CAT-HT-203-2832-11

Instruction Sheet Straight Action Hand Tool CAT- HT- 203- 2832- 11 STS-- M-- 203-- 2832-- 11-- A (416-- 28 Rev J) 15 JUN 10 PROPER USE GUIDELINES Cumulative Trauma Disorders can result from the prolonged use of manually powered hand tools. Hand tools are intended for occasional use and low volume applications. A wide selection of powered application equipment for extended-- use, production operations may be available. Insulation Crimper Front of Tool Wire Crimper Special Loading Pin Wire Barrel Anvil contact. In use, the locator/insulation stop rests in the locator slot of the contact (See Figures 1 and 2). The ratchet assures full crimping of the contact. Once engaged, the ratchet will not release until the dies have been fully closed. 3. CRIMPING PROCEDURE CAUTION ! Insulation Anvil Do NOT cut or nick the wire strands during wire stripping. Refer to Figure 2 for wire preparation information before applying the terminal. 1. Hold the tool so that the FRONT side is facing you. 2. Ensure that the tool ratchet is released by squeezing the tool handles and allowing them to open FULLY. 3. Holding the contact by its mating portion and looking straight into the crimp section, insert the contact from the BACK of the tool into the appropriate crimp chamber. Figure 1 1. INTRODUCTION This Straight Action Hand Tool (CAT--HT--203--2832--11) is designed to crimp CC03L (SFSD--Series) contacts. CAUTION ! NOTE i NOTE i For aid in loading the terminal, insert the “Special Loading Pin” into the terminal receptacle. Do NOT insert into the wire barrel area. This pin is included with the hand tool. The wire crimper bottoms against the anvil before the ratchet releases. This is a design feature that assures maximum electrical and tensile performance of the crimp. Do NOT re--adjust the ratchet. 4. Position the contact between the crimpers so that the locator/insulation stop enters the slot in the contact. The wire barrel should butt against the locator/insulation stop. Refer to Figure 1. Dimensions in these instructions are in metric units [with inches in brackets]. Figures and illustrations are for reference only and are not drawn to scale. 5. Holding the contact in this position, squeeze the tool handles together until the insulation anvil starts entry into the insulation crimper (usually two ratchet clicks). Do NOT deform the insulation barrel or wire barrel. 2. DESCRIPTION The FRONT of the tool, is marked with the tool part number, wire size ranges, and crimp height specifications. The tool features a fixed die (crimper), a movable die (anvil), a locator/insulation stop, and a ratchet. The locator/insulation stop positions the contact, and limits the insertion distance of the stripped wire into the E2010 Copyright Protected, SAMTEC All Rights Reserved. 6. Insert a properly stripped wire through the locator slot and into the wire barrel of the contact until the insulation butts against the locator/insulation stop. 7. Holding wire in place, crimp contact to the wire by squeezing the tool handles together until the ratchet releases. 8. Allow tool handles to open FULLY and remove the crimped contact from the tool. CUSTOMER SERVICE 1-- 800-- SAMTEC9 All product names, logos, or company names might be trademarks of their respective owners. 1 of 3 LOC B Straight Action Hand Tool CAT- HT- 203- 2832- 11 CONTACT NUMBER STS- M- 203- 2832- 11- A WIRE SIZE mm2 [AWG] INSULATION DIAMETER STRIP LENGTH TOOL CRIMP SYMBOL CRIMP HEIGHT 0.05--0.06 [30] 0.74--0.89 [.029--.035] 2.28--2.54 [.092--.098] B 0.41 +0.025 [.016 +.001] 0.08--0.09 [28] 0.81--0.97 [.032--.038] 2.28--2.54 [.092--.098] C 0.46 +0.025 [.018 +.001] CC03L APPLICATION SPECIFICATION STS A 006 STS--A--006 Figure 2 9. If a terminal becomes jammed in the crimp nest, S Tools used daily (occasional) -- lubricate weekly the tool jaws can be opened using the “emergency S Tools used weekly -- lubricate monthly ratchet release button,” found on the moving Wipe excess oil from tool, particularly from crimping handle lever. area. Oil transferred from the crimping area onto certain terminations may affect the electrical Damaged terminals should not be used. If a CAUTION characteristics of an application. damaged terminal is evident, it should be cut from the wire and replaced with a new one. ! 4.3. Periodic Inspection 4. MAINTENANCE AND INSPECTION PROCEDURE It is recommended that a maintenance and inspection program be performed periodically to ensure dependable and uniform terminations. Frequency of inspection depends on: S The care, amount of use, and handling of the hand tool S The presence of abnormal amounts of dust and dirt S Your own established standards The hand tool is inspected before being shipped; however, it is recommended that the tool be inspected immediately upon its arrival at your facility to ensure that the tool has not been damaged during shipment. 4.1. Daily Maintenance 1. Remove dust, moisture, and other contaminants with a clean brush, or a soft, lint--free cloth. Do NOT use objects that could damage the tool. 2. Make certain that the retaining pins are in place and that they are secured with retaining rings. 3. All pins, pivot points, and bearing surfaces should be protected with a thin coat of any good SAE 20 oil. Do not oil excessively. 4. When the tool is not in use, keep handles closed to prevent objects from becoming lodged in the crimping jaws. Store the tool in a clean, dry area. 1. Hand tool may be immersed (handles partially closed) in a reliable commercial degreasing compound (suitable for plastics) to remove accumulated dirt, grease and foreign matter. 2. Close tool handles until ratchet releases and then allow them to open freely. If they do not open quickly and fully, the spring is defective and must be replaced. 3. Inspect head assembly for worn, cracked, or broken jaws. If damage is evident, return it for evaluation and repair. 4.4. Crimp Height Inspection This inspection requires the use of micrometer with a modified anvil as shown in Figure 3. Position Point On Center of Wire Barrel Opposite Seam Wire Barrel Crimp Height Modified Anvil Figure 3 A recommended Crimp Height Comparator is RS--1019--5LP, which can be purchased from: 4.2. Lubrication Manufacturer Lubricate all pins, pivot points, and bearing surfaces with SAE 20 oil as follows: Shearer Industrial Supply Co 717--767--7575 VALCO 610-- 691-- 3205 S Tools used in daily production -- lubricate daily 2 of 3 SAMTEC All Rights Reserved. CUSTOMER SERVICE 1-- 800-- SAMTEC9 Telephone Straight Action Hand Tool CAT- HT- 203- 2832- 11 4. Hold the wire in place and squeeze the handles until the ratchet releases. Hold the handles in this position, maintaining just enough tension to keep the dies closed. 1. Select a contact and a wire (maximum size) for each crimp section. 2. Refer to the Section 3, and crimp the contact(s). 3. Using a crimp height comparator, measure wire barrel crimp height as shown in Figure 3. If the crimp height conforms to that marked on the tool, the tool is considered dimensionally correct. 5. Check the clearance between the bottoming surfaces of the wire crimper and the wire anvil. See Figure 1. If the clearance is 0.025 mm [.001 in.] or less (on at least two of the bottoming surfaces), the ratchet is satisfactory. If clearance exceeds 0.025 mm [.001 in.], the ratchet is out of adjustment and must be repaired. 4.5. Ratchet Inspection The ratchet feature on these hand tools should be checked to ensure that the ratchet does not release prematurely, allowing the crimping dies to open before they have fully bottomed. Obtain a 0.025--mm [.001--in.] shim that is suitable for checking the clearance between the bottoming surfaces of the crimping dies. Proceed as follows: STS- M- 203- 2832- 11- A The insulation crimper does not bottom on the insulation anvil. NOTE i 5. TOOL DIMENSIONS 1. Select the maximum size wire and strip it according to dimensions listed in the drawing shipped with the tool. Refer to Figure 4 for tool dimensions. 2. Select contact and crimp section corresponding to the selected wire size (refer to the drawing shipped with the tool). Since the previous release of this document, the following changes have been made: 6. REVISION SUMMARY 3. Position the contact and wire in the crimping dies, as described in the CRIMPING PROCEDURE section. S Updated document to corporate requirements S Changed contact part number in Section 1, INTRODUCTION S New information in Figure 2 30 [1.2] 230 [9.07] Emergency Ratchet Release Button 52 [2.1] Closed Weight: Approx. 622.6 g [1 lb. 6 oz.] Figure 4 SAMTEC All Rights Reserved. CUSTOMER SERVICE 1-- 800-- SAMTEC9 3 of 3