TE Connectivity 68321-1 User manual

©2012 Tyco Electronics Corporation, a TE Connectivity Ltd. company
All Rights Reserved
*Trademark
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or company names may be trademarks of their respective owners.
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Instruction Sheet
TOOLING ASSISTANCE CENTER 1-800-722-1111
PRODUCT INFORMATION 1-800-522-6752
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.te.com
408-2681
ROTA-CRIMP*
Crimping Tool
68321-1 13 APR 12 Rev C
Figure 1
1. INTRODUCTION
ROTA-CRIMP Crimping Tool 68321-1 (shown in
Figure 1) is used to crimp Series 75 Power Lock
Contact 53880-4 onto solid or stranded wire sizes 10,
8, or 6 AWG. Read these instructions thoroughly
before using the tool.
Dimensions in this instruction sheet are in
millimeters [with inches in brackets]. Figures and
illustrations are for reference only and are not
drawn to scale.
Reasons for reissue of this instruction sheet are
provided in Section 7, REVISION SUMMARY.
2. DESCRIPTION
The FRONT of the tool, into which the contact is
inserted, can be identified by the tool part number on
the link. The tool features a stationary die (6.35 mm
[.250 in.] wide F crimp nest), rotatable anvil die with
three settings, hold-down device, and contact locator.
The anvil must be set to the wire size being used. The
applicable wire size is stamped on the base of the
anvil die. When closed, the dies form one crimping
chamber.
The hold-down device and contact locator are
mounted on a metal strip. The metal strip must be
adjusted to accommodate the contact position during
the crimping process.
3. CRIMPING PROCEDURE
Refer to Figure 2, and strip the wire to within the
dimensions shown.
DO NOT use wires with missing or nicked
conductor strands.
Figure 2
Proceed as follows:
1. Open the tool head. Make sure that the anvil die
is locked in position and that the locator pin is visible
as shown in Figure 1. It is not necessary at this time
to set the anvil die to a specific wire size.
2. Place a sample contact in the nest of the
stationary die as shown in Figure 3. The open end
of the wire barrel must be aligned in the nest.
3. Loosen the two screws securing the hold-down
device and contact locator, and position the contact
locator over the contact tongue as shown in
Figure 3. Do not re-tighten the screws at this time.
The hold-down device and contact locator must be
properly adjusted so that the contact will remain
aligned during the crimping process.
4. Slowly close the tool head, making sure the
contact remains properly positioned in the nest. If
the contact is cocked or otherwise out of line, re-
align it before proceeding. The contact should
remain in the nest as shown in Figure 3. DO NOT
deform the wire barrel.
Locator Pin
Indexing Pin
Wire Size
Marking
Stationary
Die (Nest)
Anvil Die
Hold-Down
Device and
Contact Locator
Front of
Tool
NOTE
i
CONTACT WIRE SIZE (AWG) WIRE STRIP
LENGTH
53880-4 10, 8, 6 7.95-9.53
[.313-.375]
!
CAUTION
StripLength
Wire Barrel
Transition
Area
Series 75 Power Lock Contact
NOTE
i
ORIGINAL INSTRUCTIONS

408-2681
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Rev C
Figure 3
5. Crimp the contact by squeezing the tool handles.
Then tighten screws of the hold-down device and
contact locator. If the contact crimp is straight and
the wire barrel has not been damaged, the tool is
ready to use.
If the tool has been preset for wire size 10 AWG -
the smallest wire size-no further adjustment is
necessary, even though wire size 8 or 6 AWG is to
be terminated; the setting for wire size 10 will also
accommodatewiresize 8or 6.However,if theanvil
die is not set for wire size 10 and wire size 8 or 6 is
desired, then the anvil die should be set to the
appropriate wire size of either 8 or 6.
6. If the wire size marking is positioned for a wire
size other than desired, depress the anvil die
spring-loaded indexing pin and rotate the anvil die
until the desired size appears. Then release the
indexing pin and allow locator pin to snap into the
hole which locks the anvil die in place for the
desired size.
7. Open the tool head, and position the contact in
the nest, locating the outer end of the wire barrel
(wire-entry end) so that it extends from the nest
area between 0.76 to1.02 mm [.030 to .040 in.] as
shown in Figure 4.
Figure 4
8. Close tool head just enough to retain the contact;
then insert the wire into the wire barrel, making sure
the wire does not extend beyond the wire barrel.
See Figure 5.
Figure 5
9. Slowly squeeze the handles, making sure contact
remains aligned properly in the nest. It may be
necessary to open the handles slightly, allowing the
contact to be re-adjusted in the nest. Continue to
squeeze the handles to complete the crimp.
4. CRIMP INSPECTION
Inspected the crimped contact according to Figure 6.
Poorly crimped contacts can be avoided through
careful use of these instructions.
For a detailed inspection requirements, refer to
Application Specification 114-6032.
Figure 6
5. MAINTENANCE AND INSPECTION
5.1. Daily Maintenance
It is recommended that each operator of the tool be
made aware of-and responsible for-the following steps
of daily maintenance:
1. Remove dust, moisture, and other contaminants
with a clean brush, or a soft, lint-free cloth. DO NOT
use objects that could damage the tool.
WireConductorFlush
with or Recessed
Slightly in Wire Barrel
Wire Insulation Does
Not Enter Contact
Wire Barrel
Contact Must Retain
Proper Position in
Nest During Entire
Crimping Procedure
Configuration
of Nest
Wire Barrel
NOTE
i
Hold-Down Device and Contact Locator Screws
Torque of Contact
Fits in Slot
Wire Does Not Extend into
Contact Transition Area
Wire Barrel Extends
0.76-1.02[.030-.040]
from Nest
NOTE
i
Wire Strands Visible Here -
Insulation Must Not Enter
Wire Barrel Wire Strands Must Not
Extend Beyond this Area
or Above Wire Barrel
Crimp Inspection
Contact Must be
Straight in this Area

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Rev C
2. Make sure the proper retaining pins are in place
and secured with the proper retaining rings.
3. Make certain all pins, pivot points, and bearing
surfaces are protected with a THIN coat of any good
SAE 20 motor oil. DO NOT oil excessively.
4. When the tool is not in use, keep the handles
closed to prevent objects from becoming lodged in
the crimping dies and store the tool in a clean, dry
area.
5.2. Periodic Inspection
Regular inspections should be performed by quality
control personnel. A record of scheduled inspections
should remain with the tool or be supplied to personnel
responsible for the tool. Though recommendations call
for at least one inspection a month, the inspection
frequency should be based on the amount of use,
ambient working conditions, operator training and skill,
and established company standards. These
inspections should be performed in the following
sequence:
A. Visual
1. Remove all lubrication and accumulated film by
immersing the tool (handles partially closed) in a
suitable commercial degreaser that will not affect
paint or plastic material.
2. Make certain all retaining pins are in place and
secured with retaining rings. If replacements are
necessary, refer to Section 6.
3. Inspect the head assembly, with special
emphasis on checking for worn, cracked, or broken
dies. If damage to any part of the head assembly is
evident, refer to Section 6, for information on
obtaining further evaluation and repair. Examples of
possible damaged die closure surfaces are shown
in Figure 7.
Figure 7
B. Handle Adjustment
The handle adjustment should be checked to ensure
that the dies are bottoming properly. The handle
adjustment feature is provided to compensate for
normal tool wear. To check handle adjustment, first
close handles until dies are bottomed, but not under
pressure. Then measure the distance between
handles as shown in Figure 8.
Adjustment is too tight if measurement exceeds
35.05 mm [1.38 in.] Proceed as follows:
1. Turn both adjustment (ADJ) screws
counterclockwise approximately one-half to three-
quarter turn.
2. Turn, but do not remove, both lock (LOCK)
screws counterclockwise.
3. Flex tool by opening and closing the handles.
4. Tighten both lock screws.
5. Close the handles until the dies are bottomed but
not under pressure. Check the measurement
between the handles and, if necessary, repeat the
adjustment procedure.
Adjustment is too loose if measurement is less than
28.7 mm [1.13 in.]. Proceed as follows:
1. Turn both lock (LOCK) screws counterclockwise
approximately one-half to three-quarter turn.
2. Turn both adjustment (ADJ) screws clockwise
approximately one-half to three-quarter turn.
Figure 8
Broken Chipped
Pitted
DiesBottomed
but Not Under
Pressure
Adjustment
Screws (ADJ)
Lock Screws
(LOCK)
28.7-35.1
[1.13-1.38]

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Rev C
Figure 9
3. Flex tool by opening and closing handles.
4. Tighten both lock screws.
5. Close the handles until the dies are bottomed but
not under pressure. Check the measurement
between the handles and, if necessary, repeat the
adjustment procedure.
C. Gaging the Crimping Chamber
This inspection requires the use of plug gages
conforming to the dimensions provided in Figure 9.
To gage the crimping chamber, proceed as follows:
1. Remove traces of oil or dirt from the crimping
chamber and plug gage.
2. Perform handle adjustment procedure according
to Paragraph 5.2,B.
3. Close handles until dies are bottomed but not
under pressure.
4. Insert GO element into the crimping chamber; but
do not force it. The GO element must pass through
the length of the crimping chamber. See Figure 9.
5. In the same manner, try to insert the NO-GO
element into the crimping chamber. The NO-GO
element may enter partially, but must not pass
completely through the length of the crimping
chamber. See Figure 9.
If the crimping chamber conforms to the gage
inspection, the dies are considered dimensionally
correct and should be lubricated with a THIN coat of
any good SAE 20 motor oil. If the crimping chamber
does NOT conform to the gage inspection, the dies
must be returned for further evaluation and repair.
For additional information regarding the use of a plug
gage, refer to Instruction Sheet 408-7424.
6. REPLACEMENT AND REPAIR
Customer-replaceable parts are listed in Figure 10.
A complete inventory should be stocked and
controlled to prevent lost time when replacement of
parts is necessary. Parts other than those listed should
be replaced by TE Connectivity to ensure quality and
reliability. Order replacement parts through your
representative, or call 1-800-526-5142, or send a
facsimile of your purchase order to 717-986-7605, or
write to:
Suggested Plug Gage Design Inspection of Crimping Chamber
GO
Dim NO-GO
Dim Dies Bottomed But
Not Under Pressure
Crimping
Chamber
GO Element NO-GO Element
GO element must pass
completely through the
crimping chamber.
NO-GOelementmay enter
partially, but must not pass
completely through the
crimping chamber.
90°
3.017
[.1188]
Ref
0.5[.02]
R Max
0.13 ±0.03
[.005±.001]
Typ
“D” 25.4 [1.00] Typ
Die Closure
Configuration EnlargedEndView
of Gage Element
68321-1 F-CRIMP GAGE
WIRE
SIZE(AWG) GAGE ELEMENT DIMENSION D (Diameter)
GO NO-GO GO NO-GO
10 2.588-2.596 [.1019-.1022] 2.789-2.791 [.1098-.1099] 3.467-3.475 [.1365-.1368] 3.604-3.607 [.1419-.1420]
8 2.969-2.977 [.1169-.1172] 3.170-3.172 [.1248-.1249] 3.736-3.744 [.1471-.1474] 3.886-3.889 [.1530-.1531]
6 3.604-3.612 [.1419-.1422] 3.805-3.807 [.1498-.1499] 4.234-4.242 [.1667-.1670] 4.402-4.404 [.1733-.1734]

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Rev C
CUSTOMER SERVICE (038-035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
For repair service, contact a TE Representative at
1-800-526-5136.
7. REVISION SUMMARY
•Updated document to corporate requirements
•Changed dimension information in Figure 9
•Changed table in Figure 9
Figure 10
REPLACEMENT PARTS
ITEM PART NUMBER DESCRIPTION QTY PER TOOL
1 308990-1 PLATE, Side 3
2 308991-1 INDENTER 1
3 308992-1 ANVIL 1
4 601088 PLATE, Index 2
5 601089 PIN, Index 2
6 600091 RING, Retaining 2
7 601093 SPRING 1
8 21004-6 SCREW, Shoulder, .25 in. Dia x 1.25 in. L 1
9 1-21002-0 LOCKNUT, 10 x 24 2
10 601082 PLATE, Tie 2
11 1-21004-2 SCREW, Shoulder, .31 in. Dia x 1.00 in. L 2
12 21021-5 LOCKNUT, .25 in. x 20 2
13 600866-1 SPACER 2
14 601086 PIN, Aligning 1
15 1-21004-9 SCREW, Shoulder, .28 in. Dia. x 62 in. L 2
16 21021-6 LOCKNUT, .79 in. x 18 2
17 601078 ASSEMBLY, Handle 1
18 308990-2 PLATE, Side 1
19 21004-3 SCREW, Shoulder, .25 in. Dia x .62 in. L 1
20 314224-1 LOCATOR, Terminal 1
21 314225-1 TERMINAL, Hold Down 1
22 2-21000-9 SCREW, Socket Head, 8-32 x .75 in. L 2
23 21055-6 WASHER, Flat 2