Instruction Sheet STS--M--169--2024--11--A (416--32 Rev D) StraightActionHandTool CAT-HT-169-2024-11 17JUN 10 PROPERUSEGUIDELINES CumulativeTraumaDisorderscanresultfromtheprolongeduseofmanuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume applications.Awideselectionofpoweredapplicationequipmentforextended--use,productionoperationsmaybeavailable. insulation barrel during the crimping operation. The locator/insulation stop positions the contact, and limits Insulation the insertion distance of the stripped wire into the Adjustment contact. In use, the locator/insulation stop rests in the Knob Insulation locator slot of the contact (See Figures 1 and 2). The Crimper ratchet assures full crimping of the contact. Once engaged, the ratchet will not release until the dies Wire have been fully closed. Crimper Wire Barrel 3. CRIMPINGPROCEDURE Anvil Do NOT cut or nick the wire strands during wire CAUTION Insulation stripping. Anvil ! Front of Refer to Figure 2 for wire preparation information Tool 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. Figure 1 3. Holding the contact by its mating portion and looking straight into the crimp section, insert the 1. INTRODUCTION contact from the BACK of the tool into the This Straight Action Hand Tool appropriate crimp chamber. CAT--HT--169--2024--11 is designed to crimp CC69L 4. Position the contact between the crimpers so (IPBD--Series) contacts. that the locator/insulation stop enters the slot in the contact. The wire barrel should butt against the The wire crimper bottoms against the anvil before CAUTION locator/insulation stop. Refer to Figure 1. the ratchet releases. This is a design feature that assures maximum electrical and tensile 5. Holding the contact in this position, squeeze the ! performance of the crimp. Do NOT re--adjust the tool handles together until the insulation anvil starts ratchet. entry into the insulation crimper (usually two ratchet clicks). Do NOT deform the insulation barrel or wire barrel. Dimensions in these instructions are in metric NOTE units [with inches in brackets]. Figures and 6. Insert a properly stripped wire through the illustrations are for reference only and are not locator slot and into the wire barrel of the contact i drawn to scale. until the insulation butts against the locator/insulation stop. 2. DESCRIPTION 7. Holding wire in place, crimp contact to the wire by squeezing the tool handles together until the The FRONT of the tool, is marked with the tool part ratchet releases. number, wire size ranges, and crimp height specifications. 8. Allow tool handles to open FULLY and remove the crimped contact from the tool. The tool features a fixed die (crimper), a movable die (anvil), a locator/insulation stop, and a ratchet. Many Damaged terminals should not be used. If a CAUTION tools feature an insulation adjustment knob which is damaged terminal is evident, it should be cut used to regulate the crimp height of the contact from the wire and replaced with a new one. ! E2010Copyright Protected, SAMTEC CUSTOMERSERVICE 1--800--SAMTEC9 1 of 3 All Rights Reserved. LOCB All products, logos, andcompany names usedaretheproperty of theirrespectiveowners. STS-M-169-2024-11-A StraightActionHandToolCAT-HT-169-2024-11 CONTACT WIRESIZE INSULATION STRIP TOOLCRIMP CRIMP APPLICATION 2 NUMBER mm [AWG] DIAMETER LENGTH SYMBOL HEIGHT SPECIFICATION 1.35--1.50 3.12--3.38 0.94+0.05 0.20[24] A [.053--.059] [.123--.133] [.037+.002] 1.65--1.83 3.12--3.38 1.04+0.05 0.50[20] B CC69L STS--A--002 [.066--.072] [.123--.133] [.041+.002] 1.50--1.65 3.12--3.38 0.99+0.05 0.35[22] C [.059--.065] [.123--.133] [.039+.002] Figure 2 4. MAINTENANCEANDINSPECTIONPROCEDURE 4.3. PeriodicInspection 1. The hand tool may be immersed (handles It is recommended that a maintenance and inspection partially closed) in a reliable commercial program be performed periodically to ensure degreasing compound (suitable for plastics) to dependable and uniform terminations. Frequency of remove accumulated dirt, grease and foreign inspection depends on: matter. S The care, amount of use, and handling of the 2. Close tool handles until the ratchet releases and hand tool then allow the handles to open freely. If they do not S The presence of abnormal amounts of dust and open quickly and fully, the spring is defective and dirt must be replaced. See Section 5. S Your own established standards 3. Inspect the head assembly for worn, cracked, or broken jaws. If damage is evident, return it for The hand tool is inspected before being shipped; evaluation and repair. however, it is recommended that the tool be inspected immediately upon its arrival at your facility to ensure 4.4. CrimpHeightInspection that the tool has not been damaged during shipment. This inspection requires the use of micrometer with a modified anvil as shown in Figure 3. 4.1. DailyMaintenance A recommended Crimp Height Comparator is RS--1019--5LP, which can be purchased from: 1. Remove dust, moisture, and other contaminants with a clean brush, or a soft, lint--free cloth. Do Manufacturer Telephone NOT use objects that could damage the tool. Shearer IndustrialSupplyCo 717--767--7575 2. Make certain that the retaining pins are in place and that they are secured with retaining rings. VALCO 610--691--3205 3. All pins, pivot points, and bearing surfaces Proceed as follows: should be protected with a thin coat of any good 1. Select a contact and a wire (maximum size) for SAE 20 oil. Do not oil excessively. each crimp section. 2. Refer to the Section 3, and crimp the contact(s). 4. When the tool is not in use, keep handles closed to prevent objects from becoming lodged in the 3. Using a crimp height comparator, measure wire crimping jaws. barrel crimp height as shown in Figure 3. If the crimp height conforms to that marked on the tool, 5. Store the tool in a clean, dry area. the tool is considered dimensionally correct. 4.2. Lubrication Position Point Lubricate all pins, pivot points, and bearing surfaces On Center of Wire Barrel with SAE 20 oil as follows: Wire Barrel Crimp Height Opposite Seam Tools used in daily production -- lubricate daily Tools used daily (occasional) -- lubricate weekly Tools used weekly -- lubricate monthly Modified Anvil Wipe excess oil from tool, particularly from crimping area. Oil transferred from the crimping area onto certain terminations may affect the electrical Figure 3 characteristics of an application. SAMTEC CUSTOMERSERVICE 1--800--SAMTEC9 2 of 3 All Rights Reserved. STS-M-169-2024-11-A StraightActionHandToolCAT-HT-169-2024-11 4.5. RatchetInspection position, maintaining just enough tension to keep the dies closed. The ratchet feature on these hand tools should be 5. Check the clearance between the bottoming checked to ensure that the ratchet does not release surfaces of the wire crimper and the wire anvil. See prematurely, allowing the crimping dies to open before Figure 1. If the clearance is 0.025 mm [.001 in.] or they have fully bottomed. Obtain a 0.025--mm less (on at least two of the bottoming surfaces), the [.001--in.] shim that is suitable for checking the ratchet is satisfactory. If clearance exceeds clearance between the bottoming surfaces of the crimping dies. Proceed as follows: 0.025 mm [.001 in.], the ratchet is out of adjustment and must be repaired. See Section 5. Proceed as follows: The insulation crimper does not bottom on the NOTE 1. Select the maximum size wire and strip it insulation anvil. according to the dimensions listed in the drawing i shipped with the tool. 2. Select the contact and crimp section 5. REVISIONSUMMARY corresponding to the selected wire size (refer to the drawing shipped with the tool). S Updated document to corporate requirements S Changed text in Section 1, INTRODUCTION 3. Position the contact and wire in the crimping S Added new NOTE to Paragraph 3.8 dies, as described in the CRIMPING S Added new information to Figure 2 PROCEDURE section. S Added new references to Paragraphs 4.3.2, 4.4, 4.4.3, and 4.5.5 4. Hold the wire in place and squeeze the handles S Deleted Figure 3 and renumbered until the ratchet releases. Hold the handles in this 52 [2.1] Closed 30 [1.2] 303 [11.9] Weight: Approx. 622.6 g [1 lb. 6 oz.] Figure 4 SAMTEC CUSTOMERSERVICE 1--800--SAMTEC9 3 of 3 All Rights Reserved.