29249 [TE]
ROTA-CRIMP Hand Crimping Tools;
| 型号： | 29249 |
| 厂家： | 
TE CONNECTIVITY |
| 描述： | ROTA-CRIMP Hand Crimping Tools |
| 文件： | 总10页 (文件大小：322K) |
| 中文： | 中文翻译 | 下载： | 下载PDF数据表文档文件 |
Instruction Sheet
408-2029
ROTA-CRIMP* Hand Crimping Tools
601075 and 601075-1
21 APR 11 Rev D
PROPER USE GUIDELINES
Cumulative Trauma Disorders can resultfrom the prolonged use ofmanually powered hand tools. Hand tools are intended for occasional use and low volume
applications. A wide selection of powered application equipment for extended-use, production operations is available.
1. INTRODUCTION
3. CRIMPING PROCEDURE FOR
SOLISTRAND TERMINALS AND SPLICES
This instruction sheet covers TE Connectivity Hand
Crimping Tools 601075 and 601075--1, which are
used to apply SOLISTRAND* 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.
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.
Embossed Numbers Must Match
Do NOT use these tools on aircraft applications
or on aluminum wire terminations.
NOTE
Locator
Pin
Locator
Pin
i
Reasons for reissue are provided in Section 9,
REVISION SUMMARY.
Indexing Pins
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.
SOLISTRAND TERMINALS AND SPLICES
Ring Type
Terminal
Butt Splice
Parallel Splice
WIRE STRIP LENGTH
BUTT
PARALLEL
SPLICES
TERMINAL OR SPLICE
WIRE SIZE RANGE,
mm 2 [CMA]
APPROX
WIRE SIZE,
AWG
TERMINALS
MIN MAX
SPLICES
MIN
MAX
MIN
MAX
6.6 -- 10.5 [13,100 -- 20,800]
10.5 -- 16.7 [20,800 -- 33, 100]
16.7 -- 26.6 [33,100 -- 52,600]
26.6 -- 42.4 [52,600 -- 83,700]
42.4 -- 60.5 [83,700 -- 119,500]
8
6
8.33 [.328] 9.12 [.359] 10.32 [.406] 11.11 [.438] 10.32 [.406] 11.11 [.438]
9.92 [.391] 10.71 [.422] 11.90 [.469] 12.70 [.50] 11.11 [.438] 11.90 [.469]
11.50 [.453] 12.30 [.484] 13.49 [.531] 14.28 [.562] 13.49 [.531] 14.28 [.562]
13.09 [.515] 13.89 [.547] 15.08 [.594] 15.87 [.625] 15.08 [.594] 15.87 [.625]
18.65 [.734] 20.24 [.797] 15.87 [.625] 17.46 [.688] 17.46 [.688] 19.05 [.75]
4
2
1/0
Figure 2
E2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
*Trademark
TOOLING ASSISTANCE CENTER 1--800--722--1111 This controlled document is subject to change.
1 of 10
PRODUCT INFORMATION 1--800--522--6752
For latest revision and Regional Customer Service,
visit our website at www.te.com
LOC B
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners.
408-2029
3. Depress the spring--loaded indexing pins and
rotate the desired size dies into crimping position.
The embossed die numbers must match.
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.
NOTE
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.
i
Always store the tool with the crimping dies in the
No. 4 setting.
NOTE
A. First Crimp
i
1. Position the end of the terminal or splice wire
barrel in the dies as shown in Figure 4.
3.2. Wire Preparation and Loading (Figure 2)
2. Close the tool handles until the terminal or splice
is held in place. Do not deform the wire barrel.
1. Strip the wire(s) to the dimensions indicated. Do
NOT use wires with nicked or missing strands.
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.
2. Select the proper size terminal or splice for the
wire size being used.
4. Complete the crimp by closing the tool handles
until they bottom.
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.
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.
3.3. Performing a Single Crimp on Wire Sizes 8
Through 4 (Figure 3)
2. Refer to Section 5 and to Figure 7 for terminal
and splice crimp inspection procedures.
Make sure that the wire size stamped on the
terminal or splice corresponds with the wire size
embossed in the tool dies.
NOTE
3.5. Performing a Dual Crimp on SOLISTRAND Butt
Splices with Wire Size 2 and 1/0 (Figure 4)
i
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.
NOTE
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.
i
2. Close the tool handles until the terminal or splice
is held firmly in place. Do NOT deform the terminal
or splice wire barrel.
A. First and Second Crimps
1. Position the end of the splice wire barrel in the
dies.
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.
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. To complete the crimp, close the tool handles
until they bottom. Open the handles and remove
the crimped terminal or splice.
4. Close the tool handles until they bottom to
complete the crimp.
5. If terminating a butt splice, repeat the procedure
for the second splice end.
5. Move the splice into position for the second
crimp, as shown in Figure 4.
6. Refer to Section 5 and Figure 7 for terminal and
splice crimp inspection procedure.
6. Close the tool handles to complete the crimp.
Do not overlap the crimps.
2 of 10
Rev D
408-2029
A
B
C
Terminals
Butt Splices
Parallel Splices
Conductor is Flush with
or Extended Slightly Beyond End of
Wire Barrel
Brazed Seam
Against Flat
of Die
Brazed Seam
Against Flat
of Die
Brazed Seam
Against Flat
of Die
Conductor
Butted Against
Wire Stop
Splice
Centered in
Dies
Wire Barrels
Centered in Dies
Conductors are Flush with
or Extended Slightly Beyond
End of Wire Barrel
Figure 3
Conductor is Flush with
or Extended Slightly Beyond End
of Wire Barrel
A
Terminals
1st Crimp
(a)
Brazed Seam
Against Flat
of Die
2nd Crimp
(b)
Conductor
Butted Against
Wire Stop
Brazed Seam
Against Flat of Die
1st Crimp
(a)
2nd Crimp
(b)
Conductor
Butted Against
Wire Stop
B
Butt Splices
3rd Crimp
(c)
4th Crimp
(d)
Conductor is Flush
with or Extended
Slightly Beyond
End of Wire Barrel
C
Parallel Splices
Brazed Seam
Against Flat of Die
2nd Crimp
(b)
1st Crimp
(a)
Figure 4
Rev D
3 of 10
408-2029
B. Third and Fourth Crimps (Figure 4)
4. CRIMPING PROCEDURE FOR CABLE MAKER
BATTERY TERMINALS
1. Position the splice into position for the third
crimp.
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.
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.
1. Open the tool handles.
2. Depress the spring--loaded index pins.
4. Close the tool handles until they bottom to
complete the crimp.
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.
5. Move the splice into position for the fourth
crimp.
4. Release the indexing pins, making sure that the
die locator pins return fully and are visible at the
points indicated in Figure 1.
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.
4.2. Wire Preparation and Loading
1. Strip the wires to the dimensions indicated in
Figure 5.
3.6. Performing a Dual Crimp on SOLISTRAND
Parallel Splices with Wire Size 2 and 1/0 (Figure 4)
Do not use wires with nicked or missing strands.
NOTE
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.
NOTE
i
i
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.
A. First Crimp
4.3. Crimping Procedure for Straight Terminals
(Figure 6)
1. Position the end of the splice wire barrel in the
dies.
A. First Crimp
2. Close the tool handles until the splice is held in
place. Do not deform the wire barrel.
1. Position the end of the terminal wire barrel in the
dies.
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.
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 they bottom to
complete the crimp.
4. Close the tool handles until the dies bottom to
complete the crimp.
B. Second 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.
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 7 for terminal and
splice crimp inspection procedure.
2. Refer to Section 5 and Figure 8 for terminal
crimp inspection procedure.
4 of 10
Rev D
408-2029
CABLE MAKER Battery Terminals
Area 1 (Die Setting for Tool
Nos. 600850, 600850-1 and 69015)
Area 1 (Die Setting for Tool
Nos. 600850, 600850-1 and 69015
Area 2 (Die Setting for Tool
Nos. 601075, 601075-1, and
69015
Straight
Flag
Area 2 (Die Setting for Tool
Nos. 601075, 601075-1, and 69015)
B
WIRE STRIP LENGTH
STRAIGHT
TERMINAL
PART
NUMBER
TOOL DIE
WIRE
DIAMETER
RANGE
SETTINGS (See
FLAG
Area 2 on Terminal)
MIN
MAX
5.56 -- 6.91
4
6
29251
[.219 -- .272]
4.75 -- 5.54
[.187 -- .218]
29253
20.637
[.813]
21.432
[.843]
“B” Dim
+.795 [.031]
29245--3
29245--5
9.78 -- 10.97
[.385 -- .432]
0
2
29249
29249--3
29249--5
6.93 -- 8.76
[.273 -- .345]
Figure 5
4.4. Crimping Procedure for Flag Terminals (Figure 6)
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.
Make sure that crimps do not overlap or go off
the end of the wire barrel.
NOTE
i
A. First Crimp (Figure 6)
1. Orient and position the flag terminal in the tool
dies.
6. INITIAL TOOL INSPECTION
2. Close the tool handles until the terminal is held
in place. Do not deform the wire barrel.
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.
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.
7. MAINTENANCE/INSPECTION
7.1. Daily Maintenance
B. Second Crimp (Figure 6)
1. Move the terminal into position for the second
crimp. Close the tool handles to complete the
crimp.
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.
2. Refer to Section 5 and Figure 8 for battery
terminal crimp inspection procedure.
Rev D
5 of 10
408-2029
Straight
Terminals
Flag
Terminals
A
B
C
D
End of Conductor Flush or
Extended Approximately .79 [.031] Beyond
Terminal Wire Barrel
1st
Crimp
2nd
Crimp
1st
Crimp
2nd Crimp
Do Not
Overlap
First Crimp
Figure 6
2. Make certain that all pins, pivot points, and
2. Make certain that all parts are securely in place.
If replacements are necessary, refer to the parts
list in Figure 11.
bearing surfaces are protected with a THIN coat of
any good SAE 20 motor oil. Do NOT oil
excessively.
3. Inspect crimping areas for chipped or cracked
surfaces.
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.
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:
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:
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.
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.
6 of 10
Rev D
408-2029
Single Crimp
SOLISTRAND Terminals
and Splices
Dual Crimp
SOLISTRAND Terminals
and Splices
3
3
1
5
1
Terminal
5
Terminal
Wire Size
Stamped Under
Tongue
2
2
1
Wire Size
Stamped Under
Tongue
1
5
3
Parallel
Splice
2
5
3
Wire Size
Stamped
on Splice
Parallel
Splice
3
1
1
Wire Size
Stamped
on Splices
5
Wire Size
Stamped
on Splice
2
2
4
4
Butt Splice
3
Butt Splice
1
1
3
1
1
2
Crimp centered. Crimp may be off center BUT NOT
OFF END OF WIRE BARREL.
Wire size stamped on terminal or splice matches
CMA of wire being used.
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.
2
3
4
3
4
Insulation does not enter wire barrel.
Insulation does not enter wire barrel.
Wire is visible through inspection hole of butt splice.
Wire is visible through inspection hole of butt splice.
5
5
On terminals and parallel splices, bare wire ends
must be flush with or extend slightly beyond end of wire
barrel.
On terminals and parallel splices, bare wire ends
must be flush with or extend slightly beyond end
of wire barrel.
Figure 7
Rev D
7 of 10
408-2029
CABLE MAKER Battery Terminals
Straight Terminal
Flag Terminal
2
3
2
3
1
1
Area 2
5
4
4
Area 2
5
Straight Terminal
Flag Terminal
1
2
1
Crimps evenly spaced BUT NOT OVERLAPPED OR
OFF END OF WIRE BARREL.
Crimps properly located. Crimps must not be off end of wire
barrel.
2
Diameter of stripped wire is within wire diameter
range of terminal.
Diameter of stripped wire is within wire diameter
range of terminal.
3
4
3
4
No nicked or missing conductor strands.
No nicked or missing conductor strands.
Wire fully inserted.
End of conductor is flush or extended approximately
0.79 [.031] beyond end of terminal wire barrel.
Selected die numbers match the number displayed in
Area 2.
5
5
Selected die numbers match the number displayed in
Area 2.
Figure 8
5. To loosen the adjustment:
No. 4 Dies in
Crimp Position
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.
Dies Bottomed
But Not Under
Pressure
c. --Flex the tool by opening and closing the tool
handles.
Adjustment
Screws
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.
Lock
Screws
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.
28.58 [1.125]
to
38.10 [1.500]
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.
Figure 9
8 of 10
Rev D
408-2029
C. Crimp Height Inspection (Figure 10)
9. REVISION SUMMARY
S Updated document to corporate requirements
S New logo
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.
Crimp Height Measurements
(Tool Handles Properly Adjusted. See paragraph 7.2, B)
2. Crimp a properly prepared stranded wire in a
SOLISTRAND terminal or splice, as previously
described.
“A”
Do not use wires with missing conductor strands.
NOTE
i
“B”
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.
Avoid
Brazed
Seam
Measure at
Midpoints
of Flats
Do not allow the cone point to enter the terminal
brazed seam.
NOTE
i
“A”
Cross Section
“A” + “B” = Crimp
of Crimped Wire
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.
Height Dimension
Barrel
“B”
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.
WIRE
SIZE,
AWG
CRIMP HEIGHT
DIMENSION
RANGE
CRIMP HEIGHT
MEASUREMENTH
10.46--11.05
[.412--.435]
8
8. REPAIR/REPLACEMENT
13.00--13.59
[.512--.535]
6
MEASUREMENTS
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:
16.23--16.92
[.639--.666]
19.41--20.14
[.764--.793]
22.63--23.42
[.891--.922]
“A” + “B” =
CRIMP HEIGHT
DIMENSION
4
2
1/0
CUSTOMER SERVICE (38--35)
TYCO ELECTRONICS CORPORATION
P.O. BOX 3608
H Tool handles properly adjusted.
Figure 10
HARRISBURG, PA 17105--3608
For tool repair service, please contact a TE
Representative at 1--800--526--5136.
Rev D
9 of 10
408-2029
13
11
12
117.6 mm
[4.63 in.]
381 mm [15.0 in.]
11
12
NOTE: CERTI -CRIMP* Hand Tool Ratchet Assembly No. 604220-1
(Items 1 Thru 10) is Used on Tool No. 601075-1 Only.
1
4
5
3
8
6
QTY PER
TOOL
ITEM
PART NO.
DESCRIPTION
5
1
2
3
4
5
6
7
8
9
10
11
12
13
1--21004--2
604222--1
604224--1
604223--1
21021--5
986816--2
604228--1
21021--6
604229--1
2--21004--1
601092
2
SCREW, Shoulder 5/16 in. Dia.
GUARD
BUSHING
PAWL
NUT ,1/4 in.
SPRING
RACK
NUT, 5/16 in.
WASHER, Nylon
SCREW, Shoulder 3/8 in. Dia.
DIES
PIN ASSEMBLY, Index
HANDLE, Grips,
9
1
1
1
2
1
1
1
1
1
2
2
2
1
7
2
601077
604274--1
10
Figure 11
10 of 10
Rev D
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