Tyco Electronics ROTA-CRIMP 68321-1 Bedienungsanleitung

Instruction Sheet

408-2681

LOC B

of 6

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

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

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408-2681

ROTA-CRIMP Crimping Tool 68321-1

Rev

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

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408-2681

ROTA-CRIMP Cr mp ng Tool 68321-1

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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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ROTA-CRIMP Crimping Tool 68321-1

Rev

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

Suggested Plug Gage Design

Die Closure

Configuration

0.13+0.03

[.005+.001]

3.030

[.1193]

Enlarged End View

of Gage Element

25.4 [1.00] yp

D"

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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ROTA-CRIMP Crimping Too 68321-1

of 6Rev

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:

Updated document to corporate requirements

Removed reference to company for plug gages

from Paragraph 5.2, C

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ROTA-CRIMP Crimping T l 68321-1

of 6 Tyco Electronics Corporation

57.2 [2.25]

114 [4.5]

(Closed)

400.5 [15.75]

23 24 20 19

16 17

11 12

5 6 8 9

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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