Instruction Sheet STS--M--281--2430--11--A (416--38 Rev A) StraightActionHandTool CAT-HT-281-2430-11 26MAY 10 PROPERUSEGUIDELINES CumulativeTraumaDisorderscanresultfromtheprolongeduseofmanuallypoweredhandtools.Handtoolsareintendedforoccasionaluseandlowvolume applications.Awideselectionofpoweredapplicationequipmentforextended--use,productionoperationsmaybeavailable. insulation barrel during the crimping operation. The Insulation locator/insulation stop positions the contact, and limits Adjustment the insertion distance of the stripped wire into the Knob contact. In use, the locator/insulation stop rests in the Insulation locator slot of the contact (See Figures 1 and 2). The Crimper ratchet assures full crimping of the contact. Once Wire engaged, the ratchet will not release until the dies Crimper have been fully closed. Wire Barrel Anvil 3. CRIMPINGPROCEDURE Insulation Do NOT cut or nick the wire strands during wire Anvil CAUTION stripping. ! Front of Tool 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 Figure 1 open fully. 1. INTRODUCTION 3. Holding the contact by its mating portion and looking straight into the crimp section, insert the CAT--HT--281--2430--11 was designed to crimp C--281 contact from the back of the tool into the (IPDI--Series) terminals. appropriate crimp chamber. 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 barrel i drawn to scale. or wire barrel. 6. Insert a properly stripped wire through the locator slot and into the wire barrel of the contact 2. DESCRIPTION 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 7. Holding wire in place, crimp contact to the wire specifications. 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. Many tools feature an insulation adjustment knob which is 8. Allow tool handles to open fully and remove the used to regulate the crimp height of the contact crimped contact from the tool. E2010 Copyright Protected, SAMTEC CUSTOMERSERVICE 1--800--SAMTEC9 1 of 4 All Rights Reserved. LOCB All product names, logos, orcompany names might be trademarks of theirrespective owners. US007945 - 2010-12-10T16:01:43Z STS-M-281-2430-11-A StraightActionHandToolCAT-HT-281-2430-11 WIRECRIMP CONTACT WIRESIZE INSULATION STRIP TOOLCRIMPSYM- HEIGHT 2 NUMBER mm [AWG] DIAMETER LENGTH BOL +0.026mm [+.001in.] 0.74--0.97 0.08--0.05[28--30] A 0.445[.0175] [.029--.038] 1.35--1.50 2.79--3.56 0.20[24] B 0.712[.028] C--281 [.053--.059] [.1 [.115 15--.145] .145] 1.22--1.37 0.12[26] C 0.585[.023] [.048--.054] Figure 2 Damaged terminals should not be used. If a CAUTION S The care, amount of use, and handling of the damaged terminal is evident, it should be cut hand tool from the wire and replaced with a new one. S The presence of abnormal amounts of dust and ! dirt S Your own established standards 9. If a terminal becomes jammed in a crimp nest, open the tool jaws using the“Emergency Ratchet The hand tool is inspected before being shipped; Release Button” on the moving handle lever. however, it is recommended that the tool be inspected immediately upon its arrival at your facility to ensure InsulationAdjustmentProcedure that the tool has not been damaged during shipment. On many tools, the insulation barrel crimp height is 4.1. DailyMaintenance regulated by the insulation adjustment knob (Figure 3). The insulation crimp should hold the 1. Remove dust, moisture, and other contaminants insulation firmly without cutting into the insulation. To with a clean brush, or a soft, lint--free cloth. Do not determine the proper insulation crimp setting, test use objects that could damage the tool. crimp a loose piece contact using the setting which corresponds to the insulation diameter: (1) ---- small; 2. Make certain that the retaining pins are in place (2) and (3) ---- medium; or (4) ---- large. If the crimped and that they are secured with retaining rings. insulation barrel is too tight or loose, change the 3. All pins, pivot points, and bearing surfaces setting by pulling out and rotating the adjustment should be protected with a thin coat of any good knob to the desired setting. SAE 20 oil. Do not oil excessively. 4. When the tool is not in use, keep handles closed Insulation to prevent objects from becoming lodged in the Adjustment crimping jaws. Knob (Knob Shownin 5. Store the tool in a clean, dry area. Position4 ---- Largest 4.2. Lubrication Setting) Lubricate all pins, pivot points, and bearing surfaces with SAE 20 oil as follows: Tools used in daily production -- lubricate daily Tools used daily (occasional) -- lubricate weekly Tools used weekly -- lubricate monthly 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. 4.3. PeriodicInspection 4. MAINTENANCEANDINSPECTIONPROCEDURE 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. SAMTEC CUSTOMERSERVICE 1--800--SAMTEC9 2 of 4 All Rights Reserved. US007945 - 2010-12-10T16:01:43Z STS-M-281-2430-11-A StraightActionHandToolCAT-HT-281-2430-11 2. Close tool handles until the ratchet releases and 4.5. RatchetInspection then allow the handles to open freely. If they do not The ratchet feature on these hand tools should be open quickly and fully, the spring is defective and checked to ensure that the ratchet does not release must be replaced. prematurely, allowing the crimping dies to open before they have fully bottomed. Obtain a 0.025--mm 3. Inspect the head assembly for worn, cracked, or [.001--in.] shim that is suitable for checking the broken jaws. If damage is evident, return it for clearance between the bottoming surfaces of the evaluation and repair. crimping dies. Proceed as follows: 4.4. CrimpHeightInspection Proceed as follows: This inspection requires the use of micrometer with a 1. Select the maximum size wire and strip it modified anvil as shown in Figure 4. according to the dimensions listed in the drawing shipped with the tool. A recommended Crimp Height Comparator is RS--1019--5LP, which can be purchased from: 2. Select the contact and crimp section corresponding to the selected wire size (refer to the drawing shipped with the tool). Manufacturer Telephone 3. Position the contact and wire in the crimping Shearer IndustrialSupplyCo 717--767--7575 dies, as described in Section 3, CRIMPING PROCEDURE. VALCO 610--691--3205 4. Hold the wire in place and squeeze the handles Proceed as follows: until the ratchet releases. Hold the handles in this position, maintaining just enough tension to keep 1. Select a contact and a wire (maximum size) for the dies closed. each crimp section. 5. Check the clearance between the bottoming 2. Refer to the Section 3, and crimp the contact(s). surfaces of the wire crimper and the wire anvil. See Figure 1. If the clearance is 0.025 mm [.001 in.] or 3. Using a crimp height comparator, measure wire less (on at least two of the bottoming surfaces), the barrel crimp height as shown in Figure 4. If the ratchet is satisfactory. If clearance exceeds crimp height conforms to that marked on the tool, 0.025 mm [.001 in.], the ratchet is out of the tool is considered dimensionally correct. adjustment and must be repaired. The insulation crimper does not bottom on the NOTE insulation anvil. Position Point On Center of i Wire Barrel Wire Barrel Crimp Height Opposite Seam 5. TOOLDIMENSIONS Refer to Figure 5 for tool dimensions. Modified Anvil 6. REVISIONSUMMARY S Initial release of document Figure 4 SAMTEC CUSTOMERSERVICE 1--800--SAMTEC9 3 of 4 All Rights Reserved. US007945 - 2010-12-10T16:01:43Z STS-M-281-2430-11-A StraightActionHandToolCAT-HT-281-2430-11 30 [1.2] 230 [9.07] Emergency Ratchet Release Button 52 [2.1] Closed Weight: Approx. 622.6 g [1 lb. 6 oz.] Figure 5 SAMTEC CUSTOMERSERVICE 1--800--SAMTEC9 4 of 4 All Rights Reserved. US007945 - 2010-12-10T16:01:43Z