Power Signal Group Hand Crimp Tool User manual

Hand Crimp Tool
User Manual
User Manual
North America
Power & Signal Group
World Headquarters
6675 Parkland Blvd
Solon, OH 44139
USA
Phone: [phone]
440-836-6600
Fax: [phone]
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: [phone]
Email: [email protected]
Asia
Power & Signal Group
11F, BM Intercontinental Business Center
100 Yu Tong Road
Shanghai 200070
China
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Europe, the Middle East & Africa
Power & Signal Group GmbH
Balcke-Duerr-Allee 2
40882 Ratingen
Germany
Phone: [phone]
[phone]
Fax: [phone]
E-mail: [email protected]
[email protected]

Table of Contents
General hand crimp tool (HCT) information
 •Introduction
 •FunctionofHCTratchet
 •Scopeofusage
 •Responsibilitiesofuser
 •NoteregardingHCTmanualdimensions
HCTPowerAssistDevices
ToolTypes
 •ToolType1:Blade&BoxTerminals
 •ToolType2:Pin&SleeveTerminals
AssemblyandRemovalofHCTDieSets
 •Dieselection
 •Dieinsertion
 •Dieremoval
 •Crimpverication
 •CrimpHeightAdjustment
CrimpToolReferenceDataSheet
CrimpingInstructions
 •TerminalLoading
 •TerminalCrimping
 •CrimpHeightMeasurement
VisualCrimpQualityRecommendations
 •Goodcrimp
 •Crimpdimensionsnotintolerance
 •Lowcore
 •Insulationundercorewing
 •Twistedordistortedterminalsorcableseals
 •ExcessiveTab
 •Allstrandsnotcapturedbycorewings
 •Terminalstraightness
 •Cutormissingstrands
HCTMaintenance&Cleaning
HCTVisualInspection
WireStripperInstructions
HCTSupport
2

General Hand Crimp Tool (HCT) information
Introduction
 Power&SignalGroup’sHCTshavebeendesignedtooptimizecrimpqualityforlowvolume,repair,or
 prototypeusage.InNorthAmericaandAsia,theHCTsmaybeorderedasindividualdiesets.In
 Europe,theMiddleEast&Africa,theHCTsmaybeorderedpre-assembledorasindividual
 compo nentstocrimpmultipleDelphiConnectionSystemterminalstovariouscablesizes.TheHCT
 issoldinoneoftwodesigns,bothensuringoptimumcrimpquality.Type2crimpspinandsleeve
 terminalswhileType1crimpsbladeandboxterminals.
Function of HCT ratchet
 ThePowerSignalGroupHCTratchethasdetents.Therearesixaudible“clicks”fromopeningto
 closing.Thecrimptoolisdesignedtocompletethefullcycleofdetentsinordertoassureaquality
 crimp.
 IfitisnecessarytoopentheHCTpriortofullclosure,pressthehandlestogetherslightly.Turnthe
 emergencyunlockingreleaseclockwise(directionofthearrow)andopenthehandles
 simultaneously.
 NOTE:Iftheemergencyreleaseisutilized,thecrimpedterminalisnottobeused.
Scope of usage
 Power&SignalGroupHandCrimpTools(HCT)havebeendevelopedforoptimalcrimpingin:
  •Lowvolumeproduction
  •Repair
  •FieldService
  •Prototyping
 TheHCTshouldnotbeusedforotherpurposes.RepetitiveStressInjury(RSI)canresultfroma
 prolongeduseofmanuallypoweredhandcrimptools.Power&SignalGrouphandcrimptoolsare
 intendedforoccasionalandlowvolumeapplicationsonly.PleasecallPower&SignalGroupfor
 availabilityofpowerapplicatordiesandequipmentforhigh-volumeapplications.
Responsibilities of user
 Theoperation,maintenanceandserviceofthePower&SignalGroupHCTrequiresadegreeof
 practiceandskill.EachpersonwhoisworkingwiththeHCTmustbefamiliarwiththetool’soperation
 andfollowthemanual’sinstruction.Therefore,theinstructionsheetmustbeconstantlywithinreach
 oftheHCT.Inaddition,anyotherinstructionsresultingfromcurrentnationalregulationsintermsof
 healthandsafetyshouldbemaintainedwiththetool’sinstructionsheet.Theusershallnotmakeany
 revisionstotheHCTwithouttheconsentofthemanufacturerorsupplier.BeforeusingtheHCT,the
 operatorshouldconductavisualinspectionofthetooltoverifythatitisnotdamaged,maladjusted,
 orotherwisemalfunctioning.Power&SignalGroupdeclinestoacceptanyliabilityfordamagesthat
 occurduetoinappropriateuseoftheHCTordisregardfortheguidelinessetforthinthetool’s
 insructionsheet.TheuseroftheHCTisresponsibleforthequalityofthecrimp.
Note Regarding HCT manual dimensions
 DimensionsprovidedinthisHCTUsageManualareinmillimeters(mm).Figuresandillustrationsare
 notdrawntoscale.
HCT Power Assist Devices
 Power&SignalGroupcanalsorecommendor,inlimitedinstances,supplyPneumaticorMechanicalAssistdevicesfor
 usewithstandardPSGHandCrimpTools.Formoreinformation,pleasecontactthetechnicalsupportgroupforyour
 region.
3

Tool Types
4
Type 1: Box & Blade Terminal
Type 2: Pin & Sleeve Terminals
Type 3: Pin & Sleeve Terminals
WireStop
WireStop
WireStop
Chamfer
UpperDie
LowerDie
Stationaryjaws
M4X25mmAllenScrew
M4X11mmAllenScrew
M4X11mm
AllenScrew
M4X16mmAllenScrew
M4X16mmAllenScrew
M4X18mm
AllenScrew
DieRetaingScrews
M4LockNut
M4RegularNut
Locator
Locator
Assemblescrewswithoutfully
tightening.Tightenscrewsafter
closinghandlestofullyseatthe
upperandlowerdie.
Turnsmallknobtoopenandclose
holdterminal.
Donotovertightenthewirestop
M4nut.Makecertainthatthewire
stopspringloadedblademoves
freely.
-PresstoOpen
-Insertcontact
-ReleasetocloseonContact
-Opentoreleasecontact
-Aligntobottomdie-Snap
Emergencyrelease
For All Tool Types: Placeendofstrippedwireagainstthewirestop.

Assembly and Removal of HCT Die Sets
Ifyouhavepurchasedapre-assembledHCTbeginwiththecrimpvericationinstructions.
Die selection
 •SelecttheappropriatediefortheterminalpartandgaugesizeasdenedintheCrimpToolReference
 DataSheet.
Die insertion
 •Assembletheupperandlowerdieinsertstogetherwiththeterminallocatorandwirestop.
 •Besurethatthebevelingsidepointstotheleft.
 •Thepropernutandallenscrewsareprovidedwitheachtoolkit.
Die Removal
 •Openthetoolhandles.
 •LoosenandremovethetwodieretainingscrewsbymeansofanAllenwrench
 •Slidethediesoutofthetooljaws.
Crimp verication
 Inordertoensurepropercrimpingandtocontrolthewearingofthetoolanddie,crimpvericationmustbedoneafter
 everydiesetchangeandregularlythereafter.
 StepOne
 Measurethecrimpheightandwidthwithacaliper.
 StepTwo
 ComparethecaliperresultstothespeciedtolerancerangefoundintheCrimpHeightReferenceDataSheetincluded
 witheachdieset.
 Ifthecrimpheightisoutofthespeciedtolerancerange,theHCTneedstobeadjusted.
Crimp Height Adjustment
 •Removesetscrew.
 •Rotatingtheadjustmentwheelcounterclockwiseincreasesthecrimpforceanddecreasesthecrimpheight.
 •Rotatingtheadjustmentwheelclockwisedecreasesthecrimpforceandincreasesthecrimpheight.
 •Reinsertsetscrew
5

Crimp Tool Reference Data Sheet
 Power&SignalGroupsuppliesspecicrequiredinformationwitheachshipmentofitspre-assembledhandcrimptools
 andwithindividualdieinserts.Informationincludesterminalpartnumber,cabletype,striplength,andotherinformation
 relevanttoobtainingaqualitycrimpedterminal.Additionalvalidationdataisavailableuponrequest.
Crimping Instructions
 Theproperinserts,terminallocatorandwirestopshouldalwaysbeusedfortheintendedterminalandwiregaugesize
 (SeeCrimpToolReferenceDataSheet).
  •Referencetoolnumber,terminalnameandwiregaugesizesontoolparts.
  •Referenceterminalpartnumbersandcablegaugesizesfromauthorizedwiringprintsorotherdocuments.
  •UsethespeciccablestriplengthfromtheCrimpToolReferenceDataSheet.
Terminal Loading
 InsertloosepieceterminalintoholderopeningasshowninFigure1.Type2(Pin&SleeveTerminal)locatorsmustbe
 openedwithknurledwheelandclosedtoorientterminalsoastocaptureterminalwings.Usecorrectcablesealif
 required(Figure2).
Figure 1 Figure 2
 Makesureterminalisfullyinsertedsowingsareoverthecrimpanvils.Ifwingsdonotcatchproperly,
 slightlybendinwardtoclearupperplate.Partiallycloseratchethandlestocaptureterminal.(Use
 wrenchtoturnsquarenutclockwisetoreleasehandlesifterminalisnotcapturedproperly.)
 PositionstrippedwireendagainstwirestopinbottomofcrimpwingsforType2orinupperdiefor
 Type1.Makesurethespringloadedwirestopreturnsaftereachcrimp.(Ifwirestopdoesnotreturn,
 thelockingnutistootightorthestopneedstobelubricated.)Ifacablesealisused,makesurethe
 sealispositionedsothattheinsulationwingscapturetheseal.Makesurenostrandsarecutorare
 missinginthestrippingprocess.
Terminal Crimping
 Completetheratchetingclosureofhandlesuntiltheyspringopen.Removecrimpedleadscarefully.
 InspectcrimpedleadaccordingtotheVisualCrimpQualityRecommendationstoeliminatenonconformances:
 Measureallcrimpdimensionswithcalibratedmeasuringequipment.Comparetocrimpdimensionssuppliedwiththe
 toolinsertsforspeciccablesizeandterminalpartnumber.
 Ifcrimpsaretoohigh,removesetscrewandturnserratedwheelcounterclockwise(+)untilpropercrimpheightis
 achieved.(Reinsertscrewbeforetryingagain.)Ifcorecrimpheightistootight,followthesameprocedureexceptturnina
 clockwisedirection.
6

Crimp Height Measurements
 Inordertoinsurepropercrimpquality,thecrimpheightmustbemeasuredandreadjustedifitdoesnotmeettheCore
 CrimpHeight(CCH)requirementsasshownintheCrimpToolReferenceDataSheetforthespeciedterminalandcable
 size.TheCCHshouldbemeasuredwithapprovedcalipers.
Visual Crimp Quality Recommendations
Good Crimp:
        Correctcrimptoolapplicationwillminimizeoreliminate
        non-conformingcrimps.Improperlycrimpedterminals
        mayfailelectrically.Practiceonsamplesuntilgoodquality
        crimpsareconsistentlymade.Crimpedterminalsmust
        alwaysbe100%visuallyinspectedaftercrimpingprocess
        byfollowingthenon-conformancelistingsbelow.
Crimp dimensions not in tolerance:
        Wronginserttooling,crimpadjustmentnotright,inserts
        notseated,wronginsertjaw,wrongcableorterminal
        (Seedatasheetwithtooling.)
Low core:
        Corenotshowinginfrontofterminalcorewingsdueto
        shortstrip,notusingwirestoporincorrectplacement.
Insulation under core wing:
        Nostrip,shortstrip,wirestopnotused,incorrectplacement
        (mayalsoresultinhighcore).
Twisted or distorted terminals or cable seals:
        Terminalnotpositionedcorrectlyintool.
7

Excessive Tab
        Maydamagesealorcausesealtonotsealproperly.
        Terminalsnotcutostripproperly.
All strands not captured by core wings:
        Maycausealoosecrimpandelectricalormechanical
        non-conformance.Mayneedtoinspectstrandspriorto
crimping.
Terminal straightness:
        Excessivelybentterminalsmaycauseterminalsnotto
        seat,pushmatingterminaloutofcavity,ornotbeableto
        seatTerminalPositionLock.Maybecausedbylocating
        terminalincorrectlyintool.
Cut or missing strands:
        Incorrectstrippingofcable.Maycausealoosecrimpand
        electricalormechanicalnon-conformance.
HCT Maintenance and Cleaning
 ResponsiblepersonnelandoperatorsofthePower&SignalGroupHCTshouldmaintainthetoolwitheachuse.
  •Useaclean,lint-freeclothtoremovedust,moisture,anddebrisfromthetool.Donotuseabrasivecleanerson
  thetool,whichcouldresultindamage.
  •Makesurethatallscrewsandotherremovablepartsaresecureandinplace.
  •Allpivotpoints,bearingsurfaces,joints,andothermovementpointsshouldberegularlyoiled.
  •Whenthetoolisnotinuse,itshandlesshouldbeclosedtopreventforeignobjectsfrombeinglodgedinthe
  nichesandrecessesofthetool.
  •Storethetoolinacleananddryarea.
8

HCT Visual Inspection
  •QualitycontrolpersonnelshouldregularlycheckupontheHCTtoensurethatcrimpqualityisoptimal.
  •Inspectionsonthetoolshouldbemaderegularlyandlogged.
  •Thefrequencyofuse,workingenvironment,companystandards,andoperatortraining,strength,and
  prociencyaresomefactorstotakeintoconsiderationwheninspectingthetool.
  •Whenvisuallyinspectingthetool,greaseshouldberemovedbyusingacommercialdegreaserthatwillnot
  negativelyaectthetool.
  •Afterthetoolhasbeendegreased,makesurethattherangeofmotiononthetoolisquickandcleanwhenyou
  openandclosethetool.
  •Inspectthatthewirestop,holders,jaws,andothermovingpartsareinplace.
  •Makesurethattheunitisnotmissinganyscrewsandthattheemergencyreleaseisoperational.
  •Ifthereisanydamagespotted,makesureitisnotedandproperlycaredfor.Ifthetoolisstillinuseable
  conditions,thenlubricatethetoolandreturntoservice.Donotuseexcessiveamountsofoil.
  •Ifanyadjustmentsorreplacementsneedtobemade,pleasecontactthePower&SignalGroupservicenumber
  foryourregion.
Wire Stripper Instructions
 ObtaintheproperstriplengthfromtheCrimpToolReferenceDataSheet,whichislistedforeachcablegaugesizeofthe
 speciedterminalpartnumber.(WireStrippersarenotincludedwithallHCTs)
  •Adjusttheredwirestoponthestrippertotheproperstriplength.
  •Inspectthestrippedleadscarefullyforcuts,scrapes,missingstrandsordeformedinsulationinthestriparea.
  •Readjustwirestripperifnecessary.
  •Acompletevisualinspectionisrecommendedpriortocrimping.
Imperialscale(inches)
(forwiregauge32-7)
Metricscale(mm)
(forwiregauge0.03-10)
9
HCT Technical Support
 Forassistance,pleasecontact:
 Power&SignalGroupNA
 4670RichmondRoad,Suite120
 Cleveland,OH44128USA
 EngineeringTechLine:(800)610-4837or(216)378-6600ext.5422
 Sales:(800)722-5273or(216)378-6600or[e-mail]
 Power&SignalGroupEMEA
 Itterpark9-11
 40724HildenGermany
 EngineeringTechLine:+492103250510
 Sales:+4921032500or[e-mail]
 Power&SignalGroupAsia
 6/FBuilding1
 3000LongDongAvenue
 Pudong,Shanghai201023China
 Sales:+862128932000or[e-mail]