Instruction Sheet STS--M--203--2832--11--A (416--28 Rev J) StraightActionHandTool CAT-HT-203-2832-11 15JUN 10 PROPERUSEGUIDELINES CumulativeTraumaDisorderscanresultfromtheprolongeduseofmanuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume applications.Awideselectionofpoweredapplicationequipmentforextended--use,productionoperationsmaybeavailable. 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 Insulation Front of have been fully closed. Crimper Tool Wire 3. CRIMPINGPROCEDURE Special Crimper Loading Do NOT cut or nick the wire strands during wire CAUTION Wire Barrel Pin stripping. Anvil ! Insulation Anvil 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 Figure 1 contact from the BACK of the tool into the appropriate crimp chamber. 1. INTRODUCTION For aid in loading the terminal, insert the “Special NOTE This Straight Action Hand Tool Loading Pin” into the terminal receptacle. Do (CAT--HT--203--2832--11) is designed to crimp CC03L NOT insert into the wire barrel area. This pin is (SFSD--Series) contacts. i included with the hand tool. The wire crimper bottoms against the anvil before CAUTION 4. Position the contact between the crimpers so the ratchet releases. This is a design feature that that the locator/insulation stop enters the slot in the assures maximum electrical and tensile ! contact. The wire barrel should butt against the performance of the crimp. Do NOT re--adjust the locator/insulation stop. Refer to Figure 1. ratchet. 5. Holding the contact in this position, squeeze the Dimensions in these instructions are in metric NOTE tool handles together until the insulation anvil starts units [with inches in brackets]. Figures and entry into the insulation crimper (usually two illustrations are for reference only and are not ratchet clicks). Do NOT deform the insulation i drawn to scale. barrel or wire barrel. 6. Insert a properly stripped wire through the 2. DESCRIPTION locator slot and into the wire barrel of the contact until the insulation butts against the The FRONT of the tool, is marked with the tool part locator/insulation stop. number, wire size ranges, and crimp height specifications. 7. Holding wire in place, crimp contact to the wire by squeezing the tool handles together until the The tool features a fixed die (crimper), a movable die ratchet releases. (anvil), a locator/insulation stop, and a ratchet. The locator/insulation stop positions the contact, and limits 8. Allow tool handles to open FULLY and remove the insertion distance of the stripped wire into the the crimped contact from the tool. E2010Copyright Protected, SAMTEC CUSTOMERSERVICE 1--800--SAMTEC9 1 of 3 All Rights Reserved. LOCB All product names, logos, orcompany names might betrademarks of theirrespectiveowners. StraightActionHandToolCAT-HT-203-2832-11 STS-M-203-2832-11-A CONTACT WIRESIZE INSULATION STRIP TOOLCRIMP CRIMP APPLICATION 2 NUMBER mm [AWG] DIAMETER LENGTH SYMBOL HEIGHT SPECIFICATION 0.74--0.89 2.28--2.54 0.41+0.025 0.05--0.06[30] B [.029--.035] [.092--.098] [.016+.001] C CC C0 03 3L L S ST TS S--A A--0 006 06 0.81--0.97 2.28--2.54 0.46+0.025 0.08--0.09[28] C [.032--.038] [.092--.098] [.018+.001] 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. PeriodicInspection 1. Hand tool may be immersed (handles partially 4. MAINTENANCEANDINSPECTIONPROCEDURE closed) in a reliable commercial degreasing It is recommended that a maintenance and inspection compound (suitable for plastics) to remove program be performed periodically to ensure accumulated dirt, grease and foreign matter. dependable and uniform terminations. Frequency of 2. Close tool handles until ratchet releases and inspection depends on: then allow them to open freely. If they do not open S The care, amount of use, and handling of the quickly and fully, the spring is defective and must hand tool be replaced. S The presence of abnormal amounts of dust and dirt 3. Inspect head assembly for worn, cracked, or broken jaws. If damage is evident, return it for S Your own established standards evaluation and repair. The hand tool is inspected before being shipped; however, it is recommended that the tool be inspected 4.4. CrimpHeightInspection immediately upon its arrival at your facility to ensure This inspection requires the use of micrometer with a that the tool has not been damaged during shipment. modified anvil as shown in Figure 3. 4.1. DailyMaintenance Position Point 1. Remove dust, moisture, and other contaminants On Center of with a clean brush, or a soft, lint--free cloth. Do Wire Barrel Wire Barrel NOT use objects that could damage the tool. Crimp Height Opposite Seam 2. Make certain that the retaining pins are in place and that they are secured with retaining rings. Modified Anvil 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. Figure 3 4. When the tool is not in use, keep handles closed to prevent objects from becoming lodged in the A recommended Crimp Height Comparator is crimping jaws. Store the tool in a clean, dry area. RS--1019--5LP, which can be purchased from: 4.2. Lubrication Manufacturer Telephone Lubricate all pins, pivot points, and bearing surfaces Shearer IndustrialSupplyCo 717--767--7575 with SAE 20 oil as follows: VALCO 610--691--3205 S Tools used in daily production -- lubricate daily SAMTEC CUSTOMERSERVICE 1--800--SAMTEC9 2 of 3 All Rights Reserved. StraightActionHandToolCAT-HT-203-2832-11 STS-M-203-2832-11-A 1. Select a contact and a wire (maximum size) for 4. Hold the wire in place and squeeze the handles each crimp section. until the ratchet releases. Hold the handles in this position, maintaining just enough tension to keep 2. Refer to the Section 3, and crimp the contact(s). the dies closed. 3. Using a crimp height comparator, measure wire 5. Check the clearance between the bottoming barrel crimp height as shown in Figure 3. If the surfaces of the wire crimper and the wire anvil. See crimp height conforms to that marked on the tool, Figure 1. If the clearance is 0.025 mm [.001 in.] or the tool is considered dimensionally correct. 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 4.5. RatchetInspection adjustment and must be repaired. The ratchet feature on these hand tools should be The insulation crimper does not bottom on the checked to ensure that the ratchet does not release NOTE prematurely, allowing the crimping dies to open before insulation anvil. they have fully bottomed. Obtain a 0.025--mm i [.001--in.] shim that is suitable for checking the clearance between the bottoming surfaces of the 5. TOOLDIMENSIONS crimping dies. Proceed as follows: Refer to Figure 4 for tool dimensions. 1. Select the maximum size wire and strip it according to dimensions listed in the drawing shipped with the tool. 6. REVISIONSUMMARY 2. Select contact and crimp section corresponding Since the previous release of this document, the to the selected wire size (refer to the drawing following changes have been made: shipped with the tool). S Updated document to corporate requirements S Changed contact part number in Section 1, 3. Position the contact and wire in the crimping INTRODUCTION dies, as described in the CRIMPING PROCEDURE section. 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 CUSTOMERSERVICE 1--800--SAMTEC9 3 of 3 All Rights Reserved.