Hand Crimp Tool User Manual
Contents
1. Hand Crimp Tool User Manual North America Power amp 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 salesna powersignal com engineering powersignal com South America Power amp Signal Group an Arrow Company Rua Jos Gomes Falcao 111 Attn Roberto Cutrupi Sales Manager South America 01139 010 Barra Funda Sao Paulo S P Brasil BR Phone 55 11 3613 9371 Email rcutrupi powersignal com de ia o Poy nal Europe the Middle East amp Africa Power amp 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 saleseuropre powersignal com engineeringeurope powersignal com Asia Power amp Signal Group 11F BM Intercontinental Business Center 100 Yu Tong Road Shanghai 200070 China Phone 86 21 22152000 Fax 86 21 22152435 E mail SalesAsia powersignal com Table of Contents General hand crimp tool HCT information e Introduction e Function of HCT ratchet e Scope of usage e Responsibilities of user Note regarding HCT manual dimensions HCT Power Assist Devices Tool Types Tool Type 1 Blade amp Box Terminals Tool Type 2 Pin amp Sleeve Terminals Assembly and Removal of HCT Die Sets e Die selection e Die insertion Die removal e Crimp verification e Crimp Height Adjustment Cri2. amp 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 sales powersignal com Power amp Signal Group EMEA Itterpark 9 11 40724 Hilden Germany Engineering Tech Line 49 2103 250 510 Sales 49 2103 250 0 or saleseurope powersignal com Power amp Signal Group Asia 6 F Building 1 3000 Long Dong Avenue Pudong Shanghai 201023 China Sales 86 21 289 32000 or salesasia powersignal com Notes
3. 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 amp 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 Tool Types Type 1 Box amp Blade Terminal Do not over tighten the wire stop M4 nut Make certain that the wire stop spring loaded blade moves Yi freely Wire Stop Chamfer N M4 X 25 mm Allen Screw Upper Die M4 Lock Nut No Die Retaing Screws M4 X 16 mm Allen Screw Locator ol Assemble screws without fully Itightening Tighten screws after Lower Die Iclosing handles to fully seat the Jupper and lower die Type 2 Pin amp Sleeve Terminals M4X 11mm Allen Screw Wire Stop M4 Regular Nut HO O M4 X 18 mm Allen Screw urn small knob to open and close hold terminal Type 3 Pin amp Sleeve Terminals Press to Open Insert contact Release to close on Contact Open to release contact Ali
4. 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 specific 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 equi te prt ie TA A ye is Es Ee BENS ps E RES HE Lay Be u te at fee ui A 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 Hei
5. 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 amp Signal Group Hand Crimp Tools HCT have been developed for optimal crimping in e Low volume production e Repair e 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 amp Signal Group hand crimp tools are intended for occasional and low volume applications only Please call Power amp 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 amp 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
6. cting the tool grease should be removed by using a commercial degreaser that will not negatively affect 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 e Inspect that the wire stop holders jaws and other moving parts are in place e Make sure that the unit is not missing any screws and that the emergency release is operational e 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 e If any adjustments or replacements need to be made please contact the Power amp 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 specified terminal part number Wire Strippers are not included with all HCTs e Adjust the red wire stop on the stripper to the proper strip length e Inspect the stripped leads carefully for cuts scrapes missing strands or deformed insulation in the strip area e Readjust wire stripper if necessary e A complete visual inspection is recommended prior to crimping RENNSTEIG 607 020 Imperial scale inches Metric scale mm for wire gauge 32 7 for wire gauge 0 03 10 HCT Technical Support For assistance please contact Power
7. ght CCH requirements as shown in the Crimp Tool Reference Data Sheet for the specified 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 CAB SIZE CAB CODE PRIMARY STRIP PULLTEST CORE CH CORE CW INS CH INS CW Wrong insert tooling crimp adjustment not right inserts TERMINAL P N 12191811 GT 150 unsealed not seated wrong insert jaw wrong cable or terminal See data sheet with tooling 35 142 5 1 55 1 05 1 75 2 2 1 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 Excessive Tab All strands not captured by core wings Terminal straightness Cut or missing strands HCT Maintenance and Cleaning May damage seal or cause seal to not seal properly Terminals not cut off stri
8. gn to bottom die Snap Wire Stop Locator For All Tool Types Place end of stripped wire against the wire stop 4 Assembly and Removal of HCT Die Sets If you have purchased a pre assembled HCT begin with the crimp verification instructions Die selection e Select the appropriate die for the terminal part and gauge size as defined in the Crimp Tool Reference Data Sheet Die insertion e Assemble the upper and lower die inserts together with the terminal locator and wire stop e Be sure that the beveling side points to the left The proper nut and allen screws are provided with each tool kit Die Removal e Open the tool handles e Loosen and remove the two die retaining screws by means of an Allen wrench e Slide the dies out of the tool jaws Crimp verification In order to ensure proper crimping and to control the wearing of the tool and die crimp verification must be done after every die set change and regularly thereafter Step One Measure the crimp height and width with a caliper Me Step Two Compare the caliper results to the specified tolerance range found in the Crimp Height Reference Data Sheet included with each die set If the crimp height is out of the specified tolerance range the HCT needs to be adjusted Crimp Height Adjustment Remove set screw e Rotating the adjustment wheel counterclockwise increases the crimp force and decreases the crimp height e Rotating the adjustment wheel c
9. lockwise decreases the crimp force and increases the crimp height e Reinsert set screw Sei acrew 2 hole positions avals le Crimp Height Adjustment Crimp Tool Reference Data Sheet Power amp Signal Group supplies specific 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 e Reference tool number terminal name and wire gauge sizes on tool parts e Reference terminal part numbers and cable gauge sizes from authorized wiring prints or other documents e Use the specific 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 amp 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
10. mp Tool Reference Data Sheet Crimping Instructions Terminal Loading e Terminal Crimping e Crimp Height Measurement Visual Crimp Quality Recommendations Good crimp e Crimp dimensions not in tolerance e Low core e Insulation under core wing e Twisted or distorted terminals or cable seals Excessive Tab All strands not captured by core wings e Terminal straightness e Cut or missing strands HCT Maintenance Cleaning HCT Visual Inspection Wire Stripper Instructions HCT Support General Hand Crimp Tool HCT information Introduction Power amp 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 amp 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
11. p properly May cause a loose crimp and electrical or mechanical non conformance May need to inspect strands prior to crimping 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 Incorrect stripping of cable May cause a loose crimp and electrical or mechanical non conformance Responsible personnel and operators of the Power amp Signal Group HCT should maintain the tool with each use e 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 e Store the tool in a clean and dry area HCT Visual Inspection e Quality control personnel should regularly check up on the HCT to ensure that crimp quality is optimal e Inspections on the tool should be made regularly and logged The frequency of use working environment company standards and operator training strength and proficiency are some factors to take into consideration when inspecting the tool When visually inspe
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