Use Of 6V7061 Battery Cable Crimping Die{0709, 0710, 1400} Caterpillar

6V7061 Battery Cable Crimping Die can be used in the 6V4880 Hose Press for repair of heavy electrical cable in the wire size range of 1/0 to 4/0 AWG. Use the instructions that follow for correct use of the crimping die.

1 Use the following chart to find the correct die for the wire size to be used.

2 6V7061 Crimping Die Assembly (1) can be installed in 6V4880 Hose Press (2) two ways. One way, the die openings for 1/0, 2/0 and 3/0 wire gauge can be used. The other way, the die openings for 2/0, 3/0 and 4/0 wire gauge can be used. In each condition, the die opening which cannot be used is in alignment with the tie rods.

3 Crimping die assembly (1) should be used against 6V4913 Plate or 6V4929 Anvil (3). It can also be used against the back of 6V4931 Knife Holder.

4 Use either the knife and anvil (part of 6V4880 Hose Press) or the 6V3022 Cable Cutter (part of 6V3025 Battery Cable Repair Kit) to cut the battery cable to the length desired.

5 The insulation must be removed from each end of the cable in order to install the terminals. The stripped (insulation removed) ends should be even with or a little beyond the end of the wire barrel and the insulation should fit against the wire barrel, as shown. For a battery terminal, the insulation should fit against the wire barrel, as shown, when the wire is against the end of the wire barrel. Use the following method to remove insulation from the cables.

6 Use knife (4) to cut the O.D. of the insulation, but do not cut through the insulation and nick (scratch) the wires. Next, make a cut through the insulation from the O.D. cut to the end of the insulation.

7 Hold one corner of the insulation with pliers (5) and pull the piece from the end of the cable.

8 Put crimping die (1) in the position desired in the hose press. Install the cable in the battery or cable terminal. Put the assembly in the correct jaws of the crimping die. Close the press until the crimping die is fully closed. Open the press and remove the completed assembly.

NOTE: If a cable terminal has a wire barrel seam, turn the terminal in the jaws until the seam is against one of the flats of the jaws. After crimping, the seam should not be at a corner.

9 The crimping die is made to give the best crimp when the die is fully closed. If the die is not closed, under-crimped terminal (6) will not hold the cable with enough force. The terminal may pull off and the wire strands will not be tight enough to give good conductivity. If terminal (7) is over-crimped, the cross-sectional area is made smaller and an electrical hot spot will be the result. See page 7 for Inspection of Crimps.

Inspection Of Crimps

NOTE: Use only the terminal and splice crimp conditions shown that are Acceptable. Correct use of the tooling and procedures can prevent the crimp conditions shown that are Not Acceptable.

1 Cable Terminal Crimps - Acceptable

a. Crimp (1) is in the center of the wire barrel. The crimp may be slightly off the center, but not off the end of the barrel.

b. The terminal or splice (2) is correct for the CMA of the wire size used.

c. Insulation (3) is not in the wire barrel.

d. The wire shows through inspection hole (4) of the butt splice.

e. Stripped wire ends (5) are even with or slightly beyond the end of the wire barrel.

2 Cable Terminal Crimps - Not Acceptable

a. Crimp (1) is off the end of the barrel of the terminal or splice.

b. The terminal or splice (2) is not correct for the wire used.

c. Insulation (3) has been put into the wire barrel. Check for wrong wire strip length.

d. The wire does not show through inspection hole (4) of the butt splice.

e. The stripped wire ends (5) are not even with or slightly beyond the end of the barrel.

f. Strands (6) are nicked (marked) or there are not enough complete strands.

3 Battery Terminal Crimps - Acceptable

a. Crimps (1) are in the correct position. They do not make contact with each other and are not off the end of the barrel.

b. The diameter of stripped wire (2) is correct for the wire diameter range of the battery terminal.

c. Wire (2) is in position in the wire barrel correctly.

d. The wire is not nicked (marked) and has the correct number of strands (3).

4 Battery Terminal Crimps - Not Acceptable

a. Crimp (1) is off the end of the barrel or makes contact with the other crimp.

b. The diameter of stripped wire (2) is not correct for the wire diameter range of the terminal

c. Wire (2) is not in the correct position in the wire barrel. Check for wrong wire strip length.

d. The wire is nicked (marked) or does not have the correct number of complete strands (3).

Battery Terminals

Cable Terminals