINALS SPLICES SPLICES WWIIRREESSIIZZEERRANGEANGE,, WIRWIREESSIZEIZE,, 2 mm CMA AWG 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 17.46 .688 17.46 .688 19.05 .75 Figure 2 E2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company TOOLING ASSISTANCE CENTER 1--800--722--1111 This controlled document is subject to change. 1 of 10 All Rights Reserved PRODUCT INFORMATION 1--800--522--6752 For latest revision and Regional Customer Service, *Trademark visit our website at www.te.com LOCB TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners. ORIGINAL INSTRUCTIONS408-2029 3. Depress the spring--loaded indexing pins and 3.4. PerformingaDualCrimponSOLISTRAND rotate the desired size dies into crimping position. TerminalswithWireSize2and1/0 (Figure 4) The embossed die numbers must match. For best results, position the brazed seam of the NOTE terminal against one of the flats of the dies, as 4. When the correct size dies are in position, shown in Figure 4. Make sure that the crimps do release the indexing pins. Make sure that the die i not overlap or go off either end of the wire barrel. locator pins return fully and are visible at the points Make sure that the wire size being used, the wire indicated. size stamped on the terminal, and the wire size embossed on the dies all correspond. Always store the tool with the crimping dies in the NOTE No. 4 setting. A. FirstCrimp i 1. Position the end of the terminal or splice wire barrel in the dies as shown in Figure 4. 3.2. WirePreparationandLoading (Figure 2) 2. Close the tool handles until the terminal or splice is held in place. Do not deform the wire barrel. 1. Strip the wire(s) to the dimensions indicated. Do 3. Insert the stripped wire into the terminal or NOT use wires with nicked or missing strands. splices wire barrel until the end of the conductor is flush with, or is extended slightly beyond, the wire 2. Select the proper size terminal or splice for the barrel. wire size being used. 4. Complete the crimp by closing the tool handles 3. Determine the correct terminal or splice wire until they bottom. loading by referring to the CMA range listed. The B. SecondCrimp total CMA of the wires being used must be within the terminal or splices CMA range. 1. Move the terminal or splice into position for the second crimp, then close the tool handles to complete the crimp. Do not overlap the crimps. 3.3. PerformingaSingleCrimponWireSizes8 Through4 (Figure 3) 2. Refer to Section 5 and to Figure 7 for terminal and splice crimp inspection procedures. Make sure that the wire size stamped on the NOTE 3.5. PerformingaDualCrimponSOLISTRANDButt terminal or splice corresponds with the wire size SpliceswithWireSize2and1/0 (Figure 4) embossed in the tool dies. i For best results, position the brazed seam of the NOTE terminal against one of the flats of the dies, as 1. Center the wire barrel of the terminal or splice in shown in Figure 4. Make sure that the crimps do i the dies. For best results, position the brazed not overlap or go off either end of the wire barrel. seam against one of the flats of the dies, as Make sure that the wire size being used, the wire shown in Figure 3. size stamped on the terminal, and the wire size embossed on the dies all correspond. 2. Close the tool handles until the terminal or splice is held firmly in place. Do NOT deform the terminal A. FirstandSecondCrimps or splice wire barrel. 1. Position the end of the splice wire barrel in the dies. 3. Insert the stripped wire into the terminal or splice until the wire conductor is at least flush with, 2. Close the tool handles until the splice is held in or is extending beyond, the end of the wire barrel. place. Do not deform the wire barrel. 3. Insert a properly stripped wire into the first end of the splice until the wire bottoms against the 4. To complete the crimp, close the tool handles splice wire stop. until they bottom. Open the handles and remove the crimped terminal or splice. 4. Close the tool handles until they bottom to complete the crimp. 5. If terminating a butt splice, repeat the procedure 5. Move the splice into position for the second for the second splice end. crimp, as shown in Figure 4. 6. Refer to Section 5 and Figure 7 for terminal and 6. Close the tool handles to complete the crimp. splice crimp inspection procedure. Do not overlap the crimps. 2 of 10 Rev D