Hand Crimp Tool User Manual - Electronic Component Distributor

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: [email protected] [email protected]

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: [email protected]

AsiaPower & Signal Group11F, BM Intercontinental Business Center100 Yu Tong RoadShanghai 200070ChinaPhone: +86 21 22152000Fax: +86 21 22152435E-mail: [email protected]

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: [email protected] [email protected]

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)[email protected] Power&SignalGroupEMEA Itterpark9-11 40724HildenGermany EngineeringTechLine:+492103250510 Sales:[email protected]

Power&SignalGroupAsia 6/FBuilding1 3000LongDongAvenue Pudong,Shanghai201023China Sales:[email protected]

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