CERTI- CRIMP* Hand Crimping

Transcription

1 CERTI- CRIMP* Hand Crmpng Instructon Sheet Tool for PIDG* FASTON* Termnals 19 FEB 10 Termnal Crmpng Jaws Back of Tool (Wre Sde) Wre Sze Range Markng Insulaton Crmpng Adjustment Pns (ShownnPoston3) ratchet. When closed the crmpng jaws form two crmpng chamers: one crmps the termnal wre barrel and the other crmps the nsulaton barrel. The sprng--loaded termnal locator postons and holds the termnal n the tool. The nsulaton crmpng adjustment pns are used to control the crmp heght of the termnal nsulaton barrel. The tool s marked on the back wth the wre sze range. The ratchet assures full crmpng of the termnal. Once engaged, the ratchet wll not release untl the handles have FULLY closed. Ratchet CAUTION! The crmpng jaws bottom before the ratchet releases. Ths feature assures maxmum electrcal and tensle performance of the crmp. DO NOT re -adjust the ratchet. 3. CRIMPING PROCEDURE Each hand tool s coated wth a preservatve to prevent rust or corroson. Wpe ths preservatve from the tool, partcularly from the crmpng jaws, before usng the tool. Refer to Fgure 2 and select applcable termnal and wre wthn the specfed sze and nsulaton dameter. Strp the wre to the length ndcated DO NOT cut or nck the wre strands. Fgure 1 Typcal PIDG FASTON Termnal Wre Barrel 1. INTRODUCTION CERTI--CRIMP Hand Crmpng Tool , shown n Fgure 1, s desgned to crmp PIDG FASTON termnals lsted n Fgure 2 onto stranded wre szes 22 to 18 AWG wth a maxmum nsulaton dameter of 2.54 mm [.100 n.]. Read these nstructons thoroughly before usng the tool. Dmensons n ths nstructon sheet are n mllmeters [wth nches n brackets]. Fgures are not drawn to scale. Reasons for ressue of ths nstructon sheet are provded n Secton 7, REVISION SUMMARY. 2. DESCRIPTION The tool features two crmpng jaws, a termnal locator, two nsulaton crmpng adjustment pns, and Note: Not to Scale Wre Strp Length 4.75 [.187] SIZE RANGE (AWG) WIRE INSUL DIA (Max) [.100] Proceed as follows: Fgure 2 Insulaton Barrel TERMINAL , , , Open the tool jaws by squeezng the handles untl the ratchet releases and then allow the handles to open FULLY. E2010 Tyco Electroncs Corporaton, Berwyn, PA TOOLING ASSISTANCE CENTER All Rghts Reserved PRODUCT INFORMATION TE logo and Tyco Electroncs are trademarks. *Trademark. Other products names, logos, or company names mght be trademarks of ther respectve owners. Ths controlled document s subject to change. For latest revson and Regonal Customer Servce, vst our webste at 1 of 5 LOC B

2 2. Rase the locator, and nsert the termnal nto the slot, makng sure the open porton of the termnal s turned away from the base of the locator. Poston the termnal so that the nsulaton butts aganst the locator and s centered on the jaw as shown n Fgure 3. Crmpng the Termnal 4. Your own establshed standards. The hand tool s nspected before beng shpped; however, t s recommended that the tool be nspected mmedately upon arrval at your faclty to ensure that the tool has not been damaged durng shpment. Due to the precson desgn, t s mportant that no parts of these tools be nterchanged except those replacement parts lsted n Fgure 5. Slot n Open Porton of Termnal Back of Tool 4.1. Daly Mantenance 1. Remove dust, mosture, and other contamnants wth a clean brush, or a soft, lnt--free cloth. DO NOT use objects that could damage the tool. 2. Make certan that the retanng pns are n place and that they are secured wth retanng rngs. 3. All pns, pvot ponts, and bearng surfaces should be protected wth a thn coat of any good SAE 20 motor ol. DO NOT ol excessvely. Base of Press to Rase Termnal Insulaton Aganst 4. When the tool s not n use, keep handles closed to prevent objects from becomng lodged n the crmpng jaws. Store the tool n a clean, dry area Lubrcaton Lubrcate all pns, pvot ponts, and bearng surfaces wth SAE 20 motor ol as follows: Fgure 3 4. Close tool handles slowly untl the termnal s held frmly n place. DO NOT deform termnal wre barrel. 5. Insert strpped wre nto termnal untl the wre nsulaton begns to wedge aganst the termnal nsulaton or untl the wre nsulaton butts aganst the termnal wre barrel. The end of the wre should be flush wth the end of the wre barrel. 6. Holdng the wre n place, close tool handles untl ratchet releases. Allow the handles to open FULLY, then rase the locator, and remove the crmped termnal. 4. MAINTENANCE AND INSPECTION It s recommended that a mantenance and nspecton program be performed perodcally to ensure dependable and unform termnatons. Frequency of nspecton depends on: 1. The care, amount of use, and handlng of the hand tool. 2. The presence of abnormal amounts of dust and drt. 3. The degree of operator skll. SAE s a trademark of SAE Internatonal Corporaton. Tools used n daly producton lubrcate daly Tools used daly (occasonal) lubrcate weekly Tools used weekly lubrcate monthly Wpe excess ol from tool, partcularly from crmpng area. Ol transferred from the crmpng area onto certan termnatons may affect the electrcal characterstcs of an applcaton Perodc Inspecton 1. Hand tool should be mmersed (handles partally closed) n a relable commercal degreasng compound to remove accumulated drt, grease, and foregn matter. 2. Close tool handles untl ratchet releases and then allow them to open freely. If they do not open quckly and fully, the sprng s defectve and must be replaced. See Secton 6, REPLACEMENT AND REPAIR. 3. Inspect head assembly for worn, cracked, or broken jaws. If damage s evdent, return the tool to AMP for evaluaton and repar. See Secton 6, REPLACEMENT AND REPAIR Gagng the Crmpng Chamber Ths nspecton requres the use of a plug gage conformng to the dmensons provded n Fgure 4. To gage each crmpng chamber, proceed as follows: 1. Remove traces of ol or drt from the crmpng chamber and plug gage. 2 of 5 Tyco Electroncs Corporaton

3 Dameter Suggested Plug Gage Desgn for Wre Barrel Crmpng Chamber NO - Dameter Suggested Plug Gage Desgn for Insulaton Barrel Crmpng Chamber Dameter NO - Dameter 25.4 [1.00] Mn (Typ) W [ ] (Typ) NO W GAGE ELEMENT DIAMETER NO [.0625] [.0675] Inspecton of Wre Barrel Crmpng Chamber Crmpng Chamber GAGE ELEMENT DIAMETER NO - W (Wdth) (Max) [.0290] [.0510] 1.91 [.075] Inspecton of Insulaton Barrel Crmpng Chamber Crmpng Chamber Element NO - Element Element NO - Element element must pass NO - element may enter partally, but must not pass element must pass NO - element may enter partally, but must not pass Fgure 4 2. Close the tool handles untl t s evdent that the jaws have bottomed; then hold n ths poston. DO NOT force the jaws beyond ntal contact. 3. Algn the element of the wre barrel crmp plug gage wth the wre barrel Push element straght nto the crmpng chamber wthout usng force. The element must pass crmpng chamber, as shown n Fgure Algn the NO-- element and try to nsert t straght nto the same The NO-- element may start entry, but must not pass SeeFgure4. 5. Insert the nsulaton crmp adjustment pns nto Poston Check the nsulaton barrel crmpng chamber usng the nsulaton crmp plug gage n the same manner as n Steps 3 and 4. See Fgure 4. If the crmpng chambers conform to the gage nspecton, the tool s consdered dmensonally correct, and should be lubrcated wth a THIN coat of any good SAE 20 motor ol. If not, refer to Secton 6, REPLACEMENT AND REPAIR, for nformaton on obtanng further evaluaton and repar. For addtonal nformaton regardng the use of plug gages, refer to nstructon sheet Ratchet Inspecton The ratchet on ths hand tool should be checked to ensure that the ratchet does not release prematurely, allowng the crmpng jaws to open before they have fully bottomed. Obtan a [.001] shm that s sutable for checkng the clearance between the bottomng surfaces of the crmpng jaws. Proceed as follows: 1. Select a maxmum sze wre and termnal. Strp the wre to the dmensons ndcated. 2. Poston the termnal and wre between the crmpng jaws, as descrbed n Secton 3, CRIMPING PROCEDURE. 3. Hold the wre n place and squeeze the handles untl the ratchet releases. Hold the handles n ths poston, mantanng just enough tenson to keep the jaws closed. Tyco Electroncs Corporaton 3 of 5

4 4. Check the clearance between the bottomng surfaces of the crmpng jaws. If the clearance s [.001] or less, the ratchet s satsfactory. If clearance exceeds [.001], the ratchet s out of adjustment and must be repared. See Secton 6, REPLACEMENT AND REPAIR. 5. INSULATION CRIMPING ADJUSTMENT The tool has three nsulaton crmpng adjustment postons to adjust the wre nsulaton grp: 1 Tght, 2 Medum, and 3 Loose. To determne the proper nsulaton crmp settng, proceed as follows: 1. Insert adjustment pns nto Poston 3 as shown n Fgure 1. Both pns must be n the same poston. 2. Poston termnal nto crmpng jaws as descrbed n Secton 3, CRIMPING PROCEDURE. 3. Insert UNSTRIPPED wre nto just the termnal nsulaton barrel. Crmp termnal and remove from crmpng jaws. 4. Check the nsulaton support by bendng the wre back and forth once. The nsulaton barrel should retan grp on the wre nsulaton. If the wre pulls out, move the nsulaton crmpng adjustment pn to the next tghter poston and perform another test crmp. If the wre does not pull out, the pn s properly adjusted and the tool s ready for crmpng. Do not use a tghter crmp than necessary. Adjust pn as necessary untl the desred nsulaton grp s obtaned. Crmp should hold wre nsulaton frmly wthout cuttng nto t. 6. REPLACEMENT AND REPAIR Customer--replaceable parts are lsted n Fgure 5. Parts other than those lsted should be replaced by Tyco Electroncs to ensure qualty and relablty of the tool. Order the replacement part through your Representatve, or call , or send a facsmle of your purchase order to , or wrte to: CUSTOMER SERVICE (38--35) TYCO ELECTRONICS CORPORATION PO BOX 3608 HARRISBURG PA For customer repar servce, call REVISION SUMMARY Revsons to ths nstructon sheet nclude: S Updated nstructon sheet to corporate requrements S Removed references to des 4 of 5 Tyco Electroncs Corporaton

5 [3.0] (Closed) [.875] 279 [11.0] REPLACEMENT PARTS ITEM PART NUMBER DESCRIPTION QTY PER TOOL RING, Retanng PIN, Straght RING, Retanng PIN, Straght SPRING, Hold Down PIN, Adjustment LOCATOR HOUSING, SPRING, SCREW, 1 Fgure 5 Tyco Electroncs Corporaton 5 of 5