Hand Crimp Tool User Manual - Power and Signal · PDF fileHand Crimp Tool User Manual North America ... In order to ensure proper crimping and to control the wearing of the tool and

Hand Crimp ToolUser ManualUser Manual

North AmericaPower & Signal GroupWorld Headquarters6675 Parkland BlvdSolon, OH 44139USAPhone: 1-800-722-5273 440-836-6600Fax: 440-836-6122E-mail: salesna@powersignal.com engineering@powersignal.com

South AmericaPower & Signal Group, an Arrow CompanyRua José Gomes Falcão, 111Attn: Roberto Cutrupi, Sales Manager South America01139-010 - Barra Funda - São Paulo - S.P. - Brasil - BRPhone: 55 11 3613 9371Email: rcutrupi@powersignal.com

AsiaPower & Signal Group11F, BM Intercontinental Business Center100 Yu Tong RoadShanghai 200070ChinaPhone: +86 21 22152000Fax: +86 21 22152435E-mail: SalesAsia@powersignal.com

Europe, the Middle East & AfricaPower & Signal Group GmbHBalcke-Duerr-Allee 240882 RatingenGermanyPhone: +49 2102/1677-0 +49 800 10 10 772Fax: +49 (0)2102/1677-160E-mail: saleseurope@powersignal.com engineeringeurope@powersignal.com

Table of Contents

General hand crimp tool (HCT) information •Introduction •FunctionofHCTratchet •Scopeofusage •Responsibilitiesofuser •NoteregardingHCTmanualdimensions

HCTPowerAssistDevicesToolTypes •ToolType1:Blade&BoxTerminals •ToolType2:Pin&SleeveTerminals

AssemblyandRemovalofHCTDieSets •Dieselection •Dieinsertion •Dieremoval •Crimpverification •CrimpHeightAdjustment

CrimpToolReferenceDataSheetCrimpingInstructions •TerminalLoading •TerminalCrimping •CrimpHeightMeasurement

VisualCrimpQualityRecommendations •Goodcrimp •Crimpdimensionsnotintolerance •Lowcore •Insulationundercorewing •Twistedordistortedterminalsorcableseals •ExcessiveTab •Allstrandsnotcapturedbycorewings •Terminalstraightness •Cutormissingstrands

HCTMaintenance&CleaningHCTVisualInspectionWireStripperInstructionsHCTSupport

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General Hand Crimp Tool (HCT) information

Introduction Power&SignalGroup’sHCTshavebeendesignedtooptimizecrimpqualityforlowvolume,repair,or prototypeusage.InNorthAmericaandAsia,theHCTsmaybeorderedasindividualdiesets.In Europe,theMiddleEast&Africa,theHCTsmaybeorderedpre-assembledorasindividual compo nentstocrimpmultipleDelphiConnectionSystemterminalstovariouscablesizes.TheHCT issoldinoneoftwodesigns,bothensuringoptimumcrimpquality.Type2crimpspinandsleeve terminalswhileType1crimpsbladeandboxterminals.

Function of HCT ratchet ThePowerSignalGroupHCTratchethasdetents.Therearesixaudible“clicks”fromopeningto closing.Thecrimptoolisdesignedtocompletethefullcycleofdetentsinordertoassureaquality crimp.

IfitisnecessarytoopentheHCTpriortofullclosure,pressthehandlestogetherslightly.Turnthe emergencyunlockingreleaseclockwise(directionofthearrow)andopenthehandles simultaneously. NOTE:Iftheemergencyreleaseisutilized,thecrimpedterminalisnottobeused.

Scope of usage Power&SignalGroupHandCrimpTools(HCT)havebeendevelopedforoptimalcrimpingin: •Lowvolumeproduction •Repair •FieldService •Prototyping TheHCTshouldnotbeusedforotherpurposes.RepetitiveStressInjury(RSI)canresultfroma prolongeduseofmanuallypoweredhandcrimptools.Power&SignalGrouphandcrimptoolsare intendedforoccasionalandlowvolumeapplicationsonly.PleasecallPower&SignalGroupfor availabilityofpowerapplicatordiesandequipmentforhigh-volumeapplications.

Responsibilities of user Theoperation,maintenanceandserviceofthePower&SignalGroupHCTrequiresadegreeof practiceandskill.EachpersonwhoisworkingwiththeHCTmustbefamiliarwiththetool’soperation andfollowthemanual’sinstruction.Therefore,theinstructionsheetmustbeconstantlywithinreach oftheHCT.Inaddition,anyotherinstructionsresultingfromcurrentnationalregulationsintermsof healthandsafetyshouldbemaintainedwiththetool’sinstructionsheet.Theusershallnotmakeany revisionstotheHCTwithouttheconsentofthemanufacturerorsupplier.BeforeusingtheHCT,the operatorshouldconductavisualinspectionofthetooltoverifythatitisnotdamaged,maladjusted, orotherwisemalfunctioning.Power&SignalGroupdeclinestoacceptanyliabilityfordamagesthat occurduetoinappropriateuseoftheHCTordisregardfortheguidelinessetforthinthetool’s insructionsheet.TheuseroftheHCTisresponsibleforthequalityofthecrimp.

Note Regarding HCT manual dimensions DimensionsprovidedinthisHCTUsageManualareinmillimeters(mm).Figuresandillustrationsare notdrawntoscale.

HCT Power Assist Devices Power&SignalGroupcanalsorecommendor,inlimitedinstances,supplyPneumaticorMechanicalAssistdevicesfor usewithstandardPSGHandCrimpTools.Formoreinformation,pleasecontactthetechnicalsupportgroupforyour region.

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Tool Types

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Type 1: Box & Blade Terminal

Type 2: Pin & Sleeve Terminals

Type 3: Pin & Sleeve Terminals

WireStop

WireStop

WireStop

ChamferUpperDie

LowerDie

Stationaryjaws

M4X25mmAllenScrew

M4X11mmAllenScrew

M4X11mmAllenScrew

M4X16mmAllenScrew

M4X16mmAllenScrew

M4X18mmAllenScrew

DieRetaingScrews

M4LockNut

M4RegularNut

Locator

Locator

Assemblescrewswithoutfullytightening.Tightenscrewsafterclosinghandlestofullyseattheupperandlowerdie.

Turnsmallknobtoopenandcloseholdterminal.

DonotovertightenthewirestopM4nut.Makecertainthatthewirestopspringloadedblademovesfreely.

-PresstoOpen-Insertcontact-ReleasetocloseonContact-Opentoreleasecontact

-Aligntobottomdie-Snap

Emergencyrelease

For All Tool Types: Placeendofstrippedwireagainstthewirestop.

Assembly and Removal of HCT Die SetsIfyouhavepurchasedapre-assembledHCTbeginwiththecrimpverificationinstructions.

Die selection •SelecttheappropriatediefortheterminalpartandgaugesizeasdefinedintheCrimpToolReference DataSheet.

Die insertion •Assembletheupperandlowerdieinsertstogetherwiththeterminallocatorandwirestop. •Besurethatthebevelingsidepointstotheleft. •Thepropernutandallenscrewsareprovidedwitheachtoolkit.

Die Removal •Openthetoolhandles. •LoosenandremovethetwodieretainingscrewsbymeansofanAllenwrench •Slidethediesoutofthetooljaws.

Crimp verification Inordertoensurepropercrimpingandtocontrolthewearingofthetoolanddie,crimpverificationmustbedoneafter everydiesetchangeandregularlythereafter. StepOne Measurethecrimpheightandwidthwithacaliper.

StepTwo ComparethecaliperresultstothespecifiedtolerancerangefoundintheCrimpHeightReferenceDataSheetincluded witheachdieset.

Ifthecrimpheightisoutofthespecifiedtolerancerange,theHCTneedstobeadjusted.

Crimp Height Adjustment •Removesetscrew. •Rotatingtheadjustmentwheelcounterclockwiseincreasesthecrimpforceanddecreasesthecrimpheight. •Rotatingtheadjustmentwheelclockwisedecreasesthecrimpforceandincreasesthecrimpheight. •Reinsertsetscrew

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Crimp Tool Reference Data Sheet Power&SignalGroupsuppliesspecificrequiredinformationwitheachshipmentofitspre-assembledhandcrimptools andwithindividualdieinserts.Informationincludesterminalpartnumber,cabletype,striplength,andotherinformation relevanttoobtainingaqualitycrimpedterminal.Additionalvalidationdataisavailableuponrequest.

Crimping Instructions Theproperinserts,terminallocatorandwirestopshouldalwaysbeusedfortheintendedterminalandwiregaugesize (SeeCrimpToolReferenceDataSheet). •Referencetoolnumber,terminalnameandwiregaugesizesontoolparts. •Referenceterminalpartnumbersandcablegaugesizesfromauthorizedwiringprintsorotherdocuments. •UsethespecificcablestriplengthfromtheCrimpToolReferenceDataSheet.

Terminal Loading InsertloosepieceterminalintoholderopeningasshowninFigure1.Type2(Pin&SleeveTerminal)locatorsmustbe openedwithknurledwheelandclosedtoorientterminalsoastocaptureterminalwings.Usecorrectcablesealif required(Figure2).

Figure 1 Figure 2

Makesureterminalisfullyinsertedsowingsareoverthecrimpanvils.Ifwingsdonotcatchproperly, slightlybendinwardtoclearupperplate.Partiallycloseratchethandlestocaptureterminal.(Use wrenchtoturnsquarenutclockwisetoreleasehandlesifterminalisnotcapturedproperly.) PositionstrippedwireendagainstwirestopinbottomofcrimpwingsforType2orinupperdiefor Type1.Makesurethespringloadedwirestopreturnsaftereachcrimp.(Ifwirestopdoesnotreturn, thelockingnutistootightorthestopneedstobelubricated.)Ifacablesealisused,makesurethe sealispositionedsothattheinsulationwingscapturetheseal.Makesurenostrandsarecutorare missinginthestrippingprocess.

Terminal Crimping Completetheratchetingclosureofhandlesuntiltheyspringopen.Removecrimpedleadscarefully. InspectcrimpedleadaccordingtotheVisualCrimpQualityRecommendationstoeliminatenonconformances: Measureallcrimpdimensionswithcalibratedmeasuringequipment.Comparetocrimpdimensionssuppliedwiththe toolinsertsforspecificcablesizeandterminalpartnumber.

Ifcrimpsaretoohigh,removesetscrewandturnserratedwheelcounterclockwise(+)untilpropercrimpheightis achieved.(Reinsertscrewbeforetryingagain.)Ifcorecrimpheightistootight,followthesameprocedureexceptturnina clockwisedirection.

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Crimp Height Measurements Inordertoinsurepropercrimpquality,thecrimpheightmustbemeasuredandreadjustedifitdoesnotmeettheCore CrimpHeight(CCH)requirementsasshownintheCrimpToolReferenceDataSheetforthespecifiedterminalandcable size.TheCCHshouldbemeasuredwithapprovedcalipers.

Visual Crimp Quality Recommendations

Good Crimp: Correctcrimptoolapplicationwillminimizeoreliminate non-conformingcrimps.Improperlycrimpedterminals mayfailelectrically.Practiceonsamplesuntilgoodquality crimpsareconsistentlymade.Crimpedterminalsmust alwaysbe100%visuallyinspectedaftercrimpingprocess byfollowingthenon-conformancelistingsbelow.

Crimp dimensions not in tolerance: Wronginserttooling,crimpadjustmentnotright,inserts notseated,wronginsertjaw,wrongcableorterminal (Seedatasheetwithtooling.)

Low core:

Corenotshowinginfrontofterminalcorewingsdueto shortstrip,notusingwirestoporincorrectplacement.

Insulation under core wing:

Nostrip,shortstrip,wirestopnotused,incorrectplacement (mayalsoresultinhighcore).

Twisted or distorted terminals or cable seals:

Terminalnotpositionedcorrectlyintool.

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Excessive Tab

Maydamagesealorcausesealtonotsealproperly. Terminalsnotcutoffstripproperly.

All strands not captured by core wings: Maycausealoosecrimpandelectricalormechanical non-conformance.Mayneedtoinspectstrandspriorto crimping.

Terminal straightness:

Excessivelybentterminalsmaycauseterminalsnotto seat,pushmatingterminaloutofcavity,ornotbeableto seatTerminalPositionLock.Maybecausedbylocating terminalincorrectlyintool.

Cut or missing strands: Incorrectstrippingofcable.Maycausealoosecrimpand electricalormechanicalnon-conformance.

HCT Maintenance and Cleaning ResponsiblepersonnelandoperatorsofthePower&SignalGroupHCTshouldmaintainthetoolwitheachuse. •Useaclean,lint-freeclothtoremovedust,moisture,anddebrisfromthetool.Donotuseabrasivecleanerson thetool,whichcouldresultindamage. •Makesurethatallscrewsandotherremovablepartsaresecureandinplace. •Allpivotpoints,bearingsurfaces,joints,andothermovementpointsshouldberegularlyoiled. •Whenthetoolisnotinuse,itshandlesshouldbeclosedtopreventforeignobjectsfrombeinglodgedinthe nichesandrecessesofthetool. •Storethetoolinacleananddryarea.

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HCT Visual Inspection •QualitycontrolpersonnelshouldregularlycheckupontheHCTtoensurethatcrimpqualityisoptimal. •Inspectionsonthetoolshouldbemaderegularlyandlogged. •Thefrequencyofuse,workingenvironment,companystandards,andoperatortraining,strength,and proficiencyaresomefactorstotakeintoconsiderationwheninspectingthetool. •Whenvisuallyinspectingthetool,greaseshouldberemovedbyusingacommercialdegreaserthatwillnot negativelyaffectthetool. •Afterthetoolhasbeendegreased,makesurethattherangeofmotiononthetoolisquickandcleanwhenyou openandclosethetool. •Inspectthatthewirestop,holders,jaws,andothermovingpartsareinplace. •Makesurethattheunitisnotmissinganyscrewsandthattheemergencyreleaseisoperational. •Ifthereisanydamagespotted,makesureitisnotedandproperlycaredfor.Ifthetoolisstillinuseable conditions,thenlubricatethetoolandreturntoservice.Donotuseexcessiveamountsofoil. •Ifanyadjustmentsorreplacementsneedtobemade,pleasecontactthePower&SignalGroupservicenumber foryourregion.

Wire Stripper Instructions ObtaintheproperstriplengthfromtheCrimpToolReferenceDataSheet,whichislistedforeachcablegaugesizeofthe specifiedterminalpartnumber.(WireStrippersarenotincludedwithallHCTs) •Adjusttheredwirestoponthestrippertotheproperstriplength. •Inspectthestrippedleadscarefullyforcuts,scrapes,missingstrandsordeformedinsulationinthestriparea. •Readjustwirestripperifnecessary. •Acompletevisualinspectionisrecommendedpriortocrimping.

Imperialscale(inches)(forwiregauge32-7)

Metricscale(mm)(forwiregauge0.03-10)

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HCT Technical Support Forassistance,pleasecontact: Power&SignalGroupNA 4670RichmondRoad,Suite120 Cleveland,OH44128USA EngineeringTechLine:(800)610-4837or(216)378-6600ext.5422 Sales:(800)722-5273or(216)378-6600orsales@powersignal.com Power&SignalGroupEMEA Itterpark9-11 40724HildenGermany EngineeringTechLine:+492103250510 Sales:+4921032500orsaleseurope@powersignal.com

Power&SignalGroupAsia 6/FBuilding1 3000LongDongAvenue Pudong,Shanghai201023China Sales:+862128932000orsalesasia@powersignal.com

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