TE Connectivity 68321-1 User manual

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1of 5

Instruction Sheet

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

408-2681

ROTA-CRIMP*

Crimping Tool

68321-1 13 APR 12 Rev C

Figure 1

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 [with inches in brackets]. Figures and

illustrations are for reference only and are not

drawn 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 mm

[.250 in.] 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 wires with missing or nicked

conductor strands.

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-down device and contact locator must be

properly adjusted so that the contact will remain

aligned during the crimping process.

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.

Locator Pin

Indexing Pin

Wire Size

Marking

Stationary

Die (Nest)

Anvil Die

Hold-Down

Device and

Contact Locator

Front of

Tool

NOTE

CONTACT WIRE SIZE (AWG) WIRE STRIP

LENGTH

53880-4 10, 8, 6 7.95-9.53

[.313-.375]

CAUTION

StripLength

Wire Barrel

Transition

Area

Series 75 Power Lock Contact

NOTE

ORIGINAL INSTRUCTIONS

408-2681

2of 5

Rev C

Figure 3

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.

If the tool has been preset for wire size 10 AWG -

the smallest wire size-no further adjustment is

necessary, even though wire size 8 or 6 AWG is to

be terminated; the setting for wire size 10 will also

accommodatewiresize 8or 6.However,if theanvil

die is not set for wire size 10 and wire size 8 or 6 is

desired, then the anvil die should be set to the

appropriate wire size of 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 mm [.030 to .040 in.] as

shown in Figure 4.

Figure 4

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

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, refer to

Application Specification 114-6032.

Figure 6

5. MAINTENANCE AND INSPECTION

5.1. Daily Maintenance

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.

WireConductorFlush

with or Recessed

Slightly in Wire Barrel

Wire Insulation Does

Not Enter Contact

Wire Barrel

Contact Must Retain

Proper Position in

Nest During Entire

Crimping Procedure

Configuration

of Nest

Wire Barrel

NOTE

Hold-Down Device and Contact Locator Screws

Torque of Contact

Fits in Slot

Wire Does Not Extend into

Contact Transition Area

Wire Barrel Extends

0.76-1.02[.030-.040]

from Nest

NOTE

Wire Strands Visible Here -

Insulation Must Not Enter

Wire Barrel Wire Strands Must Not

Extend Beyond this Area

or Above Wire Barrel

Crimp Inspection

Contact Must be

Straight in this Area

408-2681

3of 5

Rev C

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. Periodic Inspection

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. Visual

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 6.

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 6, for information on

obtaining further evaluation and repair. Examples of

possible damaged die closure surfaces are shown

in Figure 7.

Figure 7

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 mm [1.38 in.] 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 mm [1.13 in.]. 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.

Figure 8

Broken Chipped

Pitted

DiesBottomed

but Not Under

Pressure

Adjustment

Screws (ADJ)

Lock Screws

(LOCK)

28.7-35.1

[1.13-1.38]

408-2681

4of 5

Rev C

Figure 9

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 Chamber

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.

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 Instruction Sheet 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 TE Connectivity 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:

Suggested Plug Gage Design Inspection of Crimping Chamber

Dim NO-GO

Dim Dies Bottomed But

Not Under Pressure

Crimping

Chamber

GO Element NO-GO Element

GO element must pass

completely through the

crimping chamber.

NO-GOelementmay enter

partially, but must not pass

completely through the

crimping chamber.

90°

3.017

[.1188]

Ref

0.5[.02]

R Max

0.13 ±0.03

[.005±.001]

Typ

“D” 25.4 [1.00] Typ

Die Closure

Configuration EnlargedEndView

of Gage Element

68321-1 F-CRIMP GAGE

WIRE

SIZE(AWG) GAGE ELEMENT DIMENSION D (Diameter)

GO NO-GO GO NO-GO

10 2.588-2.596 [.1019-.1022] 2.789-2.791 [.1098-.1099] 3.467-3.475 [.1365-.1368] 3.604-3.607 [.1419-.1420]

8 2.969-2.977 [.1169-.1172] 3.170-3.172 [.1248-.1249] 3.736-3.744 [.1471-.1474] 3.886-3.889 [.1530-.1531]

6 3.604-3.612 [.1419-.1422] 3.805-3.807 [.1498-.1499] 4.234-4.242 [.1667-.1670] 4.402-4.404 [.1733-.1734]

408-2681

5of 5

Rev C

CUSTOMER SERVICE (038-035)

TYCO ELECTRONICS CORPORATION

PO BOX 3608

HARRISBURG PA 17105-3608

For repair service, contact a TE Representative at

1-800-526-5136.

7. REVISION SUMMARY

•Updated document to corporate requirements

•Changed dimension information in Figure 9

•Changed table in Figure 9

Figure 10

REPLACEMENT PARTS

ITEM PART NUMBER DESCRIPTION QTY PER TOOL

1 308990-1 PLATE, Side 3

2 308991-1 INDENTER 1

3 308992-1 ANVIL 1

4 601088 PLATE, Index 2

5 601089 PIN, Index 2

6 600091 RING, Retaining 2

7 601093 SPRING 1

8 21004-6 SCREW, Shoulder, .25 in. Dia x 1.25 in. L 1

9 1-21002-0 LOCKNUT, 10 x 24 2

10 601082 PLATE, Tie 2

11 1-21004-2 SCREW, Shoulder, .31 in. Dia x 1.00 in. L 2

12 21021-5 LOCKNUT, .25 in. x 20 2

13 600866-1 SPACER 2

14 601086 PIN, Aligning 1

15 1-21004-9 SCREW, Shoulder, .28 in. Dia. x 62 in. L 2

16 21021-6 LOCKNUT, .79 in. x 18 2

17 601078 ASSEMBLY, Handle 1

18 308990-2 PLATE, Side 1

19 21004-3 SCREW, Shoulder, .25 in. Dia x .62 in. L 1

20 314224-1 LOCATOR, Terminal 1

21 314225-1 TERMINAL, Hold Down 1

22 2-21000-9 SCREW, Socket Head, 8-32 x .75 in. L 2

23 21055-6 WASHER, Flat 2

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