Instruction Sheet ROTA- CRIMP* Hand Crimping Tools and

Transcription

1 Instructon Sheet ROTA- CRIMP* Hand Crmpng Tools and APR PROPER USE GUIDELINES Cumulatve Trauma Dsorders can result from the prolonged use of manually powered hand tools. Hand tools are ntended for occasonal use and low volume applcatons. A wde selecton of powered applcaton equpment for extended -use, producton operatons s avalable.. INTRODUCTION Ths nstructon sheet covers TE Connectvty Hand Crmpng Tools 6007 and , whch are used to apply SOLISTRAND* and CABLE MAKER* termnals to stranded copper wre. Fgure provdes a lst of applcable wre szes, termnal or splce CMA range, and the approprate mnmum and maxmum wre strp lengths for each wre sze and connector type.. CRIMPING PROCEDURE FOR SOLISTRAND TERMINALS AND SPLICES.. De Settng (Fgure ). Open the tool handles.. Check the de order chart on the tool and select the left (L) and rght (R) de numbers for the wre sze beng used. Embossed Numbers Must Match ORIGINAL INSTRUCTIONS Do NOT use these tools on arcraft applcatons or on alumnum wre termnatons. Locator Pn Locator Pn Reasons for ressue are provded n Secton 9, REVISION SUMMARY.. DESCRIPTION Indexng Pns The hand crmpng tools feature two rotatng crmpng des that are held n place by sprng--loaded ndexng pns. Each de s postoned usng a sprng--loaded de locator pn. Wre sze desgnatons are embossed on the crmpng des to assure proper settng of the crmpng area, and a de order chart s ncluded on the tool for easy reference. Fgure SOLISTRAND TERMINALS AND SPLICES Rng Type Termnal Butt Splce Parallel Splce WIRE STRIP LENGTH TERMINAL OR SPLICE APPROX BUTT PARALLEL TERMINALS WIRE SIZE RANGE, WIRE SIZE, SPLICES SPLICES mm [CMA] AWG MIN MAX MIN MAX MIN MAX [,00-0,800] 8 8. [.8] 9. [.9] 0. [.06]. [.8] 0. [.06]. [.8] [0,800 -, 00] [.9] 0.7 [.].90 [.69].70 [.0]. [.8].90 [.69] [,00 -,600].0 [.].0 [.8].9 [.].8 [.6].9 [.].8 [.6] [,600-8,700].09 [.].89 [.7].08 [.9].87 [.6].08 [.9].87 [.6] [8,700-9,00] /0 8.6 [.7] 0. [.797].87 [.6] 7.6 [.688] 7.6 [.688] 9.0 [.7] Fgure E0 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. of 0 LOC B

2 Depress the sprng--loaded ndexng pns and rotate the desred sze des nto crmpng poston. The embossed de numbers must match.. When the correct sze des are n poston, release the ndexng pns. Make sure that the de locator pns return fully and are vsble at the ponts ndcated. Always store the tool wth the crmpng des n the No. settng... Wre Preparaton and Loadng (Fgure ). Strp the wre(s) to the dmensons ndcated. Do NOT use wres wth ncked or mssng strands.. Select the proper sze termnal or splce for the wre sze beng used.. Determne the correct termnal or splce wre loadng by referrng to the CMA range lsted. The total CMA of the wres beng used must be wthn the termnal or splce s CMA range... Performng a Sngle Crmp on Wre Szes 8 Through (Fgure ) Make sure that the wre sze stamped on the termnal or splce corresponds wth the wre sze embossed n the tool des.. Center the wre barrel of the termnal or splce n the des. For best results, poston the brazed seam aganst one of the flats of the des, as shown n Fgure.. Close the tool handles untl the termnal or splce s held frmly n place. Do NOT deform the termnal or splce wre barrel.. Insert the strpped wre nto the termnal or splce untl the wre conductor s at least flush wth, or s extendng beyond, the end of the wre barrel.. To complete the crmp, close the tool handles untl they bottom. Open the handles and remove the crmped termnal or splce.. If termnatng a butt splce, repeat the procedure for the second splce end. 6. Refer to Secton and Fgure 7 for termnal and splce crmp nspecton procedure... Performng a Dual Crmp on SOLISTRAND Termnals wth Wre Sze and /0 (Fgure ) For best results, poston the brazed seam of the termnal aganst one of the flats of the des, as shown n Fgure. Make sure that the crmps do not overlap or go off ether end of the wre barrel. Make sure that the wre sze beng used, the wre sze stamped on the termnal, and the wre sze embossed on the des all correspond. A. Frst Crmp. Poston the end of the termnal or splce wre barrel n the des as shown n Fgure.. Close the tool handles untl the termnal or splce s held n place. Do not deform the wre barrel.. Insert the strpped wre nto the termnal or splce s wre barrel untl the end of the conductor s flush wth, or s extended slghtly beyond, the wre barrel.. Complete the crmp by closng the tool handles untl they bottom. B. Second Crmp. Move the termnal or splce nto poston for the second crmp, then close the tool handles to complete the crmp. Do not overlap the crmps.. Refer to Secton and to Fgure 7 for termnal and splce crmp nspecton procedures... Performng a Dual Crmp on SOLISTRAND Butt Splces wth Wre Sze and /0 (Fgure ) For best results, poston the brazed seam of the termnal aganst one of the flats of the des, as shown n Fgure. Make sure that the crmps do not overlap or go off ether end of the wre barrel. Make sure that the wre sze beng used, the wre sze stamped on the termnal, and the wre sze embossed on the des all correspond. A. Frst and Second Crmps. Poston the end of the splce wre barrel n the des.. Close the tool handles untl the splce s held n place. Do not deform the wre barrel.. Insert a properly strpped wre nto the frst end of the splce untl the wre bottoms aganst the splce wre stop.. Close the tool handles untl they bottom to complete the crmp.. Move the splce nto poston for the second crmp, as shown n Fgure. 6. Close the tool handles to complete the crmp. Do not overlap the crmps. of 0

3 08-09 A Termnals B Butt Splces C Parallel Splces Conductor s Flush wth or Extended Slghtly Beyond End of Wre Barrel Aganst Flat of De Aganst Flat of De Conductor Butted Aganst Wre Stop Splce Centered n Des Aganst Flat of De Wre Barrels Centered n Des Conductors are Flush wth or Extended Slghtly Beyond EndofWreBarrel Fgure Conductor s Flush wth or Extended Slghtly Beyond End of Wre Barrel A Termnals Aganst Flat of De st Crmp (a) nd Crmp (b) Conductor Butted Aganst Wre Stop AganstFlatofDe B Butt Splces st Crmp (a) Conductor Butted Aganst Wre Stop nd Crmp (b) rd Crmp (c) th Crmp (d) C Parallel Splces AganstFlatofDe Conductor s Flush wth or Extended Slghtly Beyond EndofWreBarrel Fgure nd Crmp (b) st Crmp (a) of 0

4 08-09 B. Thrd and Fourth Crmps (Fgure ). Poston the splce nto poston for the thrd crmp.. Close the tool handles untl the splce s held n place. Do not deform the wre barrel.. Insert a properly strpped wre nto the second end of the splce untl the wre bottoms aganst the splce wre stop.. Close the tool handles untl they bottom to complete the crmp.. Move the splce nto poston for the fourth crmp. 6. Close the tool handles to complete the crmp. Do not overlap the crmps. 7. Refer to Secton and Fgure 7 for termnal and splce crmp nspecton procedure..6. Performng a Dual Crmp on SOLISTRAND Parallel Splces wth Wre Sze and /0 (Fgure ) A. Frst Crmp For best results, poston the brazed seam of the termnal aganst one of the flats of the des, as shown n Fgure. Make sure that the crmps do not overlap or go off ether end of the wre barrel. Make sure that the wre sze beng used, the wre sze stamped on the termnal, and the wre sze embossed on the des all correspond.. Poston the end of the splce wre barrel n the des.. Close the tool handles untl the splce s held n place. Do not deform the wre barrel.. Insert the properly strpped wre nto the wre barrel untl the ends of the conductors are flush wth or extended slghtly beyond the end of the wre barrel.. Close the tool handles untl they bottom to complete the crmp. B. Second Crmp. Move the splce nto poston for the second crmp and close the tool handles to complete the crmp. Do not overlap the crmps.. Refer to Secton and Fgure 7 for termnal and splce crmp nspecton procedure.. CRIMPING PROCEDURE FOR CABLE MAKER BATTERY TERMINALS.. De Settng Proper de settng s determned by the part number of the termnal beng crmped and by the number dsplayed n area of the termnal, as shown n Fgure.. Open the tool handles.. Depress the sprng--loaded ndex pns.. Rotate the des untl the embossed wre sze numbers n each de crmp closure match the number dsplayed n area of the termnal.. Release the ndexng pns, makng sure that the de locator pns return fully and are vsble at the ponts ndcated n Fgure... Wre Preparaton and Loadng. Strp the wres to the dmensons ndcated n Fgure. Do not use wres wth ncked or mssng strands.. Select the proper termnal number for the wre dameter beng used. The dameter of the strpped wre must fall wthn the wre dameter range of the termnal beng used. Refer to Fgure... Crmpng Procedure for Straght Termnals (Fgure 6) A. Frst Crmp. Poston the end of the termnal wre barrel n the des.. Close the tool handles untl the termnal s held n place. Do not deform the wre barrel.. Insert the properly strpped wre nto the wre barrel untl the wre bottoms.. Close the tool handles untl the des bottom to complete the crmp. B. Second Crmp. Move the termnal nto poston for the second crmp, then close the handles to complete the crmp.. Refer to Secton and Fgure 8 for termnal crmp nspecton procedure. of 0

5 08-09 CABLE MAKER Battery Termnals Area (De Settng for Tool Nos , and 690 Area (De Settng for Tool Nos , and 690) Straght Area (De Settng for Tool Nos. 6007, , and 690 Flag Area (De Settng for Tool Nos. 6007, , and 690) B TERMINAL PART NUMBER WIRE DIAMETER RANGE TOOL DIE SETTINGS (See AreaonTermnal) MIN WIRE STRIP LENGTH STRAIGHT MAX FLAG [.9 -.7] [ ] [.8 -.] [.8]. [.8] B Dm +.79 [.0] [.7 -.] Fgure.. Crmpng Procedure for Flag Termnals (Fgure 6) A. Frst Crmp (Fgure 6) Make sure that crmps do not overlap or go off the end of the wre barrel.. Orent and poston the flag termnal n the tool des.. Close the tool handles untl the termnal s held n place. Do not deform the wre barrel.. Insert the properly strpped wre untl the end of the conductor s flush wth, or extends approxmately.79 [.0] n. beyond, the end of the termnal wre barrel.. Close the tool handles to complete the crmp. B. Second Crmp (Fgure 6). Move the termnal nto poston for the second crmp. Close the tool handles to complete the crmp.. Refer to Secton and Fgure 8 for battery termnal crmp nspecton procedure.. CRIMP INSPECTION Inspect the crmped SOLISTRAND termnal or splce by checkng the features descrbed n Fgure 7. Inspect the crmped CABLE MAKER termnal by checkng the features descrbed n Fgure 8. Use only termnals and splces that meet the condtons descrbed. 6. INITIAL TOOL INSPECTION AMP Hand Crmpng Tools 6007 and are nspected before shpment. The tool receved should be nspected mmedately upon arrval to ensure that t has not been damaged durng shpment, and that t performs accordng to the crtera descrbed n ths sheet. If the tool s damaged upon arrval, retan the shppng contaner, fle a clam wth the carrer, and notfy TE mmedately. 7. MAINTENANCE/INSPECTION 7.. Daly Mantenance. Remove dust, mosture, and other contamnants from the tool wth a clean brush or a soft, lnt--free cloth. Do NOT use objects that could damage the tool. of 0

6 08-09 Straght Flag A Termnals B C Termnals D End of Conductor Flush or Extended Approxmately.79 [.0] Beyond Termnal Wre Barrel st Crmp nd Crmp Do Not Overlap Frst Crmp st Crmp nd Crmp Fgure 6. Make certan that all pns, pvot ponts, and bearng surfaces are protected wth a THIN coat of any good SAE 0 motor ol. Do NOT ol excessvely.. When the tool s not n use, keep the handles closed to prevent objects from becomng lodged n the crmpng areas and store the tool n a clean, dry area. 7.. Perodc Inspecton Regular nspectons should be performed by qualty control personnel. A record of scheduled nspectons should reman wth the tool and/or be suppled to supervsory personnel responsble for the tool. Though recommendatons call for at least one nspecton per month, the nspecton frequency should be based on the amount of use, workng condtons, operator tranng and skll, and establshed company standards. These nspectons should be performed n the followng sequence: A. Vsual Inspecton. 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.. Make certan that all parts are securely n place. If replacements are necessary, refer to the parts lst n Fgure.. Inspect crmpng areas for chpped or cracked surfaces. B. Handle Adjustment Inspecton (Fgure 9) The handle adjustment should be checked to ensure that the des are bottomng fully. The handle adjustment feature s provded to compensate for normal de wear. To check the handle adjustment:. Open the tool handles fully.. Rotate the No. wre sze des nto crmpng poston.. Close the tool handles untl the des are bottomed, but not under pressure.. Measure the dstance between the tool handles, as shown n Fgure 9. The measurement must be between 8.8 [.] and 8.0 [.00]. If the adjustment does not fall wthn ths range, the adjustment must be tghtened or loosened as necessary. 6 of 0

7 08-09 Sngle Crmp SOLISTRAND Termnals and Splces Dual Crmp SOLISTRAND Termnals and Splces Termnal Termnal Wre Sze Stamped Under Tongue Wre Sze Stamped Under Tongue Parallel Splce Wre Sze Stamped on Splce Parallel Splce Wre Sze Stamped on Splces Wre Sze Stamped on Splce Butt Splce Butt Splce Crmp centered. Crmp may be off center BUT NOT OFF END OF WIRE BARREL. Wre sze stamped on termnal or splce matches CMA of wre beng used. Insulaton does not enter wre barrel. Crmps evenly spaced BUT NOT OVERLAPPED OR OFF END OF WIRE BARREL. Wre sze stamped on termnal or splce matches CMA of wre beng used. Insulaton does not enter wre barrel. Wre s vsble through nspecton hole of butt splce. Wre s vsble through nspecton hole of butt splce. On termnals and parallel splces, bare wre ends must be flush wth or extend slghtly beyond end of wre barrel. On termnals and parallel splces, bare wre ends must be flush wth or extend slghtly beyond end of wre barrel. Fgure 7 7 of 0

8 08-09 CABLE MAKER Battery Termnals Straght Termnal Flag Termnal Area Area Straght Termnal Crmps evenly spaced BUT NOT OVERLAPPED OR OFF END OF WIRE BARREL. Flag Termnal Crmps properly located. Crmps must not be off end of wre barrel. Dameter of strpped wre s wthn wre dameter range of termnal. Dameter of strpped wre s wthn wre dameter range of termnal. No ncked or mssng conductor strands. No ncked or mssng conductor strands. Wre fully nserted. End of conductor s flush or extended approxmately 0.79 [.0] beyond end of termnal wre barrel. Selected de numbers match the number dsplayed n Area. Selected de numbers match the number dsplayed n Area. Fgure 8 No. Des n Crmp Poston. To loosen the adjustment: a. --Turn both adjustment (ADJ) screws COUNTERCLOCKWISE approxmately /8 to / turn. Des Bottomed But Not Under Pressure Adjustment Screws b. --Slghtly loosen both lock (LOCK) screws by turnng them COUNTERCLOCKWISE. c. --Flex the tool by openng and closng the tool handles. d. --Tghten both lock screws. Lock Screws e. --Close the tool handles untl the des are bottomed, but not under pressure. Check the measurement between the tool handles and repeat the adjustment procedure f necessary. 8.8 [.] to 8.0 [.00] 6. To tghten the adjustment: a. --Turn both lock (LOCK) screws COUNTERCLOCKWISE approxmately / to / turn. --Turn both adjustment (ADJ) screws CLOCKWISE approxmately /8 to / turn. b. --Flex the tool by openng and closng the tool handles. c. --Tghten both lock (LOCK) screws. Fgure 9 d. --- Close the tool handles untl the des are bottomed but not under pressure. Check the measurement between the tool handles and repeat the adjustment procedure f necessary. 8 of 0

9 08-09 C. Crmp Heght Inspecton (Fgure 0) Crmp heght nspectons should be performed perodcally to determne f the tool s mantanng proper crmpng dmensons. To check the crmp heght:. Perform the handle adjustment nspecton as descrbed n Paragraph B, Handle Adjustment Inspecton. Adjust the handles f necessary.. Crmp a properly prepared stranded wre n a SOLISTRAND termnal or splce, as prevously descrbed. 9. REVISION SUMMARY S Updated document to corporate requrements S New logo Crmp Heght Measurements (Tool Handles Properly Adjusted. See paragraph 7., B) A Do not use wres wth mssng conductor strands. B. Usng a conventonal cone--pont mcrometer, measure the crmp heghts at the mdponts of flats A and B, as shown n Fgure 0. The SUM of the two measurements equals the crmp heght dmenson. Do not allow the cone pont to enter the termnal brazed seam.. Fgure 0 lsts the crmp heght dmenson (sum of A and B measurements) range for each wre sze. If the measured dmenson s wthn the lsted range, the de closure s consdered dmensonally correct. Avod Brazed Seam Cross Secton of Crmped Wre Barrel B A Measure at Mdponts of Flats A + B = Crmp Heght Dmenson. If the measured crmp heght dmenson s not wthn the specfed range (and the tool handles are properly adjusted), crmpng tool should be returned to TE for recondtonng. Refer to Secton 8, REPAIR/REPLACEMENT. 8. REPAIR/REPLACEMENT Replaceable parts are lsted n Fgure. Parts other than those lsted n Fgure should be replaced by TE to ensure qualty and relablty of the tool. Order replacement parts through your TE representatve, or call , or send a facsmle of your purchase order to , or wrte to: CUSTOMER SERVICE (8--) TYCO ELECTRONICS CORPORATION P.O. BOX 608 HARRISBURG, PA For tool repar servce, please contact a TE Representatve at WIRE SIZE, AWG 8 6 /0 CRIMP HEIGHT MEASUREMENTH MEASUREMENTS A + B = CRIMP HEIGHT DIMENSION H Tool handles properly adjusted. Fgure 0 CRIMP HEIGHT DIMENSION RANGE [. -.] [. -.] [ ] [ ].6 -. [ ] 9 of 0

10 mm [.6 n.] 8 mm [.0 n.] : CERTI -CRIMP* Hand Tool Ratchet Assembly No (Items Thru 0) s Used on Tool No Only ITEM PART NO QTY PER TOOL DESCRIPTION SCREW, Shoulder /6 n. Da. GUARD BUSHING PAWL NUT,/ n HANDLE, Grps, SPRING RACK NUT, /6 n. WASHER, Nylon SCREW, Shoulder /8 n. Da. DIES PIN ASSEMBLY, Index Fgure 0 of 0