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Hand Crimp Tool User Manual North America Power & Signal Group World Headquarters 6675 Parkland Blvd Solon, OH 44139 USA Phone: 1-800-722-5273 440-836-6600 Fax: 440-836-6122 E-mail: [email protected] [email protected] South America Power & Signal Group, an Arrow Company Rua José Gomes Falcão, 111 Attn: Roberto Cutrupi, Sales Manager South America 01139-010 - Barra Funda - São Paulo - S.P. - Brasil - BR Phone: 55 11 3613 9371 Email: [email protected] Asia Power & Signal Group 11F, BM Intercontinental Business Center 100 Yu Tong Road Shanghai 200070 China Phone: +86 21 22152000 Fax: +86 21 22152435 E-mail: [email protected] Europe, the Middle East & Africa Power & Signal Group GmbH Balcke-Duerr-Allee 2 40882 Ratingen Germany Phone: +49 2102/1677-0 +49 800 10 10 772 Fax: +49 (0)2102/1677-160 E-mail: [email protected] [email protected]
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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

Mar 22, 2018

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Page 1: 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: [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]

Page 2: 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
Page 3: 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

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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Page 4: 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

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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Page 5: 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

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.

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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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Page 7: 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

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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Page 8: 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

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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Page 9: 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

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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Page 10: 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

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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