instruction sheet rota- crimp* hand crimping tools 408--2029 loc b 1 of 10 e 2011 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 respecti ve owners. 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 21 apr 11 rev d 601075 and 601075- 1 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 volum e applications. a wide selection of powered application equipment for extended--use, production operations is available. 1. introduction this instruction sheet covers te connectivity hand crimping tools 601075 and 601075--1, which are used to apply solistr and* and cable maker* terminals to stranded copper wire. figure 2 provides a list of applicable wire sizes, terminal or splice cma range, and the appropriate minimum and maximum wire strip lengths for each wire size and connector type. do not use these tools on aircraft applications or on aluminum wire terminations. reasons for reissue are provided in section 9, revision summary. 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 tool for easy reference. 3. crimping procedure for solistrand terminals and splices 3.1. die setting (figure 1) 1. open the tool handles. 2. check the die order chart on the tool and select the left (l) and right (r) die numbers for the wire size being used. figure 1 locator pin indexing pins embossed numbers must match locator pin solistrand terminals and splices ring type terminal butt splice parallel splice wire strip length terminal or splice wire size range , approx wire size , terminals butt splices parallel splices w i r e s i z e r a n g e , mm 2 [cma] w i r e s i z e , 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 original instructions note i
408- 2029 rev d 2 of 10 3. depress the spring--loaded indexing pins and rotate the desired size dies into crimping position. the embossed die numbers must match. 4. when the correct size dies are in position, release the indexing pins. make sure that the die locator pins return fully and are visible at the points indicated. always store the tool with the crimping dies in the no. 4 setting. 3.2. wire preparation and loading (figure 2) 1. strip the wire(s) to the dimensions indicated. do not use wires with nicked or missing strands. 2. select the proper size terminal or splice for the wire size being used. 3. determine the correct terminal or splice wire loading by referring to the cma range listed. the total cma of the wires being used must be within the terminal or splice?s cma range. 3.3. performing a single crimp on wire sizes 8 through 4 (figure 3) make sure that the wire size stamped on the terminal or splice corresponds with the wire size embossed in the tool dies. 1. center the wire barrel of the terminal or splice in the dies. for best results, position the brazed seam against one of the ?flats? of the dies, as shown in figure 3. 2. close the tool handles until the terminal or splice is held firmly in place. do not deform the terminal or splice wire barrel. 3. insert the stripped wire into the terminal or splice until the wire conductor is at least flush with, or is extending beyond, the end of the wire barrel. 4. to complete the crimp, close the tool handles until they bottom. open the handles and remove the crimped terminal or splice. 5. if terminating a butt splice, repeat the procedure for the second splice end. 6. refer to section 5 and figure 7 for terminal and splice crimp inspection procedure. 3.4. performing a dual crimp on solistrand terminals with wire size 2 and 1/0 (figure 4) for best results, position the brazed seam of the terminal against one of the ?flats? of the dies, as shown in figure 4. make sure that the crimps do not overlap or go off either end of the wire barrel. make sure that the wire size being used, the wire size stamped on the terminal, and the wire size embossed on the dies all correspond. a. first crimp 1. position the end of the terminal or splice wire barrel in the dies as shown in figure 4. 2. close the tool handles until the terminal or splice is held in place. do not deform the wire barrel. 3. insert the stripped wire into the terminal or splice?s wire barrel until the end of the conductor is flush with, or is extended slightly beyond, the wire barrel. 4. complete the crimp by closing the tool handles until they bottom. b. second crimp 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. 2. refer to section 5 and to figure 7 for terminal and splice crimp inspection procedures. 3.5. performing a dual crimp on solistrand butt splices with wire size 2 and 1/0 (figure 4) for best results, position the brazed seam of the terminal against one of the ?flats? of the dies, as shown in figure 4. make sure that the crimps do not overlap or go off either end of the wire barrel. make sure that the wire size being used, the wire size stamped on the terminal, and the wire size embossed on the dies all correspond. a. first and second crimps 1. position the end of the splice wire barrel in the dies. 2. close the tool handles until the splice is held in 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 splice wire stop. 4. close the tool handles until they bottom to complete the crimp. 5. move the splice into position for the second crimp, as shown in figure 4. 6. close the tool handles to complete the crimp. do not overlap the crimps. note i note i note i note i
408- 2029 3 of 10 rev d a terminals b butt splices c parallel splices conductor is flush with or extended slightly beyond end of wire barrel conductor butted against wire stop wire barrels centered in dies brazed seam against flat of die splice centered in dies a terminals b butt splices c parallel splices 1st crimp (a) 2nd crimp (b) 3rd crimp (c) 4th crimp (d) figure 3 figure 4 conductors are flush with or extended slightly beyond endofwirebarrel brazed seam against flat of die brazed seam against flat of die brazed seam againstflatofdie brazed seam against flat of die conductor butted against wire stop conductor butted against wire stop conductor is flush with or extended slightly beyond endofwirebarrel conductor is flush with or extended slightly beyond end of wire barrel brazed seam againstflatofdie 2nd crimp (b) 1st crimp (a) 2nd crimp (b) 1st crimp (a)
408- 2029 rev d 4 of 10 b. third and fourth crimps (figure 4) 1. position the splice into position for the third crimp. 2. close the tool handles until the splice is held in place. do not deform the wire barrel. 3. insert a properly stripped wire into the second end of the splice until the wire bottoms against the splice wire stop. 4. close the tool handles until they bottom to complete the crimp. 5. move the splice into position for the fourth crimp. 6. close the tool handles to complete the crimp. do not overlap the crimps. 7. refer to section 5 and figure 7 for terminal and splice crimp inspection procedure. 3.6. performing a dual crimp on solistrand parallel splices with wire size 2 and 1/0 (figure 4) for best results, position the brazed seam of the terminal against one of the ?flats? of the dies, as shown in figure 4. make sure that the crimps do not overlap or go off either end of the wire barrel. make sure that the wire size being used, the wire size stamped on the terminal, and the wire size embossed on the dies all correspond. a. first crimp 1. position the end of the splice wire barrel in the dies. 2. close the tool handles until the splice is held in place. do not deform the wire barrel. 3. insert the properly stripped wire into the wire barrel until the ends of the conductors are flush with or extended slightly beyond the end of the wire barrel. 4. close the tool handles until they bottom to complete the crimp. b. second crimp 1. move the splice into position for the second crimp and close the tool handles to complete the crimp. do not overlap the crimps. 2. refer to section 5 and figure 7 for terminal and splice crimp inspection procedure. 4. crimping procedure for cable maker battery terminals 4.1. die setting proper die setting is determined by the part number of the terminal being crimped and by the number displayed in ?area 2? of the terminal, as shown in figure 5. 1. open the tool handles. 2. depress the spring--loaded index pins. 3. rotate the dies until the embossed wire size numbers in each die crimp closure match the number displayed in ?area 2? of the terminal. 4. release the indexing pins, making sure that the die locator pins return fully and are visible at the points indicated in figure 1. 4.2. wire preparation and loading 1. strip the wires to the dimensions indicated in figure 5. do not use wires with nicked or missing strands. 2. select the proper terminal number for the wire diameter being used. the diameter of the stripped wire must fall within the wire diameter range of the terminal being used. refer to figure 5. 4.3. crimping procedure for straight terminals (figure 6) a. first crimp 1. position the end of the terminal wire barrel in the dies. 2. close the tool handles until the terminal is held in place. do not deform the wire barrel. 3. insert the properly stripped wire into the wire barrel until the wire bottoms. 4. close the tool handles until the dies bottom to complete the crimp. b. second crimp 1. move the terminal into position for the second crimp, then close the handles to complete the crimp. 2. refer to section 5 and figure 8 for terminal crimp inspection procedure. note i note i
408- 2029 5 of 10 rev d cable maker battery terminals straight terminal part number wire diameter range 5.56 -- 6.91 [.219 -- .272] tool die settings (see area2onterminal) wire strip length straight min max flag flag area 2 (die setting for tool nos. 601075, 601075--1, and 69015 area 1 (die setting for tool nos. 600850, 600850--1 and 69015) b area 1 (die setting for tool nos. 600850, 600850--1 and 69015 area 2 (die setting for tool nos. 601075, 601075--1, and 69015) 4 6 0 2 20.637 [.813] 21.432 [.843] ?b? dim +.795 [.031] 4.75 -- 5.54 [.187 -- .218] 9.78 -- 10.97 [.385 -- .432] 6.93 -- 8.76 [.273 -- .345] 29251 29253 29245--3 29245--5 29249 29249--3 29249--5 figure 5 4.4. crimping procedure for flag terminals (figure 6) make sure that crimps do not overlap or go off the end of the wire barrel. a. first crimp (figure 6) 1. orient and position the flag terminal in the tool dies. 2. close the tool handles until the terminal is held in place. do not deform the wire barrel. 3. insert the properly stripped wire until the end of the conductor is flush with, or extends approximately .79 [.031] in. beyond, the end of the terminal wire barrel. 4. close the tool handles to complete the crimp. b. second crimp (figure 6) 1. move the terminal into position for the second crimp. close the tool handles to complete the crimp. 2. refer to section 5 and figure 8 for battery terminal crimp inspection procedure. 5. crimp inspection inspect the crimped solistrand terminal or splice by checking the features described in figure 7. inspect the crimped cable maker terminal by checking the features described in figure 8. use only terminals and splices that meet the conditions described. 6. initial tool inspection amp hand crimping tools 601075 and 601075--1 are inspected before shipment. the tool received should be inspected immediately upon arrival to ensure that it has not been damaged during shipment, and that it performs according to the criteria described in this sheet. if the tool is damaged upon arrival, retain the shipping container, file a claim with the carrier, and notify te immediately. 7. maintenance/inspection 7.1. daily maintenance 1. remove dust, moisture, and other contaminants from the tool with a clean brush or a soft, lint--free cloth. do not use objects that could damage the tool. note i
408- 2029 rev d 6 of 10 figure 6 abcd straight terminals flag terminals end of conductor flush or extended approximately .79 [.031] beyond terminal wire barrel 2nd crimp 1st crimp 2nd crimp do not overlap first crimp 1st crimp 2. make certain that all pins, pivot points, and bearing surfaces are protected with a thin coat of any good sae 20 motor oil. do not oil excessively. 3. when the tool is not in use, keep the handles closed to prevent objects from becoming lodged in the crimping areas and store the tool in a clean, dry area. 7.2. periodic inspection regular inspections should be performed by quality control personnel. a record of scheduled inspections should remain with the tool and/or be supplied to supervisory personnel responsible for the tool. though recommendations call for at least one inspection per month, the inspection frequency should be based on the amount of use, working conditions, operator training and skill, and established company standards. these inspections should be performed in the following sequence: a. visual inspection 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 that all parts are securely in place. if replacements are necessary, refer to the parts list in figure 11. 3. inspect crimping areas for chipped or cracked surfaces. b. handle adjustment inspection (figure 9) the handle adjustment should be checked to ensure that the dies are bottoming fully. the handle adjustment feature is provided to compensate for normal die wear. to check the handle adjustment: 1. open the tool handles fully. 2. rotate the no. 4 wire size dies into crimping position. 3. close the tool handles until the dies are bottomed, but not under pressure. 4. measure the distance between the tool handles, as shown in figure 9. the measurement must be between 28.58 [1.125] and 38.10 [1.500]. if the adjustment does not fall within this range, the adjustment must be tightened or loosened as necessary.
408- 2029 7 of 10 rev d single crimp solistrand terminals and splices dual crimp solistrand terminals and splices terminal parallel splice butt splice terminal 3 1 5 2 1 5 3 1 5 2 4 3 1 1 5 2 4 1 3 1 crimp centered. crimp may be off center but not off end of wire barrel. 2 3 4 5 wire size stamped on terminal or splice matches cma of wire being used. insulation does not enter wire barrel. wire is visible through inspection hole of butt splice. on terminals and parallel splices, bare wire ends must be flush with or extend slightly beyond end of wire barrel. crimps evenly spaced but not overlapped or off end of wire barrel. wire size stamped on terminal or splice matches cma of wire being used. insulation does not enter wire barrel. wire is visible through inspection hole of butt splice. on terminals and parallel splices, bare wire ends must be flush with or extend slightly beyond end of wire barrel. wire size stamped under tongue wire size stamped on splices wire size stamped under tongue parallel splice butt splice wire size stamped on splice figure 7 1 3 5 2 3 1 2 wire size stamped on splice 3 1 2 3 4 5
408- 2029 rev d 8 of 10 cable maker battery terminals 1 crimps evenly spaced but not overlapped or off end of wire barrel. 2 3 4 5 diameter of stripped wire is within wire diameter range of terminal. no nicked or missing conductor strands. wire fully inserted. selected die numbers match the number displayed in area 2. 1 2 3 4 5 crimps properly located. crimps must not be off end of wire barrel. end of conductor is flush or extended approximately 0.79 [.031] beyond end of terminal wire barrel. diameter of stripped wire is within wire diameter range of terminal. no nicked or missing conductor strands. selected die numbers match the number displayed in area 2. area 2 area 2 straight terminal flag terminal straight t erminal flag t erminal 1 2 3 4 5 1 3 4 figure 8 2 5 figure 9 dies bottomed but not under pressure no. 4 dies in crimp position adjustment screws lock screws 28.58 [1.125] to 38.10 [1.500] 5. to loosen the adjustment: a. --turn both adjustment (adj) screws counterclockwise approximately 1/8 to 1/4 turn. b. --slightly loosen both lock (lock) screws by turning them counterclockwise. c. --flex the tool by opening and closing the tool handles. d. --tighten both lock screws. e. --close the tool handles until the dies are bottomed, but not under pressure. check the measurement between the tool handles and repeat the adjustment procedure if necessary. 6. to tighten the adjustment: a. --turn both lock (lock) screws counterclockwise approximately 1/2 to 3/4 turn. --turn both adjustment (adj) screws clockwise approximately 1/8 to 1/4 turn. b. --flex the tool by opening and closing the tool handles. c. --tighten both lock (lock) screws. d. --- close the tool handles until the dies are bottomed but not under pressure. check the measurement between the tool handles and repeat the adjustment procedure if necessary.
408- 2029 9 of 10 rev d c. crimp height inspection (figure 10) crimp height inspections should be performed periodically to determine if the tool is maintaining proper crimping dimensions. to check the crimp height: 1. perform the handle adjustment inspection as described in paragraph b, handle adjustment inspection. adjust the handles if necessary. 2. crimp a properly prepared stranded wire in a solistrand terminal or splice, as previously described. do not use wires with missing conductor strands. 3. using a conventional cone--point micrometer, measure the crimp heights at the midpoints of flats ?a? and ?b?, as shown in figure 10. the sum of the two measurements equals the crimp height dimension. do not allow the cone point to enter the terminal brazed seam. 4. figure 10 lists the crimp height dimension (sum of ?a? and ?b? measurements) range for each wire size. if the measured dimension is within the listed range, the die closure is considered dimensionally correct. 5. if the measured crimp height dimension is not within the specified range (and the tool handles are properly adjusted), crimping tool should be returned to te for reconditioning. refer to section 8, repair/replacement. 8. repair/replacement replaceable parts are listed in figure 11. parts other than those listed in figure 11 should be replaced by te to ensure quality and reliability of the tool. order replacement parts through your te representative, or call 1--800--526--5142, or send a facsimile of your purchase order to 1--717--986--7605, or write to: customer service (38--35) tyco electronics corporation p.o. box 3608 harrisburg, pa 17105--3608 for tool repair service, please contact a te representative at 1--800--526--5136. 9. revision summary s updated document to corporate requirements s new logo figure 10 1/0 2 8 wire size, awg crimp height dimension range crimp height measurement h measurements ?a? + ?b? = crimp height dimension crimp height measurements (tool handles properly adjusted. see paragraph 7.2, b) ?a? ?b? ?b? measure at midpoints of flats avoid brazed seam cross section of crimped wire barrel ?a? + ?b? = crimp height dimension ?a? h tool handles properly adjusted. 10.46--11.05 [.412--.435] 13.00--13.59 [.512--.535] 6 16.23--16.92 [.639--.666] 4 19.41--20.14 [.764--.793] 22.63--23.42 [.891--.922] note i note i
408- 2029 rev d 10 of 10 5 13 2 3 4 1 9 5 1 8 7 12 11 11 12 10 note : certi--crimp* hand tool ratchet assembly no. 604220--1 (items 1 thru 10) is used on tool no. 601075--1 only. 13 604274--1 2 handle, grips, 12 11 10 9 8 7 6 4 3 2 5 1 601077 601092 604229--1 604228--1 604223--1 604224--1 604222--1 2 2 1 1 1 1 1 2 1 1 2 1 item part no. qty per tool description pin assembl y, index dies screw, shoulder 3/8 in. dia. washer, nylon nut, 5/16 in. rack spring pawl bushing guard screw, shoulder 5/16 in. dia. nut ,1/4 in. 1--21004--2 21021--5 986816--2 21021--6 2--21004--1 figure 11 381 mm [15.0 in.] 117.6 mm [4.63 in.] 6
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