Locator Pin Indexing Pin. Wire Size Marking CAUTION NOTE TOOLING ASSISTANCE CENTER PRODUCT INFORMATION

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1 ROTA-CRIMP* Crmpng Tool Instructon Sheet APR 12 Statonary De (Nest) Anvl De Hold-Down Devce and Contact Locator Front of Tool Locator Pn Indexng Pn Wre Sze Markng The hold-down devce and contact locator are mounted on a metal strp. The metal strp must be adjusted to accommodate the contact poston durng the crmpng process. 3. CRIMPING PROCEDURE Refer to Fgure 2, and strp the wre to wthn the dmensons shown. CAUTION! DO NOT use wres wth mssng or ncked conductor strands. ORIGINAL INSTRUCTIONS Seres 75 Power Lock Contact Transton Area Strp Length 1. INTRODUCTION Fgure 1 ROTA-CRIMP Crmpng Tool (shown n Fgure 1) s used to crmp Seres 75 Power Lock Contact onto sold or stranded wre szes 10, 8, or 6 AWG. Read these nstructons thoroughly before usng the tool. Dmensons n ths nstructon sheet are n mllmeters [wth nches n brackets]. Fgures and llustratons are for reference only and are not drawn to scale. Reasons for ressue of ths nstructon sheet are provded n Secton 7, REVISION SUMMARY. 2. DESCRIPTION The FRONT of the tool, nto whch the contact s nserted, can be dentfed by the tool part number on the lnk. The tool features a statonary de (6.35 mm [.250 n.] wde F crmp nest), rotatable anvl de wth three settngs, hold-down devce, and contact locator. The anvl must be set to the wre sze beng used. The applcable wre sze s stamped on the base of the anvl de. When closed, the des form one crmpng chamber. CONTACT Fgure 2 Proceed as follows: 1. Open the tool head. Make sure that the anvl de s locked n poston and that the locator pn s vsble as shown n Fgure 1. It s not necessary at ths tme to set the anvl de to a specfc wre sze. 2. Place a sample contact n the nest of the statonary de as shown n Fgure 3. The open end of the wre barrel must be algned n the nest. 3. Loosen the two screws securng the hold-down devce and contact locator, and poston the contact locator over the contact tongue as shown n Fgure 3. Do not re-tghten the screws at ths tme. WIRE SIZE (AWG) , 8, 6 WIRE STRIP LENGTH [ ] The hold-down devce and contact locator must be properly adjusted so that the contact wll reman algned durng the crmpng process. 4. Slowly close the tool head, makng sure the contact remans properly postoned n the nest. If the contact s cocked or otherwse out of lne, realgn t before proceedng. The contact should reman n the nest as shown n Fgure 3. DO NOT deform the wre barrel Tyco Electroncs Corporaton, a TE Connectvty Ltd. company All Rghts Reserved *Trademark TOOLING ASSISTANCE CENTER PRODUCT INFORMATION Ths controlled document s subject to change. For latest revson and Regonal Customer Servce, vst our webste at TE Connectvty, TE connectvty (logo), and TE (logo) are trademarks. Other logos, product and/or company names may be trademarks of ther respectve owners. 1 of 5

2 Wre Conductor Flush wth or Recessed Slghtly n 8. Close tool head just enough to retan the contact; then nsert the wre nto the wre barrel, makng sure the wre does not extend beyond the wre barrel. See Fgure 5. Wre Insulaton Does Not Enter Contact Fgure 3 5. Crmp the contact by squeezng the tool handles. Then tghten screws of the hold-down devce and contact locator. If the contact crmp s straght and the wre barrel has not been damaged, the tool s ready to use. Contact Must Retan Proper Poston n Nest Durng Entre Crmpng Procedure If the tool has been preset for wre sze 10 AWG - the smallest wre sze-no further adjustment s necessary, even though wre sze 8 or 6 AWG s to be termnated; the settng for wre sze 10 wll also accommodate wre sze 8 or 6. However, f the anvl de s not set for wre sze 10 and wre sze 8 or 6 s desred, then the anvl de should be set to the approprate wre sze of ether 8 or If the wre sze markng s postoned for a wre sze other than desred, depress the anvl de sprng-loaded ndexng pn and rotate the anvl de untl the desred sze appears. Then release the ndexng pn and allow locator pn to snap nto the hole whch locks the anvl de n place for the desred sze. 7. Open the tool head, and poston the contact n the nest, locatng the outer end of the wre barrel (wre-entry end) so that t extends from the nest area between 0.76 to1.02 mm [.030 to.040 n.] as shown n Fgure 4. Fgure 4 Confguraton of Nest Hold-Down Devce and Contact Locator Screws Torque of Contact Fts n Slot Wre Does Not Extend nto Contact Transton Area Fgure 5 9. Slowly squeeze the handles, makng sure contact remans algned properly n the nest. It may be necessary to open the handles slghtly, allowng the contact to be re-adjusted n the nest. Contnue to squeeze the handles to complete the crmp. 4. CRIMP INSPECTION Inspected the crmped contact accordng to Fgure 6. Poorly crmped contacts can be avoded through careful use of these nstructons. Crmp Inspecton Wre Strands Vsble Here - Insulaton Must Not Enter For a detaled nspecton requrements, refer to Applcaton Specfcaton Fgure 6 5. MAINTENANCE AND INSPECTION Extends [ ] from Nest Wre Strands Must Not Extend Beyond ths Area or Above Contact Must be Straght n ths Area 5.1. Daly Mantenance It s recommended that each operator of the tool be made aware of-and responsble for-the followng steps of daly mantenance: 1. Remove dust, mosture, and other contamnants wth a clean brush, or a soft, lnt-free cloth. DO NOT use objects that could damage the tool. 2 of 5

3 2. Make sure the proper retanng pns are n place and secured wth the proper retanng rngs. 3. Make certan all pns, pvot ponts, and bearng surfaces are protected wth a THIN coat of any good SAE 20 motor ol. DO NOT ol excessvely. 4. When the tool s not n use, keep the handles closed to prevent objects from becomng lodged n the crmpng des and store the tool n a clean, dry area Perodc Inspecton Regular nspectons should be performed by qualty control personnel. A record of scheduled nspectons should reman wth the tool or be suppled to personnel responsble for the tool. Though recommendatons call for at least one nspecton a month, the nspecton frequency should be based on the amount of use, ambent workng condtons, operator tranng and skll, and establshed company standards. These nspectons should be performed n the followng sequence: A. Vsual 1. Remove all lubrcaton and accumulated flm by mmersng the tool (handles partally closed) n a sutable commercal degreaser that wll not affect pant or plastc materal. 2. Make certan all retanng pns are n place and secured wth retanng rngs. If replacements are necessary, refer to Secton Inspect the head assembly, wth specal emphass on checkng for worn, cracked, or broken des. If damage to any part of the head assembly s evdent, refer to Secton 6, for nformaton on obtanng further evaluaton and repar. Examples of possble damaged de closure surfaces are shown n Fgure 7. B. Handle Adjustment The handle adjustment should be checked to ensure that the des are bottomng properly. The handle adjustment feature s provded to compensate for normal tool wear. To check handle adjustment, frst close handles untl des are bottomed, but not under pressure. Then measure the dstance between handles as shown n Fgure 8. Adjustment s too tght f measurement exceeds mm [1.38 n.] Proceed as follows: 1. Turn both adjustment (ADJ) screws counterclockwse approxmately one-half to threequarter turn. 2. Turn, but do not remove, both lock (LOCK) screws counterclockwse. 3. Flex tool by openng and closng the handles. 4. Tghten both lock screws. 5. Close the handles untl the des are bottomed but not under pressure. Check the measurement between the handles and, f necessary, repeat the adjustment procedure. Adjustment s too loose f measurement s less than 28.7 mm [1.13 n.]. Proceed as follows: 1. Turn both lock (LOCK) screws counterclockwse approxmately one-half to three-quarter turn. 2. Turn both adjustment (ADJ) screws clockwse approxmately one-half to three-quarter turn. Des Bottomed but Not Under Pressure Broken Chpped Ptted Adjustment Screws (ADJ) Lock Screws (LOCK) [ ] Fgure 7 Fgure 8 3 of 5

4 GO Dm Suggested Plug Gage Desgn NO-GO Dm Inspecton of Crmpng Chamber Des Bottomed But Not Under Pressure D 25.4 [1.00] Typ De Closure Confguraton Enlarged End Vew of Gage Element 90 Crmpng Chamber 0.13 ±0.03 [.005 ±.001] Typ [.1188] Ref 0.5 [.02] R Max GO Element GO element must pass completely through the crmpng chamber. NO-GO Element NO-GO element may enter partally, but must not pass completely through the crmpng chamber F-CRIMP GAGE WIRE GAGE ELEMENT DIMENSION D (Dameter) SIZE(AWG) GO NO-GO GO NO-GO [ ] [ ] [ ] [ ] [ ] [ ] [ ] [ ] [ ] [ ] [ ] [ ] Fgure 9 3. Flex tool by openng and closng handles. 4. Tghten both lock screws. 5. Close the handles untl the des are bottomed but not under pressure. Check the measurement between the handles and, f necessary, repeat the adjustment procedure. C. Gagng the Crmpng Chamber Ths nspecton requres the use of plug gages conformng to the dmensons provded n Fgure 9. To gage the crmpng chamber, proceed as follows: 1. Remove traces of ol or drt from the crmpng chamber and plug gage. 2. Perform handle adjustment procedure accordng to Paragraph 5.2,B. 3. Close handles untl des are bottomed but not under pressure. 4. Insert GO element nto the crmpng chamber; but do not force t. The GO element must pass through the length of the crmpng chamber. See Fgure In the same manner, try to nsert the NO-GO element nto the crmpng chamber. The NO-GO element may enter partally, but must not pass completely through the length of the crmpng chamber. See Fgure 9. If the crmpng chamber conforms to the gage nspecton, the des are consdered dmensonally correct and should be lubrcated wth a THIN coat of any good SAE 20 motor ol. If the crmpng chamber does NOT conform to the gage nspecton, the des must be returned for further evaluaton and repar. For addtonal nformaton regardng the use of a plug gage, refer to Instructon Sheet REPLACEMENT AND REPAIR Customer-replaceable parts are lsted n Fgure 10. A complete nventory should be stocked and controlled to prevent lost tme when replacement of parts s necessary. Parts other than those lsted should be replaced by TE Connectvty to ensure qualty and relablty. Order replacement parts through your representatve, or call , or send a facsmle of your purchase order to , or wrte to: 4 of 5

5 CUSTOMER SERVICE ( ) TYCO ELECTRONICS CORPORATION PO BOX 3608 HARRISBURG PA For repar servce, contact a TE Representatve at REVISION SUMMARY Updated document to corporate requrements Changed dmenson nformaton n Fgure 9 Changed table n Fgure 9 REPLACEMENT PARTS ITEM PART NUMBER DESCRIPTION QTY PER TOOL PLATE, Sde INDENTER ANVIL PLATE, Index PIN, Index RING, Retanng SPRING SCREW, Shoulder,.25 n. Da x 1.25 n. L LOCKNUT, 10 x PLATE, Te SCREW, Shoulder,.31 n. Da x 1.00 n. L LOCKNUT,.25 n. x SPACER PIN, Algnng SCREW, Shoulder,.28 n. Da. x 62 n. L LOCKNUT,.79 n. x ASSEMBLY, Handle PLATE, Sde SCREW, Shoulder,.25 n. Da x.62 n. L LOCATOR, Termnal TERMINAL, Hold Down SCREW, Socket Head, 8-32 x.75 n. L WASHER, Flat 2 Fgure 10 5 of 5

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