Crimping tools
Contents
1. 2 mm for sections from 1 to 10 mm When using closed crimp pins with an inspection hole the crimp conductor must be visible through the inspection holes Keeping the conductor strands visible above the contact collar enables you to check correct strippping i e make sure no strands have been cut This also ensures a certain flexibility for the connection by not transmitting to the contact any flexure stresses caused by installation However in practice some operators give priority to insulation by reducing to zero the gap between cable insulation and the contact collar 2 Insertion of crimped contacts in the connector insert It is recommended that the crimped contacts be perfectly straight and inserted within the contact slots in a single operation and without excessive force until a clicking sound is heard The correct retention of the contact should be verified with a light pulling of the wire Non alignment of the crimped contacts must be avoided because this could cause possible loosening of the retention springs and consequently jeopardise the retention of the contact in the insert For small section conductors lt 0 35 mm or for specific application the use of the insertion tool specified by the manufacturer is recommended 3 Removal of inserted contacts In the case of incorrect insertion or wiring substitution inserted contacts may only be removed using the removal tools specified by the manufacturer 4 Mounti2. MULTIPOLE CONNECTORS Crimping tools CN Crimping tools Tools and accessories for crimp contacts The crimping concept The crimp connection is an irreversible connection between one or two conductors and a crimp contact The crimp connection is obtained by pinching or pressing the contact metal or shaft firmly with the crimping tool A good crimp connection is provided by a suitable combination between the crimping base the crimping part of the contact metal i e the crimp contact firmly with and the section of the conductor These comments refer to crimped connections carried out with copper flexible conductors in class 5 flexible or 6 extra flexible according to standards IEC 60228 and IEC 60228 A Italian standard CEI 20 29 Solid copper conductors class 1 or in other materials aluminium iron etc often require special precautions for contacts and for crimping tools to be agreed with the manufacturer The main technical advantages provided by crimping connections over soldered connections are The process does not use heat and does not require materials Perfect connection is acquired that is intrinsic with cold soldering No degradation of the elastic characteristics of the female contacts a problem that arises with soldering temperatures No health risks connected with the use of heavy metals or fumes generated from the soldering process Preservation of the conductor s flexibility immediately upon
3. A CCVPP optional compressed air supply hand valve CCTP turret head excluded F f CCSPZP optional SS selector dial Checking the crimping complete cycle control mechanism Correct operation can be checked based on the following procedure 1 Install a CCTP turret 2 Reduce the pressure to 1 bar 3 Using a contact that corresponds to the installed turret with size 0 5 and a wire with section 0 5 mm use the crimping tool referring to the crimping instructions The indenters will not reach the fully closed position and the contact will be internally blocked if the geared mechanism is operating correctly 4 To release the partially crimped contact increase the air pressure of the line to 5 5 8 3 bar and again use the crimping tool It will then complete the crimping allowing the indenters to return to the fully open position Crimping instructions 1 Insert the contact and the prepared conductor through the opening of the indenter in the turret positioner 2 Activate the hand valve or the optional foot valve Once crimping has been completed the tool will return to the open position 3 Check the position of the crimping on the contact crimping foot Ideally the crimping should be between the inspection hole and the top edge of the crimping foot The head of the contact should not be squared and the inspection hole should be intact Crimping tool maintenance No maintenance is required Howev
4. CGFA 16 16 6 5 CGT 16 13 3 16 8 CGD 25 C ME 5 CGMA 25 CGFA 25 25 4 3 21 2 26 7 CGD 35 C ME 7 CGMA 35 CGFA 35 25 2 33 6 part No punching contacts mm AWG mm CGD 25 C ME 5 CYMA 16 CYFA 16 16 6 13 3 CYD 35 C ME 9 CYMA 25 CYFA 25 25 4 21 2 CYMA 35 CYFA 35 35 2 33 6 CYD 50 C ME 12 CYMA 50 CYFA 50 50 1 42 4 CYD 70C ME 17 CYMA 70 CYFA 70 70 2 0 67 4 542 General specifications The CPPZ C crimping tool are a hydraulically operated tool suitable for manually crimping contact series 70A 100A 200A max removable crimp contacts which may be used in MIXO series type CX7 CG CY and CGT 16 adaptor By using a suitable hexagonal footprint crimp matrix pair these pliers allow crimped connections to be made which conform to the highest quality standards The main features of these pliers are listed below Scope of application suitable for crimping wire terminals for up to 150 mm flexible copper wires Force developed 50 KN 6 tons Nominal operating pressure 600 bar 8 600 psi Dimensions length 346 mm 13 6 width locked moving handle 130 mm 5 1 width free moving handle 250 mm 9 8 Weight without matrixes and without ILME locator 2 0 kg 4 4 Ibs Recommended oil AGIP ARNICA 32 or SHELL TELLUS OIL TX 32 or equivalent Other features please read the user and maintenance manual supplied with the tool The pliers are equipped with a locator specifically designed for ILME CX7 CG
5. no go control gauge CCPZ RN tes aaa CCPR RN A tool used to periodically check that the crimping tool meets standard requirements CCES NO GO yo GO CCPNP RN 538 General specifications The CCPZ RN crimping tool crimps with 8 pressure points obtaining similar results to the prescriptions of standard MIL C 22520 1 The tool has a geared mechanism for controlling the complete crimping cycle and houses a positioning turret with 12 positions six of which can be used for positioning the ILME male and female crimping contacts of series CD 10A max CC 16A max and CX 40A max Crimping range Wire section dimension from 0 14 mm 26 AWG to 10 mm 8 AWG 12 seat iti adjustment knob with 1 100 mm positioner indenters Units for fine adjustment closure stop fixed handle movable handle metric scale with 2 10 mm units for approximate adjustments Description of tool Crimping tool components a first mobile handle with a precision stop mechanism with teeth and an opening limiting guide a second fixed handle with metric scale units of 2 10 mm an adjustment system with fine step adjustments of 1 100 mm four indenters a 12 seat positioner fully rotating through 360 for accurate positioning of contacts A reference table engraved on the tool surface provides the positioner POS number and crimping depth SET to select according to the type and size of the ILME contact the crimping too
6. one night to hard dry the glue 5 finally the POF has to be polished polishing disc 950 General specifications Strip the fibre about 12 mm for male contact and about 15 mm for female contact see Figures 1 and 2 min 12 mm lt Fig 1 Example of cable stripping for male crimp contact min 15 mm Fig 2 Example of cable stripping for female crimp contact Crimping instructions The data sheet for crimping tool CLPZ R explains how the crimping tool works and how to adjust the crimping depth and locator for the contacts to be crimped Position the turret on 3 push and turn of 90 the knob of turret Adjust the crimping depth on 2 unscrew the allen screw after adjusting refix the screw For the female contact unscrew the back of the contact pull out the internal central part on Figure 3 is indicated the crimping area front part of contact For male contact crimp the front part of contact Push the stripped fiber as far as possible into the contact sleeve so that it protrudes approx 1 mm from the tip of the contact Back of contact Contact fibre crimping area ae Fig 3 Female contact fibre crimping area Fig 4 Male contact fibre crimping area Insert the contact together with the fibre optic cable as far as possible into the crimping opening of the crimping tool CLPZ R see Figure 5 while applying gentle pressure to the fibre optic cable and connector cl
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8. and CY series crimp contacts already fitted on the moving part of the pliers head by means of the Allen screw provided This locator is available on request if it needs replacing NOTE It is possible to use the CPPZ C pliers with the CX7 70A CG 100A and CY 200A contact series by simply fitting the CY7PZ LOC CGPZ LOC or CYPZ LOC locator and crimping matrixes to be purchased separately WARNING For crimping the CGT 16 adaptor the crimp locating operation must be carried out by the user User instructions 1 Preliminary operations According to requirements the pliers can be fitted with one or more pairs of crimp matrixes selected from the matrixes listed in the catalogue to crimp the contacts shown in the table page 542 NOTE The crimp contacts are only suitable for crimping flexible copper wires featuring a nominal section shown in the table with the crimp matrixes shown in the table Any contacts wires matrixes combination which does not conform to these instructions is not physically possible ex using 35 mm contacts with CGD 25 C matrixes is not possible because the pliers head would not close or produces non conforming crim ped connections or not usable in the MIXO series Open the tool head by moving the matrix supporting hook 22 outwards until the matrix support 21 is released With reference to Figures 1 and 2 select a pair of matrixes suitable to the type of contact and insert them in the housings one i
9. connection No conductors with burned discoloured or overheated insulating material Excellent reproducibility of the performances of the electrical and mechanical connections Facilitated production controls Other advantages obtained by crimping connections over screw terminal connections are Less drop of currency in the connector contacts High stability in time even in the presence of vibrations High duration in presence of corrosion gastight Individual insertion of the contacts in the connector it is possible to eliminate unnecessary contacts Less time required for connection Possibility of pre production of the terminated conductors with crimp contacts Easy substitution of individual contacts during maintenance Possibility of selectively isolating the circuits during maintenance via the extraction of the contacts from the connector The crimped connections for wire sections up to 10 mm are covered by the EN 60352 2 2006 European standard equivalent to the IEC 60352 2 Issue 2 2006 02 international standard The EN 60352 2 standard also includes a practical guide which lists the following main points The quality of a crimped connection is mainly affected by the quality of materials used and by the condition of the crimp contact in particular the crimp shaft and wire surfaces To ensure a good quality crimped connection an essential parameter is the wire mechanical retention in the
10. contact The standard makes a distinction between the closed crimp shaft inherently stronger and the open crimp shaft ILME crimp contacts are closed crimp shaft contacts with inspection hole which ensures a higher mechanical performance compared to the open shaft crimp contacts such as better mechanical sturdiness and stability during operation They have been machine turned thus ensuring a better electrical performance better conductivity 2002 Amendment 2 of the previous IEC standard issue controversially unified the minimum resistance to tensile stress values established for open shaft contacts curve B of old Figure 5 and closed shaft contacts curve A of old Figure 5 by lowering them to the values shown in curve B which can be achieved by open shaft crimp contacts This has controversially relaxed the suitability requirements both for closed crimp shaft typically large machine turned and for crimp tools specially made for these contacts Several industries continue to prefer the higher performance ensured by closed shaft crimp contacts the only ones to ensure the higher resistance to tensile stress values believed to be essential for the most demanding industrial applications Therefore ILME continues to refer to curve A of Figure 5 illustrated in the EN 60352 2 1994 standard ILME closed shaft crimp contacts used with flexible copper wires featuring a section included in the ranges shown and correctly crimped with the
11. crimping cavity It is also necessary to order the interchangeable positioner inserts relative to the series of contacts to be crimped The tool operating pressure is 5 5 8 3 bar It is recommended to utilise a lubrication adjustment and air filtering unit Crimping range Wire section dimension from 0 12 mm 26 AWG to 4 mm 12 AWG Fig A complete crimping tool cable contact needle valve selector dial automatic positioner compressed air supply Checking the crimping complete cycle control mechanism Correct operation can be checked based on the following procedure 1 Reduce the pressure to 1 bar 2 Using a contact that corresponds to the installed positioner with size 0 5 and a wire with section 0 5 mm use the crimping tool referring to the crimping instructions The indenters will not reach the fully closed position and the contact will be internally blocked if the geared mechanism is operating correctly To release the partially crimped contact increase the air pressure of the line to 5 5 8 3 bar and again use the crimping tool It will then complete the crimping allowing the indenters to return to the fully open position Crimping instructions 1 To obtain the suitable selector number refer to the data plate located on the cover of the positioner insert case and adjust the selector dial as specified 2 Insert the contact and the prepared conductor through the opening of the indenter in the
12. crimping tool casing Fig A 3 Exert slight pressure until the crimping tool automatically crimps the contact CAUTION Wire sections less than 0 34 mm 24 AWG up to 0 08 mm 28 AWG or equivalent are not sufficiently rigid so that it may be rather difficult to push the contact wire Check the position of the crimping on the contact crimping foot Ideally the crimping should be between the inspection hole and the top edge of the crimping foot The head of the contact should not be squared and the inspection hole should be intact Crimping tool maintenance No maintenance is required However it is good practice to keep the indenter tips free from residual deposits of the coloured band some types of crimp contacts as per MIL standards are identified by coloured bands in the crimping area and any other debris A metal brush may be used for this purpose The following is strongly recommended 1 DO NOT immerse the tools in a solution to clean them 2 DO NOT brush oil in the tools to lubricate them 3 DO NOT try to disassemble the tool or repair it This is a high precision crimping tool and must be used as such Installation or replacement of a positioner insert 1 Disconnect the workshop compressed air source 2 Disconnect the air hoses from the automatic positioner rapid connectors 3 Remove the connection screws using the 3 5 mm Allen wrench supplied with the kit to separate the automatic positioner from the crimpi
13. depth The stripping depth is the measurement in mm of how much the stripping blades must penetrate the insulator to strip it off and depends on the type of cable used The crimping depth is the measurement in mm of how much the four indenters must penetrate the contact at the end of the crimping operation This depth depends on the size and shape of the contact crimp shaft thickness and determines the quality of the crimping operation in terms of gas tightness and resistance to tensile stress Note The machine also has a 12C program suitable for 10A 2 5 mm crimp contacts with 6 mm stripping length This program is therefore unsuitable for ILME CD series contacts stripping length 8 mm Operational setups The tool carrier carriage may be accessed by opening the front door by anticlockwise rotation of the knob which releases the pressure from all the valves For tool selection see table on page 548 For CD series male and female crimp contacts 10A max the feeding cup A must be fitted onto the machine whilst for CC series crimp contacts 16A max feeding cup B M for male contacts and B F for female contacts must be used The feeding tubes to be fitted are A for CD series contacts and B for CC series contacts respectively The wire holders which support the wire during the stripping stage feature three different sizes for CD contacts and two sizes for CC contacts The contact holders are two A M for male contacts
14. determine the number that corresponds to the contact being used Remove the retaining hook from the crimping tool selector dial Lift the selector dial and turn it until the selector number is aligned with the indicator SEL NO Replace the retaining hook if necessary retaining hook selector dial positioner identification colour code turret selector blocking lever indicator line turret selector in free position screws data plate Removing the CCPT turret With the crimping tool in the open position to disassemble the turret loosen the socket head screws using the 3 5 mm Allen wrench supplied with the kit After the threads are released from the support ring pull off the turret with a straight movement Releasing a partially crimped contact To release a partially crimped contact do the following 1 Increase the air pressure to 8 5 bar and use the crimping tool If the increase in air pressure does not release the contact do the following 2 Turn the selector dial clockwise to the highest lockable setting the selector dial must be in the blocked position before continuing Use the crimping tool 3 If it does not release after several attempts contact the ILME offices Instructions to check calibration The operations to check the crimping tool must be carried out with the selector dial in position 4 and the CCPNP gauge CAUTION Do not crimp the gauge Calibration check Put the crimping tool in the compl
15. heads gauge CDD 10A 67 74 CDG a 16A 99 103 CCEA ee 16A 110 115 COE e aa 16A 138 143 CQEE T 16A 146 147 CMCE TE ee 16A 148 160 COO reais 10A 16A 165 168 CX 8 24 16A 10A 169 CX 6 36 10A 170 CX 2 27 eee 10A WEL CX GO 2 2 16A 175 MIXO 10A 16A 185 203 the underlined polarities indicate those contacts that require the tools shown in this page description part No part No pneumatic crimping tool for 10A and 16A contacts model DANIELS WA27F turret excluded CCPZP turret heads see note for 10A contacts CDF and CDM series CCTP 10 for 16A contacts CCF and CCM series CCTP 16 support for CCPZP pneumatic crimping tool CCSPZP pneumatic foot valve CCVPP go no go control gauge to verify indenter closure see note CCPNP insertion tool for insertion of the contacts into the inserts for crimped contacts up to 0 75 mm CCINA removal tools for the extraction of contacts from the inserts for 10A contacts 1 CCES for 16A contacts 2 CQES replacement tip for CCES removal tool CCPR RN 1 for CQ CD CDD CX inserts 10A auxiliary contacts and MIXO module 10A tona deni 2 for CQ CQE CQEE CCE CMCE inserts excluded CAPING Sep 16 2 MIXO module 16A CX6 6 16A and CDC adjuster selector For CMCE 16 2 CX inserts contacts 16A insert CX 8 24 using a flat 3 mm screwdriver CCINA Notes EN Positioning turret a Y conf
16. page manual crimping tool polishing disc polish paper removal tool CX PLFIPLM 1 22 4 2 See 209 jacket stripper and fibre stripper CX MEF MEM n a ue cen 209 cable cutter Sy description part No part No crimping tool for POF CX PL and MOST CX ML contacts CLPZ R RENNSTEIG model polishing disc RATIOPLAST 910 PS OSC 00 001 for POF and MOST contacts CLDL polish paper grain size 1000 RATIOPLAST 910 PB 001 00 001 CLC1 grain size 4000 RATIOPLAST 910 PB 001 40 250 CLC4 removal tool CLES for the extraction of contacts from the CX L inserts jacket stripper RATIOPLAST 910 AZ 001 00 PA1 CLSG for POF and MOST fibre optic with PA jacket fibre stripper RATIOPLAST 910 AB 001 00 001 CLSP for POF fibre optic cable cutter RATIOPLAST 910 SW 001 00 001 CLTE for 2 3 mm max for POF and MOST fibre optic on request tool CLPZ RATIOPLAST 910 CZ 001 00 008 for contacts POF IMOST crimping on the back POF POLYMER OPTICAL FIBRE MOST MEDIA ORIENTED SYSTEM TRANSPORT CLC1 CLC4 A OoN Note CLDL as alternative to crimping please use glue UHU PLUS ENDFEST 300 BICOMPONENT part No CL GL provide a strain relief by cable CLPZ R glands 1 mix the two components on a sheet just a drop each 2 the stripped ca 5 mm POF that means the inner fibre has to be dipped in the glue just 5 mm 3 the POF has to be pushed now in the contact ferrule 4 min
17. recommended tools ensure breakage resistant connections at least equal to the values shown in the table shown below for reference the corresponding R S unified tensile stress load value is also shown N mm Section S Resistance to R S traction R AWG mm N N mm 26 150 150 24 150 150 22 150 150 0 6 7 150 150 150 150 150 147 143 130 130 125 120 108 100 130 103 92 80 66 56 NOTE For 10 mm wire sections the resistance to tensile stress shown in italics are those specified in the NF F 61 030 standard for 10 mm the value in brackets The basic criteria used for the resistance to tensile stress values required by EN 60352 2 standard is that such resistance is at least equal to 60 of the breakage unified load of the same annealed copper wire This applies to wire sections up to about 1 5 mm above this section the ratio is slightly lower as retention is also affected by friction which increases linearly with the housing diameter whilst the section increases by the square IEC EN 60352 2 standard which targets the electronics industry restricts its requirements to crimp connections for wires with a maximum section of 10 mm For sections higher than 10 mm up to 70 mm the standard to refer to is the NF F 61 030 1989 French standard which relates to electrical connectors to be used on board of railway rolling stock in particular for large crimp contacts s
18. the column indicating the proper conductor section determine the number that corresponds to the contact being used Remove the retaining hook from the crimping tool selector dial Lift the selector dial and turn it until the selector number is aligned with the indicator SEL NO Replace the retaining hook if necessary retaining hook CO selector dial screws data plate Removing the CXPT turret With the crimping tool in the open position to disassemble the turret loosen the socket head screws using the 3 5 mm Allen wrench supplied with the kit After the threads are released from the support ring pull off the turret with a straight movement Instructions to check calibration The operations to check the crimping tool must be carried out with the selector dial in position 4 and the CCPNP gauge ATTENTION Do not crimp the gauge Calibration check Put the crimping tool in the completely closed position GO Insert the end green of the gauge as shown Fig 1 The gauge must pass freely between the indenter tips NO GO Insert the end red of the gauge as shown Fig 2 The gauge should not pass through the opening A 0 00254 mm GO green 1 549 mm B 0 00254 mm NO GO red 1 676 mm tool selector pos No CXPNP 4 Gauge tools and accessories for crimp contacts M gt for contacts of insert series page manual crimping tool insertion tool removal tools
19. 1 contact stop for CD contact series 1 contact stop for CC contact series 1 wire holder for 0 34 mm cables 1 wire holder for 0 5 to 1 5 mm cables 1 wire holder for 2 5 mm cables 1 GO NO GO control gauge 1 Allen wrench for setup operations 1 set of spacers to regulate the stripping length 1 removal tool to extract contacts from the crimping chamber 548 General specifications The Zoller Frohlich AM 03 Universal stripping crimping machine is a semi automatic electro pneumatically operated bench machine used to quickly and reliably strip flexible copper wires and to crimp loose turned crimp male and female CD series 10A max and CC series 16A max contacts in a single run The contacts are automatically fed by means of a vibro conveyor unit fitted on the top section of the machine The machine carries out the crimping operation with four eight pressure point indenters in compliance with the requirements set out in the MIL C 22520 1 standard The stripping depth and crimping depth adjustment is controlled by a software controlled motor Up to 50 different combinations may be stored and retrieved from the program these combinations are useful for example to meet different requirements related to the wire insulator type and thickness The adjustment and programming operations are carried out by using the keypad located on the front panel The LCD display shows all the functions the main information a
20. CCPZPA pneumatic crimping bench tool with automatic positioner for 10A and 16A crimp contacts is suitable for workshop jobs where compressed air is available for medium high or high work loads It is recommended in particular for crimping high quantities of contacts that are the same type or have the same section thus saving a significant amount of time thanks to automatic operation and reduced operator fatigue Where the type or kind of contact must be changed frequently it is preferred to use the version without automatic positioner The CXPZP D pneumatic crimping bench tool without automatic positioner for 40A crimp contacts is suitable for use in the workshop where compressed air is available for high or medium high work loads By using the same positioners as those of manual crimper CXPZ D the size of a contact can be rapidly changed with one of the same type However the positioner must be changed in order to change over from male to female contacts The semiautomatic stripping crimping machine type ZFU CD is suitable to be used in workshops where an electrical or pneumatic power supply is available and for heavy work loads It enables to produce large amounts of crimped connections in less time because of the possibility of simultaneously carrying out stripping and crimping operations The contact and tool replacement operations which are minimized because of the preset programs that can be stored and customized by the user requ
21. CCTP turret positioned against the support ring tighten the socket head screws with the 3 5 mm Allen wrench supplied with the kit 5 Refer to the data plate on the CCTP turret From the colour code column select the colour of the positioner that corresponds to the appropriate code and dimension of the contact to be crimped 6 With the CCTP turret in the adjustment position turn the turret until the colour coded positioner is aligned with the indicator line Press the turret until it clicks into the connected position 7 Refer to the data plate on the CCTP turret From the column indicating the proper conductor section determine the number that corresponds to the contact being used 8 Remove the retaining hook from the crimping tool selector dial Lift the selector dial and turn it until the selector number is aligned with the indicator SEL NO Replace the retaining hook if necessary retaining hook C_O selector dial positioner identification colour code turret clicking lever indicator line turret in free position data plate screws Removing the CCPT turret With the crimping tool in the open position to disassemble the turret loosen the socket head screws using the 3 5 mm Allen wrench supplied with the kit After the threads are released from the support ring pull off the turret with a straight movement Instructions to check calibration The operations to check the crimping tool must be
22. a 0 14 0 25 0 34 0 5 0 75 1 0 1 5 2 5 3 0 4 0 condutor CoMo epep 0 40 25 0 34 0 5 0 75 1 0 1 5 25 conductor E A mm mm mm mm mm mm mm mm mm mm section ae Blue mm mm mm mm mm mm mm mm section male AWG male AWG Ca E o e e E ee C E a ee a eee es On 0 Se a cee ee O O a ee CE oe C E O ee 10 10 A ge o i Oe i a a a Pe oe es Se ee 15 15 et7 7 7st ssjo DA Ee SS E 2 E ee ee E 25 25 7 0 ESO SS SS ES SSS Ease A a SS ES SS SS Sara 534 use and maintenance instructions General specifications The CCPZ MIL crimping tool conforms to the international standard MIL C 22520 1 Crimping is performed with 8 pressure points The tool is equipped with a geared mechanism to control the complete crimping cycle The tool must be equipped with an interchangeable turret CCTP according to the series of contacts to be crimped Crimping range Wire section dimension from 0 12 mm 26 AWG to 4 mm 12 AWG Caution The handle of the tool must be in the open position when the turret is installed disassembled or opened If not the turret and the crimping tool may be damaged tool in open position support ring selector indicator selector dial Crimping instructions 1 Insert the contact and the prepared conductor through the opening of the indenter in the turret positioner 2 Tighten the crimping too
23. and A F for female contacts for CD series contacts according to the different rear diameter between male and female contacts in this series whilst there is only one holder B for CC series contacts The contact holder is A for CD series contacts and B for CC series contacts Feeding the wire The wire must be cut straight and the single braids must not be bent or pulled apart in particular the first 4cm must be perfectly straight Checking the stripping depth The machine can be operated simply as a stripping machine by disabling the crimping Operation Please refer to the machine user manual Maintenance and repairs Stripping residues collection tray empty the tray approximately every 2000 cycles the frequency depends on the sizes of the stripped wire and on the stripping length Pneumatically controlled maintenance unit regularly drain any water that may have collected The trap may be cleaned with water To remove the trap simply disconnect the air supply The filter unit may be unscrewed for cleaning purposes then immerged in a cleaning agent such as petrol or oil thoroughly washed and dried Checking the calibration values The correct calibration of the machine must be periodically checked by using the GO NO GO caliper supplied as standard with the machine by following the procedure described in the machine user and maintenance manual tools and accessories for crimp contacts M gt for contacts series
24. ase with no further interventions e The removable parts of the tool such as the crimping dies and the locators must be designed in such a way as to make it possible to be inserted within the tool only in the correct manner f The tools must be supplied with the appropriate means for a correct positioning of the pins to be crimped and of the conductors during crimping g The tools must be designed in such a way so that only the necessary adjustments may be made h The action of the tool must be such that both the pin to be crimped and the fixture of the isolation when present are respectively crimped or compressed with a single action The design of the tool must ensure that the dies for a particular tool may be interchangeable within tools of the same type lf they are not interchangeable the identification of tools for which they are suitable must be marked on the dies The tools may be designed so as to produce a marking or coding of the die on the pin to be crimped so that the crimping may be checked for verification of the correct die k The design of the tool must allow the verification of the dies with gauges to measure wear The gauge verification method must be that specified by the manufacturer of the tools With suitable flexible copper conductors the crimping tool proposed by ILME gives 8 impression crimp see figure in conformity with standard EN 60352 2 Periodic control of the wear of the crimping matrixes can be ca
25. carried out with the selector dial in position 4 and the CCPNP gauge ATTENTION Do not crimp the gauge Calibration check Put the crimping tool in the completely closed position GO Insert the end green of the gauge as shown Fig 1 The gauge must pass freely between the indenter tips NO GO Insert the end red of the gauge as shown Fig 2 The gauge should not pass through the opening Gauge tool selector A 0 00254 mm B 0 00254 mm pos No GO green NO GO red CCPNP 4 0 991 mm 1 118 mm OB Fig 1 Fig 2 935 tools and accessories for crimp contacts for contacts of insert series page CX 6 36 Tae 40A 170 GX 12 2 voice esses 40A 171 MIXO eee 40A 184 188 the underlined polarities indicate those contacts that require the tools shown in this page On request is possible to supply the pneumatic crimping tool version part No CXPZP D please contact us for further details description crimping tool for 40A DANIELS M309 model turret excluded turret heads see note for male contacts 40A for female contacts 40A go no go control gauge to vertify indenter closure see note removal tool for the extraction of contacts from the inserts for 40A contacts Notes Positioning turret An interchangeable and indispensable accessory of the CXPZ D crimping tool it precisely positions the contact where crimping is performed Each series of
26. contacts male or female requires its own turret go no go control gauge A tool used to periodically check that the crimping tool meets standard requirements red no go green go 536 manual crimping tool turret heads gauge part No CXPZ D CXTP 40 M CXTP 40 F CXPNP On request is possible to supply the pneumatic crimping tool version part No CXPZP D please contact us for further details crimping depth adjuster selector CXPZ D CXTP 40 M and CXTP 40 F removal tool part No CXES CXES General specifications The CXPZ D crimping tool performed with 8 pressure points The tool is equipped with a geared mechanism to control the complete crimping cycle The tool must be equipped with an interchangeable turret CXTP according to the series of contacts to be crimped Crimping range Wire section dimension from 1 5 mm 16 AWG to 6 mm 10 AWG Caution The handle of the tool must be in the open position when the turret is installed disassembled or opened If not the turret and the crimping tool may be damaged tool in open position position selector indicator selector dial Crimping instructions 1 Insert the contact and the prepared conductor through the opening of the indenter in the turret positioner 2 Tighten the crimping tool handle until the stop gear is released The tool will return to the open position 3 Check the position o
27. e braid shield 5 Crimp the ferrule with position 3 25 of crimping tool COPZ We recommend the use of code pins CRF CX CRM CX As alternative to crimping it is possible to solder the central contact CX 50 F M and CX 75 F M coaxial contacts use and maintenance instructions for contacts series page manual crimp pliers E RJ45 503 MIXO RJ45 202 203 description part No RJ45 CJ series plug insert crimp pliers basic tool YAMAICHI Y ContTool 11 mod CJPZ Y with plug insert inserter Y ContTool 20 cable stripper cuts the cable sheath and releases the wires in a single operation How to use the RJ45 plug insert crimp pliers o 6 7 mm 35 mm screened cable stripper part No CJST 553 tools and accessories for crimp contacts lt gt inserts page manual crimp pliers shielded cable stripper MIXO RJ45 CX 8 J6M 200 description part No part No RJ45 CJ series plug insert crimp pliers CJPZ T cable stripper CJST cuts the cable sheath and releases the wires in a single operation How to use the RJ45 plug insert crimp pliers min 40 mm 2 3 MAX displacement 1 mm 4 554 tools and accessories for crimp contacts inserts page manual IDC pliers MIXO RJ45 CX 8 J6IM 200 description wrenches pliers for CX 8 J6IM about 0 2 in min 20 mm Connection Application RJ45 DIN i 1 Gigabit Token Ring
28. er it is good practice to keep the indenter tips free from residual deposits of the coloured band some types of crimp contacts as per MIL standards are identified by coloured bands in the crimping area and any other debris A metal brush may be used for this purpose The following is strongly recommended 1 DO NOT immerse the tools in a solution to clean them 2 DO NOT brush oil in the tools to lubricate them 3 DO NOT try to disassemble the tool or repair it This is a high precision crimping tool and must be used as such CCTP turret installation 1 Position the previously selected CCTP turret on the support ring located on the crimping tool matching the special pin on the base of the turret with the corresponding hole on the support ring aligning the tapped holes with the socket head screws With the CCTP turret positioned against the support ring tighten the socket head screws with the 3 5 mm Allen wrench supplied with the kit Refer to the data plate on the CCTP turret From the colour code column select the colour of the positioner that corresponds to the appropriate code and dimension of the contact to be crimped With the CCTP turret in the adjustment position turn the turret selector until the colour coded positioner is aligned with the indicator line Press the turret until it clicks into the connected position Refer to the data plate on the CCTP turret From the column indicating the proper conductor section
29. etely closed position GO Insert the end green of the gauge as shown Fig 1 The gauge must pass freely between the indenter tips NO GO Insert the end red of the gauge as shown Fig 2 The gauge should not pass through the opening A 0 00254 mm GO green 0 991 mm B 0 00254 mm NO GO red 1 118 mm tool selector pos No CCPNP 4 Gauge tools and accessories for crimp contacts W gt for contacts of insert series page pneumatic crimping tool insertion tool removal tools replacement tip a 10A 53 614 with automatic positioner inserts gauge CDD 10A 67 74 CDG a 16A 99 103 CCEA ee 16A 110 115 COE e aa 16A 138 143 CQEE T 16A 146 147 CMCE TE ee 16A 148 160 COO reais 10A 16A 165 168 CX 8 24 16A 10A 169 CX 6 36 10A 170 CX 2 27 eee 10A VEL CX GO 2 2 16A 175 MIXO 10A 16A 185 203 the underlined polarities indicate those contacts that require the tools shown in this page description part No part No crimping tool with automatic positioner model DANIELS WA27FAP inserts excluded CCPZPA positioner inserts see note male contacts 10A CDM series CCTPADM female contacts 10A CDF series CCTPADF male contacts 16A CCM series CCTPACM female contacts 16A CCF series CCTPACF go no go control gauge to verify indenter closure see note CCPNP insertion tool for insertion
30. f the crimping on the contact crimping foot Ideally the crimping should be between the inspection hole and the top edge of the crimping foot The head of the contact should not be squared and the inspection hole should be intact Crimping tool maintenance No maintenance is required However it is good practice to keep the indenter tips free from residual deposits of the coloured band some types of crimp contacts as per MIL standards are identified by coloured bands in the crimping area and any other debris A metal brush may be used for this purpose The following is strongly recommended 1 DO NOT immerse the tools in a solution to clean them 2 DO NOT brush oil in the tools to lubricate them 3 DO NOT try to disassemble the tool or repair it This is a high precision manual crimping tool and must be used as such CXTP turret installation 1 The crimping tool must be in the open position 2 Choose the turret to be used according to the contacts that should be crimped male or female 3 Position the previously selected CXTP turret on the support ring located on the crimping tool matching the special pin on the base of the turret with the corresponding hole on the support ring aligning the tapped holes with the socket head screws With the CXTP turret positioned against the support ring tighten the socket head screws with the 3 5 mm Allen wrench supplied with the kit Refer to the data plate on the CXTP turret From
31. ight 0 5 mm 1 0 mm 0 5 mm 1 0 mm Contaci breaker m a eea a see list of tools contact holder pins A M B Feeding Ae an a a a e eeteeneeee vibrating conveyor contact holder bushes A F Crimping dorm A T acter eres 4 8 ratchets contact stop A B Cycle stime a ae a E E uae emcee 2 58 35 Continuous SOUNGIOVEll no iccccatiriarcetsemmacn lt 70 dB A Preset stripping and contact crimping programs Dimensions x d X Mss 530 x 500 x 480 mm CD 10A max CC 16A max C Gloire blue RAL5012 conductor section mm 0 34 0 5 0 75 1 0 15 2 5 05 0 75 1 0 15 2 5 WEIGhiE nce A curicrn mance E A 40 Kg AWG approximate 22 M208 mie Tiem A ae e e TE Program number 1A 2A 3A 4A 5A 6A 7B 8B 9B 10B 11B stripping position mm 0 75 1 00 1 20 1 30 1 40 1 70 1 00 1 20 1 30 1 40 1 70 crimping position 1 30 leS 1 40 1 50 155 LA 1 40 1 40 1 50 1 55 1 70 Supplied with the following accessories 1 vibrating conveyor feeder bowl for CD contact series 1 vibrating conveyor feeder bowl for male CC contact series 1 vibrating conveyor feeder bowl for female CC contact series 1 feeder tube contact passage from vibrating conveyor to machine for CD contact series 1 feeder tube contact passage from vibrating conveyor to machine for CC contact series 1 contact holder in crimping position for male CD contact series 1 contact holder in crimping position for female CD contact series 1 contact holder in crimping position for CC contact series
32. indenter tips NO GO Insert the end of the gauge as shown Fig 2 The gauge should not pass through the opening tool selector OA OB pos No GO NO GO Gauge CCPNP RN 2 1 94 mm 2 06 mm for contacts of insert series page manual crimping tool insertion removal tool MIXO CI contacts 25 poles 196 turret head MIXO CI contacts 8 poles 198 and 514 crimping tool for CI contacts DANIELS AFM8 model turret excluded insertion tool for insertion of the contacts into the inserts and removal tool for the extraction of contacts from the inserts for Cl contacts CIFD and CIMD series N B CITP D turret head to be ordered separately for contacts of insert series page manual crimping tool insertion removal tool D SUB 206 turret head crimping tool for 5A contacts DANIELS AFM8 model turret excluded insertion tool for insertion of the contacts into the inserts and removal tool for the extraction of contacts from the inserts for 5A D SUB contacts CIVFD and CIVMD series N B CIVTP D turret head to be ordered separately tools and accessories for crimp contacts for contacts of insert series page manual crimping tool removal tool CX 6 0 T eee 100A 175 crimp matrixes MIXO 200A 100A 70A 180 183 description part No part No crimping tool for 70A 100A 200A series contacts basic tool mod CEMBRE HT 45 CPPZ C excluding crimp matrixes and locators crimp ma
33. ire the production to be programmed to reduce downtime When a sequential processing is required despite the economic advantages offered by the above described solution it is preferable to use pneumatic bench pliers without the above described positioner or one of the manual pliers In any case the quality of the results from the crimping tools combined with the ILME crimp contacts is identical and at the highest market levels exceeding the requirements of the standard EN 60352 2 Although the crimping appliances and tools suggested here include a set of control automatisms and mechanisms which prevent the chief misunderstandings and errors the operator is advised to always take care not to work in inappropriate conditions MULTIPOLE CONNECTORS Crimping tools CN Crimping tools Crimping The crimping operation The practical guide in standard EN 60352 2 supplies further general information regarding crimp contacts for multipole connectors 1 Insertion of the conductor in the crimp contacts The conductor must be correctly positioned in the pin to be crimped The crimping indentations must be correctly positioned on the foot to be crimped There must be sufficient space in conformity with the manufacturer s instructions between the end of the insulating material of the conductor and the pin to be crimped d As a general rule the stripping length is equal to the pin insertion depth 1 mm for sections up to 1 mm and
34. l can be set to any crimping depth which may be required by the contact manufacturer Crimping instructions The reference matrix on the crimping tool indicates the correct seat of the positioner POS M1 F2 M3 F4 M5 F6 to select and the crimping depth SET to adjust for the contact to be crimped The contact is inserted through the crimper entry hole on the opposite side of the positioner The contact is closed by closing the handles in the first stop position in order to prevent the contact coming out off the crimper and to facilitate fitting the conductor in the contact The precision stop mechanism with teeth ensures consistently precise crimps by forcing the crimper to close completely and finish the crimping cycle before the crimper can be re opened Adjustment tool Positioner seat M1 male F2 female CDMA D male Section Crimp CDFA D female mm7 depth mm 0 3 0 14 1 3 025 0 37 0 5 0 5 poo 0 7 0 75 1 55 1 0 1 0 155 15 1 5 1 55 25 25 1 55 Positioner seat M3 male F4 female CCMA D male Section Crimp CCFA D female mm depth mm 0 3 0 14 1 2 0 3 0 25 0 37 1 3 0 5 0 5 1 55 0 7 O75 1 55 1 0 1 0 1 55 15 1 5 1 8 25 25 1 8 3 0 3 0 1 9 4 0 4 0 2 0 Positioner seat M4 male F6 female CXMA D male Section Crimp CXFA D female mm depth mm RS 15 1 55 2 5 2 5 1 8 4 0 4 0 2 0 6 0 6 0 2 0 10 0 10 0 2 3 Adjustment of crimp dep
35. l handle until the stop gear is released The tool will return to the open position 3 Check the position of the crimping on the contact crimping foot Ideally the crimping should be between the inspection hole and the top edge of the crimping foot The head of the contact should not be squared and the inspection hole should be intact Crimping tool maintenance No maintenance is required However it is good practice to keep the indenter tips free from residual deposits of the coloured band some types of crimp contacts as per MIL standards are identified by coloured bands in the crimping area and any other debris A metal brush may be used for this purpose The following is strongly recommended 1 DO NOT immerse the tools in a solution to clean them 2 DO NOT brush oil in the tools to lubricate them 3 DO NOT try to disassemble the tool or repair it This is a high precision manual crimping tool and must be used as such For automatic crimping operations refer to the CCPZP and or CCPZPA crimping tool models W CCTP turret installation 1 The crimping tool must be in the open position 2 Press the clicking lever that releases the turret in the adjustment position 3 Position the previously selected CCTP turret on the support ring located on the crimping tool matching the special pin on the base of the turret with the corresponding hole on the support ring aligning the tapped holes with the socket head screws 4 With the
36. lay within this limit especially during the uncoupling phase guide pins CRM and CRF may be used The use of ILME pliers code number CPES is recommended for the uncoupling operations for CD inserts 64 poles and CDD inserts 108 poles The pliers work on the fulcrum and lever principle and perform the following main tasks Reduce effort and coupling times to the minimum even when working in the most impractical and inaccessible points Il Perform the uncoupling of multipolar connectors in full conformity of standard DIN 43652 now EN 175301 801 The pliers allow the extraction of the inserts to be made perfectly axially with respect to the contacts evenly distributing the pressure on four points housing pins tools and accessories for crimp contacts W gt for contacts of insert series page CDe ree 10A 53 61 CDD a aa 10A 67 74 CDCA R 16A 99 103 CCE Reet 16A 110 115 COET a 16A 138 143 COEES TONT 16A 146 147 CMCE T aa 16A 148 160 CO 10A 16A 165 168 CX 8 24 16A 10A 169 CX 6 36 ao as 10A 170 CX 12 2 casi 10A 171 CX 6 6 eea 16A 175 MIXO 10A 16A 185 203 the underlined polarities indicate those contacts that require the tools shown in this page description crimping tool for 10A and 16A contacts DANIELS AF8 model turret excluded turret heads see note for 10A contacts CDF and CDM series for 16A contacts CCF and CCM series go no go contr
37. n the matrix support 21 the other one in the matrix pusher support 26 NB the two matrixes of each pair are the same Insert the contact by resting it in the locator with the tip forward then close the head The contact crimp housing will be accessible in the mouth between the matrixes Remove the moving handle 36 by removing the handle locking belt from the handle Before carrying out the next operations make sure the head is fully closed to avoid damages The pliers head can rotate by 180 in relation to the body thus allowing the operator to work in the most comfortable position WARNING do not force the head by trying to rotate it when the tool is under pressure 2 Approaching the matrixes If possible closing the dies rest the pliers head on a work top then move the moving handle to start moving the matrixes closer to the contact then carry on moving them until the contact is locked between the matrixes Push the correctly stripped and suitable long 15 mm wire all the way in the contact or the CGT adaptor crimp housing by carefully checking that the braids are fully compacted are not damaged and above all are all fully inserted Correctly pushing the contact in the locator ensures that the matrixes are exactly in the right area to compress the contact crimp shaft centre Make sure that the locator is free from any residue which would alter the position of the contact For crimping the CGT 16 earth adaptor manuall
38. nd any errors The machine is fitted with devices used to check that the crimping cycle has been completed The general safety instructions described in the machine user and maintenance manual must be followed and the use of the machine should only be restricted to qualified and trained personnel vibro conveyor unit feeding cup feeding tube display cable entry front panel filter stripping residues collection tray Crimping range Wire section from 0 34 mm AWG 26 to 2 5 mm AWG 14 Description of the machine To ensure a correct operation the machine must be positioned on a hard bench which does not amplify the effects of the internal movements occurring inside the machine The machine consists of a vibrator which loads the contacts of a tube which feeds the contacts and of a motorised wire stripping and contact crimping unit For each type and size of contact the machine is provided with a factory stored preset program see the machine user manual which may be customised at any time The program allows the user to load edit and save a program as well as check edit the stripping length and depth and the crimping depth Warning when the machine is switched on the working program is always the last program used The machine electronics adjustment is carried out by means of the keypad Select one of the 12 programs see table on page 548 according to the contact used Each program stores the stripping and crimping
39. ng and flexure of multiwired bundles or multipolar cables with crimp contacts Bundles of conductors or multipolar cables with crimp contacts for multipole connectors must not cause stress to the inserted contacts with their weight as this would cause the contacts to bend over to the coupling area of the connectors and consequently damage them The connectors must therefore be provided with cable clamps or the conductor bundles or multipolar cables must be mounted as described in the figures herebelow Multipolar cable Conductor cables If the conductor bundles or the multipolar cables have to be immediately folded over on the back of the connector insert it is recommended not to use any mechanical force in the axial direction with respect to the coupled contacts The figure herebelow shows a correct bending and clamping of the multiwire bundles using the crimp contacts 5 Coupling and uncoupling of multipolar connectors with crimp contacts In order to prevent stress on the crimp contacts the connectors must be coupled and uncoupled in the axial direction with respect to the contacts without touching the conductor bundles or cables Standard DIN 43652 incorporated into specification EN 175301 801 that applies to the ILME inserts of the CD series this recommendation is also valid for the CDD series prescribes a maximum deflection from the axis of 5 on the greater side and 2 on the smaller side Correct Incorrect To keep the p
40. ng tool Unscrew the positioner closing housing Install or replace the proper positioner insert in the positioner housing replacing the underlying spring Reverse the operations as described from point 4 to point 1 Fig B automatic positioner lt q _ positioner insert closing retainer screws body cap lt q insert free lt lock pin insert locked lt q valve body to lower to raise Crimping position adjustment Fig B 1 Release the automatic positioner from the crimping tool body see points 1 and 2 Installation replacement of a positioner insert 2 While holding the positioner body in position using a 19 mm wrench loosen the lock nut with a 14 mm wrench Push the positioner insert toward the bottom and lock it using the lock pin 3 4 If the pin doesn t lock unscrew the valve body toward the bottom 5 With the pin locked tighten the valve body toward the top until it strikes against the positioner insert 6 While maintaining that position tighten the lock nut 7 Replace and connect the positioner on the crimping tool 8 Release the lock pin in the free position Instructions to check calibration The operations to check the crimping tool must be carried out with the selector dial in position 4 and the CCPNP gauge CAUTION Do not crimp the gauge Calibration check Disconnect the compressed air Push the positioner insert toward the bottom and l
41. ock it using the lock pin Reconnect the compressed air Turn the needle valve counterclockwise to open the air supply Fig A The indenters will extend and remain in the extracted position until the valve is closed Check using the gauge referring to the go no go instructions reported below When the calibration check has been completed close the needle valve turning it clockwise Fig A 8 Put the lock pin in the free position GO Insert the end green of the gauge as shown Fig 1 The gauge must pass freely between the indenter tips NO GO Insert the end red of the gauge as shown Fig 2 The gauge should not pass through the opening tool selector pos No CCPNP 4 A 0 00254 mm GO green 0 991 mm B 0 00254 mm NO GO red 1 118 mm Gauge tools and accessories for crimp contacts W gt for contacts of insert series page stripping crimping machine insertion tool removal tools replacement tip CD ee 10A 53 61 CDD a S 10A 67 74 CDC E 16A 99 103 CCE oiiaii 16A 110 115 CQE oiiiiiaainaanna 16A 138 143 CQEE ann 16A 146 147 CMCE 16A 148 160 CO 10A 16A 165 168 CX 8 24 16A 10A 169 CX 6 36 eee 10A 170 CX ID E 10A Izi CX 6 6 eee 16A 175 MIXO 10A 16A 185 203 the underlined polarities indicate those contacts that require the tools shown in this page desc
42. of the contacts into the inserts for crimped contacts up to 0 75 mm CCINA removal tools for the extraction of contacts from the inserts for 10A contacts 1 CCES for 16A contacts 2 CQES replacement tip for CCES removal tool CCPR RN crimping depth adjuster selector CCINA 1 for CQ CD CDD CX inserts 10A auxiliary contacts and MIXO module 10A 2 for CQ CQE CQEE CCE CMCE inserts excluded 16 2 MIXO module 16A CX6 6 16A and CDC For CMCE 16 2 CX inserts contacts 16A insert CX 8 24 using a flat 3 mm screwdriver Notes Positioner inserts Interchangeable and indispensable accessories of the CCPZPA crimping tool precisely position the contact where crimping is performed Each contact requires its own positioner insert selected according to the type of contact 10A or 16A and the kind male or female go no go control gauge conforms with international standard MIL C 22520 3 A tool used to periodically check that the crimping tool meets standard requirements CCPZPA red no go green go CCTPADM and CCTPADF CCTPACM and CCTPACF 546 General specifications This is the pneumatic version of the manual crimping tool Crimping is performed with 8 pressure points The tool is equipped with a geared mechanism to control the complete crimping cycle Thanks to the automatic positioner it is possible to crimp simply by inserting the uncrimped contact wire into the tool
43. ol gauge to verify indenter closure see note insertion tool for insertion of the contacts into the inserts for crimped contacts up to 0 75 mm removal tools for the extraction of contacts from the inserts for 10A contacts 1 for 16A contacts 2 replacement tip for CCES removal tool 1 for CQ CD CDD CX inserts 10A auxiliary contacts and MIXO module 10A 2 for CQ CQE CQEE CCE CMCE inserts excluded 16 2 MIXO module 16A CX6 6 16A and CDC For CMCE 16 2 CX inserts contacts 16A insert CX 8 24 using a flat 3 mm screwdriver Notes Positioning turret conforms to international standard MIL C 22520 1 An interchangeable and indispensable accessory of the CCPZ MIL crimping tool it precisely positions the contact where crimping is performed Each series of contacts requires its own turret go no go control gauge conforms with international standard MIL C 22520 3 A tool used to periodically check that the crimping tool meets standard requirements red no go green go manual crimping tool insertion tool removal tools replacement tip turret heads gauge part No part No CCPZ MIL CCTP 10 CCTP 16 CCPNP CCINA CCES CQES CCPR RN crimping depth adjuster selector CCINA SS A RN CCES A contact selector CCPZ MIL male red i female blue Um none white stop b release button for ejection of selector CCTP CMD Cer
44. orms to international standard MIL C 22520 1 a An interchangeable and indispensable accessory of CCPZP CCPR RN the CCPZP crimping tool it precisely positions the contact where crimping is performed Each series of contacts requires its own turret CCES ran go no go control gauge contact selector a conforms to international standard MIL C 22520 3 male red A tool used to periodically check that the crimping female blue tool meets standard requirements none white stop release button for ejection of selector red no go green go CCSPZP CCVPP 544 General specifications This is the pneumatic version of the crimping tool Crimping is performed with 8 pressure points The tool is equipped with a geared mechanism to control the complete crimping cycle The tool must be equipped with an interchangeable turret CCTP according to the series of contacts to be crimped It is possible to use a hand valve located on the crimping tool or a foot valve optional The tool operating pressure is 5 5 8 3 bar It is recommended to utilise a lubrication adjustment and air filtering unit Crimping range Wire section dimension from 0 12 mm 26 AWG to 4 mm 12 AWG Operation with foot valve optional Connect the foot valve between the compressed air source and the tool air inlet Lower the hand valve and stop it in the lowered position with the stop screw A using a 1 5 mm Allen wrench CCPZP screw
45. ose the tool until you hear it disengages adjustment knob with 1 100 mm indenters Units for fine adjustment closure stop metric scale with 2 10 mm units for approximate adjustments crimp depth adjustment knob with 1 100 mm units for fine adjustment crimp depth scale in mm with 2 10 mm units Fig 5 Manual crimping tool Finishing the front surface Insert the contact into the polishing disc CLDL as shown in Figure 6 Work on a smooth surface such as a sheet of glass use grade 1000 polishing paper to grind off the protruding fibre and polish it with grade 4000 polishing paper Wipe away any residue remaining after grinding The best optical attenuation values are achieved when a wet grinding method is used Polishing disc Protruding fibre end Fig 6 Polishing Disc with Guide for Connector Sleeve Final mounting instructions Screw the back female part contact Put inside the insert CX 04 LF CX 04 LM for contacts series page manual crimping tool removal tool CX 50 F M CX 75 F M crimping tool COPZ for CX 50 F M and CX 75 F M coaxial contacts Crimping instructions 1 Strip the cable as per drawing page 210 2 Crimp the central contact of coaxial connector in the correct crimping area with the position 0 7 of crimping tool COPZ 3 Insert the central contact in the coaxial connector put the braid shield around the back cylinder of contact 4 Insert the brass back end on th
46. replacement tip CDE o 10A 53 61 gauge CDD eee 10A 67 74 CDCA 16A 99 103 CCE 16A 110 115 COE a 16A 138 143 COREE mon 16A 146 147 CMCE 16A 148 160 CO 10A 16A 165 168 CX 8 24 16A 10A 169 CX 6 36 40A 10A 170 CX 12 2 40A 10A dea CX 6 6 aoaiina 16A 175 MIXO 40A 16A 10A 184 203 the underlined polarities indicate those contacts that require the tools shown in this page description part No part No crimping tool for 10A 16A and 40A contacts RENNSTEIG model turret included CCPZ RN go no go control gauge to verify indenter closure see note CCPNP RN insertion tool for insertion of the contacts into the inserts for crimped contacts up to 0 75 mm CCINA removal tools for the extraction of contacts from the inserts for 10A contacts 1 CCES for 16A contacts 2 CQES for 40A contacts 3 and cables lt 5 mm CXES for 40A contacts 4 and cables lt 7 5 mm CXES 10 replacement tip for CCES removal tool CCPR RN 1 for CQ CD CDD CX inserts 10A auxiliary contacts and MIXO module 10A 2 for CQ CQE CQEE CCE CMCE inserts excluded positioning turret 16 2 MIXO module 16A CX6 6 16A and CDC m incorporated For CMCE 16 2 CX inserts contacts 16A insert No CX 8 24 using a flat 3 mm screwdriver 3 for CX inserts 40A contacts and MIXO module 40A 4 for MIXO module CX 03 4B and contacts 10 mm CCINA Notes go
47. ription part No part No stripping crimping machine Zoller Frohlich AM 03 Universal model ZFU CD insertion tool for insertion of the contacts into the inserts for crimped contacts up to 0 75 mm CCINA removal tools for the extraction of contacts from the inserts for 10A contacts 1 CCES for 16A contacts 2 CQES replacement tip for CCES removal tool CCPR RN 1 for CQ CD CDD CX inserts 10A auxiliary contacts and MIXO module 10A 2 for CQ CQE CQEE CCE CMCE inserts excluded 16 2 MIXO module 16A For CX 6 6 16A and CDC CMCE 16 2 CX inserts 16A contacts CX 8 24 insert a 3 mm flat screwdriver should be used Technical specifications Tools list contacts CD 10A max CC 16A max BIS nee en eh Ea E E AOTEA electro pneumatic conductor section mm qe 06 07S l l6 26 MS 07S lM l5 25 Electne feeder m cans e E 230V 50Hz AWG approximate 22 20 16 18 16 14 20 18 18 16 14 Apso pe OMe mnt anaes 120VA feeding bowl male A B M Fuse on the system filter module 00 2x2AmT feeding bowl female B F Air operating Press re cessera renen 5 5 bar feeding tube A B ACON SUMO O 2 nl cycle wire holder 0 34 0 5 1 5 25 0 5 1 5 2215 Flexible conductors in conformity with IEC 60228 class 5 starting unit AB AB Rated SeCtOMN acer 0 34 2 5 mm 22 AWG 14 AWG stripping blades V shaped blades V shaped blades PECCING IGNOU stews een veces recs 52 mm rear blade spacers n a FeO A A E loose turned left r
48. rried out with the appropriate go no go gauges purchased separately For extra operational details consult the following pages on tools and the relevant instruction sheets and or use and maintenance manuals a The manual and automatic crimping tools selected by ILME are carefully designed to ensure symmetrical deformation of the crimping area of the contact and wire by means of their own internal high pressure forming parts The positioner ensures that the wire and crimp contact meet in the appropriate part of the tool Sprung mechanisms built into the tools ensure that the contacts are not inserted in the tool before the indenters are fully open and that the tool does not open before the crimping process has been completed The CCPZ MIL for 10A and 16A crimp contacts and CXPZ D for 40A crimp contacts manual crimping tools are suitable for use when compressed air sources are unavailable for low or medium low work loads The CCPZ RN for 10A 16A and 40A crimp contacts manual crimping tool is also suitable for for low or medium low work loads The CCPZP pneumatic crimping bench tool without automatic positioner for 10A and 16A crimp contacts is suitable for use in the workshop where compressed air is available for high or medium high work loads Using the same manual crimping tool turrets it is possible to change rapidly from crimping on male contacts to crimping on female contacts of the same series 10A and 16A The
49. th Crimp depth to be adjusted ad follows the adjustment knob should be turned clockwise to reduce crimping depth and anti clockwise to increase it Adjustment tolerances 1 scale mark on the knob adjustment of 1 100 mm 0 01 mm 1 complete rotation of knob adjustment of 2 10 mm 0 2 mm this indication can be read on the knob and on the approximate scale 5 knob rotations adjustment of 1 0 mm this indication can be read on the scale crimp depth Ml adjustment knob with 1 100 mm units for fine adjustment IS leal crimp depth scale in mm with 2 10 mm units Maintenance and repair Keep the crimping tool clean and store it correctly when not in use The joints need to be lubricated periodically and the pin stop circular clips must always stay in position This is a high precision crimping tool and must be used as such Calibration check The crimping tool is adjusted in the manufacturer s plant To ensure correct calibration we advise you to check the tool with a gauge every working day This is easily done with the CCPNP RN cylindrical gauge in the 2 0 mm position ATTENTION Do not crimp the gauge Crimping depth of 2 mm can be adjusted with the adjustment knob scale marked on 2 screw indicator on 0 as shown in the above figure Put the crimping tool in the completely position GO Insert the end of the gauge as shown Fig 1 The gauge must pass freely between the
50. trixes for CX7 contacts with 10 mm AWG 8 7 section CGD 10 C for CX7 contacts with 16 mm AWG 6 5 section CGD 16 C for CX7 contacts with 25 mm AWG 4 3 section CGD 25 C crimp matrixes for CG contacts with 16 mm AWG 6 5 section CGD 16 C for CG contacts with 25 mm AWG 4 3 section CGD 25 C for CG contacts with 35 mm AWG 2 section CGD 35 C crimp matrixes for CY contacts section 16 mm AWG 6 CGD 25 C for CY contacts section 25 mm AWG 4 and section CYD 35 C 35 mm AWG 2 for CY contacts section 50 mm AWG 1 CYD 50 C for CY contacts section 70 mm AWG 2 0 CYD 70C locator for CX7 contacts CX7PZ LOC for CG contacts CGPZ LOC for CY contacts CYPZ LOC removal tool for 70A CX7 series contact C7ES Part No CCPZ CF Manual crimping tool carrying case CGPZ VLG complete with crimp matrixes CGD CYD locator CX7PZ LOC CGPZ LOC CYPZ LOC and removal tool C7ES NOTE For CGMA 35 and CGFA 35 contacts and their corresponding CGD 35 C matrix pair the contact may be inserted even after closing the head part No punching contacts mm AWGmin AWG max mm mm CGD 10 C ME 2 CX7MA 10 CX7FA 10 10 8 7 8 4 10 6 CGD 16 C ME 3 CX7MA 16 CX7FA 16 16 6 5 13 3 16 8 CGD 25 C ME 5 CX7MA 25 CX7FA 25 25 4 3 21 2 26 7 part No punching contacts mm AWG min AWG max mm mm CGD 10 C ME 2 CGMA 10 CGFA 10 10 8 7 8 4 10 6 CGD 16 C ME 3 CGMA 16
51. uch as those manufactured by ILME NOTE Alternatively for wire sections between 35 mm and 300 mm EN 61238 1 2003 standard can be referred to This standard requires constant R S values equal to 60 N mm lower than those established by the above mentioned French standard MULTIPOLE CONNECTORS Crimping tools CN Crimping tools Tools and accessories for crimp contacts Selecting the crimping tool and relevant controls When you have selected quality crimp contacts and conductors the next step and most important step is to select the correct work tool The practical guide of standard EN 60352 2 provides the following recommendations on the subject They list some of the ideal requirements for crimping tools some optional characteristics but above all they provide a preview of the indispensable controls a The crimping tools and the contacts used must be supplied by the Same manufacturer otherwise the user must assume all responsibility for the quality and reliability of the crimp connections b The crimping tools must function correctly and provide a correct crimp without damage to the pin or the component to crimp c In order to obtain a reliable crimp connection a crimping device with a mechanism that controls the entire crimping cycle must be used At the end of the crimping cycle the handles and the ratchet must return to the open position d In all cases the crimping operation must be made in one single ph
52. y locate the area to be crimped between the matrixes If necessary re open the matrixes by following the instructions described in paragraph 4 and reposition the contact 3 Crimping Continue to operate the moving handle pumping the piston will gradually move forward until the matrixes come into contact Continue the pumping action until the maximum pressure valve clicks in 4 Releasing the dies Fully press the pressure release lever 50 located on the pliers pumping body until the piston goes back and the matrixes open To remove the crimped contact re open the pliers head 5 Storage Fully return the piston as described in paragraph 4 then lock the moving handle in position by using the belt provided Cleaning and maintenance The tool is very sturdy and does not required any special care a correct operation is ensured by following a few simple precautions The tool is supplied with a user and maintenance manual which gives all detailed instructions Read this manual before use CGPZ VLG carrying case for CPPZ crimping tool dimensions 445 x 290 x h 95 mm weight 1 2 kg houses 20 pairs of matrixes to store the CPPZ crimping tool inside the carrying case turn the pliers head by 180 so that the locator becomes visible tools and accessories for crimp contacts W gt for contacts of insert series page pneumatic crimping tool insertion tool removal tools replacement tip COL AAT 10A 53 614 turret
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