Tyco Electronics ROTA-CRIMP 68321-1 User manual

Instruction Sheet
408-2681
LOC B
1 of 6
E 2008 Tyco Electronics Corporation, Harrisburg, PA
All International ights eserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
TOOLING ASSISTANCE CENTE 1-800-722-1111
P ODUCT INFO MATION 1-800-522-6752 This controlled document is subject to change. For latest revision and egional Customer Service,
visit our website at www.ty oele troni s. om
08 SEP 08 ev B
ROTA-CRIMP* Crimping Tool 68321-1
Figure 1
Stationary Die
(Nest)
Anvil Die
Hold-Down Device
and Contact Locator
Indexing
Pin
Front of Tool
Wire Size
Marking
Locator Pin
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 [ ith inches in brackets]. Figures are
not dra n 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 [.250]
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 ires ith missing or nicked
conductor strands.
Transition
Area Wire Barrel
Series 75 Power Lock Contact
Strip Length
CONTACT WIRE SIZE (AWG) WIRE STRIP
LENGTH
53880-4 10, 8, 6 7.95-9.53
[.313-.375]
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-do n device and contact locator must
be properly adjusted so that the contact ill
remain aligned during the crimping process.
NOTE
i
NOTE
i
NOTE
i
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408-2681
ROTA-CRIMP Crimping Tool 68321-1
Rev B2 of 6 Tyco Electronics Corporation
Figure 3
Wire Conductor Flush
With or Recessed
Sli htly in Wire Barrel
Wire Insulation Does
Not Enter Contact
Wire Barrel
Wire
Barrel
Confi uration
of Nest
Contact Must Retain Proper
Position in Nest During Entire
Crimping Procedure
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.
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.
I the tool has been preset or wire size 10 AWG
Ċthe smallest wire sizeĊno urther adjustment is
necessary, even though wire size 8 or 6 AWG is
to be terminated; the setting or wire size 10 will
also accommodate wire size 8 or 6. However, i
the anvil die is not set or wire size 10 and wire
size 8 or 6 is desired, then the anvil die should be
set to the appropriate wire size o 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 [.030 to .040] as shown
in Figure 4.
Hold-Down Device and
Contact Locator Screws
Figure 4
Ton ue of Contact
Fits in Slot
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
Wire Does Not Extend
into Contact Transition
Area
Wire Barrel Extends
0.76-1.02 [.030-.040]
from Nest
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, re er to
Application Speci ication 114-6032.
NOTE
i
NOTE
i
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408-2681
ROTA-CRIMP Cr mp ng Tool 68321-1
3 of 6Rev B
Tyco Electronic Corporation
Figure 6
Wire Strand Mu t Not
Extend Beyond Thi Area
or Above Wire Barrel
Wire Strand Vi ible HereĊ
In ulation Mu t Not Enter
Wire Barrel
Contact Mu t Be Straight
in Thi Area
Crimp Inspection
5. MAINTENANCE AND INSPECTION
5.1. Da ly Ma ntenance
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.
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. Per od c Inspect on
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. V sual
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 .
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 , for information on
obtaining further evaluation and repair. Examples
of possible damaged die closure surfaces are
shown in Figure 7.
Figure 7
Broken Chipped
Pitted
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
[1.38] 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 [1.13]. 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.
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408-2681
ROTA-CRIMP Crimping Tool 68321-1
Rev B4 of 6 yco Electronics Corporation
Figure 8
Dies Bottomed
But Not Under
Pressure
Adjustment
Screws (ADJ)
Lock Screws
(LOCK)
28.7-35.1
[1.13-1.38]
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 Cham er
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.
NO-GO
Dim
GO
Dim
Suggested Plug Gage Design
Die Closure
Configuration
70 _
0.13+0.03
[.005+.001]
yp
3.030
[.1193]
Enlarged End View
of Gage Element
25.4 [1.00] yp D"
ÉÉ
ÉÉ
ÉÉ
ÉÉ
ÉÉ
ÉÉ
ÉÉ
ÉÉ
ÉÉ
ÉÉ
ÉÉ
ÉÉ
GO Element NO-GO Element
GO element must pass
completely through the
crimping chamber.
NO-GO element may enter
partially, but must not pass
completely through the
crimping chamber.
Crimping
Chamber
Inspection of Crimping Chamber
Dies Bottomed But
Not Under Pressure
WIRE SIZE GAGE ELEMENT DIMENSION D (Diameter)
WIRE SIZE
(AWG) GO NO-GO GO NO-GO
10 2.565-2.573 [.1010-.1013] 2.817-2.819 [.1109-.1110] 3.226-3.243 [.1270-.1272] 3.396-3.401 [.1337-.1339]
8 2.946-2.954 [.1160-.1163] 3.198-3.200 [.1259-.1260] 3.548-3.553 [.1397-.1399] 3.724-3.729 [.1466-.1468]
6 3.581-3.589 [.1410-.1413] 3.833-3.835 [.1509-.1510] 4.102-4.107 [.1615-.1617] 4.285-4.290 [.1687-.1689]
Figure 9
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408-2681
ROTA-CRIMP Crimping Too 68321-1
5 of 6Rev B
Tyco Electronics Corporation
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 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 Tyco Electronics 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:
CUSTOMER SERVICE (038–035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105–3608
For repair service, contact a representative at
1–800–526–5136.
7. REVISION SUMMARY
Revisions to this instruction sheet include:
S Updated document to corporate requirements
S Removed reference to company for plug gages
from Paragraph 5.2, C
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408-2681
ROTA-CRIMP Crimping T l 68321-1
ev B6 of 6 Tyco Electronics Corporation
57.2 [2.25]
114 [4.5]
(Closed)
400.5 [15.75]
22
21
7
23 24 20 19
4
3
1
2
16 17
18
15
13
11 12
5 6 8 9
10
7
REPLACEMENT PARTS
ITEM PART NUMBER DESCRIPTION QTY PER TOOL
1 308990-1 PLATE, Side 3
2 308991-1 INDENTE 1
3 308992-1 ANVIL 1
4 601088 PLATE, Index 2
5 601089 PIN, Index 2
6 600091 ING, etaining 2
7 601093-0 SP ING 1
8 21004-6 SC EW, Shoulder, .25 in. Dia
 1.25 in. L 1
9 1-21002-0 LOCKNUT, 10
 24 2
10 601082 PLATE, Tie 2
11 1-21004-2 SC EW, Shoulder, .31 in. Dia
 1.00 in. L 2
12 21021-5 LOCKNUT, .25 in.
 20 2
13 600866-1 SPACE 2
14 601086 PIN, Aligning 1
15 1-21004-9 SC EW, Shoulder, .28 in. Dia
 .62 in. L 2
16 21021-6 LOCKNUT, .79 in.
 18 2
17 601078 ASSEMBLY, Handle 1
18 308990-2 PLATE, Side 1
19 21004-3 SC EW, Shoulder, .25 in. Dia
 .62 in. L 1
20 314224-1 LOCATO , Terminal 1
21 314225-1 TE MINAL, Hold Down 1
22 2-21000-9 SC EW, Socket Head, 8-32
 .75 in. L 2
23 21055-6 WASHE , Flat 2
Figure 10
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